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Operator for Roller Shutters and Grills
Intelligent control systems for safe and reliable industrial door operation.
Genesys partnered with Chamberlain to develop the control electronics for the eDrive +2.0, an advanced operator designed for industrial roller shutters and grills.
The Technology
The eDrive +2.0 is an intelligent door operator designed to manage the movement and safety of commercial roller doors. The system includes an absolute position encoder for accurate door positioning and supports both manual and automated operation.
The operator integrates multiple safety and control features, including:
• Forward and reverse motor control
• Open and close limit management
• Obstruction detection sensors
• Infrared safety beams
• Mechanical safety switches
• Wireless communication via 430 MHz links
The system also supports remote control and integration into broader building management systems, enabling more advanced automation within industrial environments.
The Challenge
Industrial roller doors operate under high loads and involve significant safety risks if not properly controlled. The system needed to ensure fail-safe operation at all times, even in the event of faults such as power failure, component malfunction or user intervention.
In addition, the device operates under high-voltage conditions, requiring strict compliance with safety standards. Managing electrical isolation, current monitoring and fault detection was critical to ensure safe operation in both single-phase and three-phase systems.
The Solution
To address these requirements, Genesys Electronics Design designed a robust control system with built-in redundancy and safety monitoring.
A primary control unit manages door movement and system logic, while a secondary microcontroller independently monitors the primary system to detect faults and ensure fail-safe behaviour. This dual-layer architecture enables rapid detection of issues such as stuck contactors, stop button activation or power anomalies.
The system also incorporates monitoring of three-phase current, safety sensors and mechanical inputs, ensuring reliable operation under demanding industrial conditions.
Genesys Engineering Contribution
Genesys developed the logic control board for the eDrive +2.0, including:
• Motor control systems for forward and reverse operation
• Safety monitoring systems and sensor integration
• Dual microcontroller architecture for fail-safe operation
• High-voltage design with appropriate isolation (creepage and clearance)
• Wireless communication integration
• Compliance with relevant electrical and safety standards
All designs were validated and approved by an accredited independent test laboratory to ensure regulatory compliance.
In addition to the core system, Genesys also developed an expansion board to extend functionality, including:
• Control of auxiliary systems such as lights and sirens
• Automatic door closing for applications such as car parks
Genesys also designed a manufacturing test jig to automate firmware programming, electrical testing and functional validation during production.
Impact
The eDrive +2.0 provides a reliable and intelligent control solution for industrial roller doors, improving safety, automation and operational efficiency in commercial environments.
Through its collaboration with Chamberlain, Genesys Electronics Design delivered a robust, compliant and scalable control system capable of meeting the demands of modern industrial facilities.
Genesys Electronics Design partners with companies to develop safe, compliant and high-performance solutions.