Development of a Concealed Power and Signal Transfer System for Sliding Doors

Abstract: This master’s thesis report describes the product development process of a durable and concealed product for transferring power and signals to the moving door leafs of sliding doors. The thesis has been conducted in collaboration with Assa Abloy Entrance Systems, with the goal of enabling the use of accessories such as privacy e-glass, screens integrated in the glass, electric locks and sensors mounted on the door leafs for their sliding doors. To better understand Assa Abloy’s product portfolio as well as restrictions of different solutions to this problem, an extensive background research was conducted. This background research laid the groundwork for a concept generation where 28 concepts using many different technologies for power and signal transfer was generated. The concept ultimately chosen for further development consists of a spiral cable mounted on a support wire, installed completely concealed in the header profile of a sliding door. A prototype of the concept was subject to a life cycle test, confirming the feasibility of the concept, before a detail design phase was initiated. During this phase, focus was put into developing the concept with regards to manufacturability. Tools such as CAD-modelling, 3D-printing and sheet metal manufacturing enabled a rapid iteration of prototypes. The final design consists of a spiral cable with a durable cable jacket, a support wire that enables easy installation, an injection molded bracket securing spiral cables of different dimensions with minimal cable wear to the door leaf as well as a sheet metal bracket that enables mounting of the support wire in the header profile. This product proved to be an easy to install, low cost and durable solution for transferring power and signals to the door leafs of sliding doors.