Modular elevator sheave assembly

Abstract

An illustrative example embodiment of an elevator sheave assembly includes a plurality of polymer rings secured together. The plurality of polymer rings includes at least two polymer rings each having an outer circumferential surface defining a portion of a belt guide surface adjacent a flange at a longitudinal end of the sheave assembly. The at least two polymer rings each include a bearing supported inside the ring.

Description

TECHNICAL FIELD

[0001] The present application relates to an elevator assembly, and more particularly, to a modular elevator sheave assembly. BACKGROUND

[0002] Elevator systems are useful for carrying passengers and items between different floors of a building. Many elevator systems are traction-based and include a rope that suspends an elevator car and a counterweight. A machine causes movement of a traction sheave, which in turn causes movement of the rope for moving the elevator car as desired. The rope typically follows a path that includes several sheaves.

[0003] Elevator sheaves include surfaces that engage the rope. There are different rope configurations, such as round steel ropes and flat belts. There are different sizes of belts for different load or load capacity. While the various rope options are useful, they present a challenge to maintain an inventory of the corresponding various sheaves for installation or replacement over time. SUMMARY

[0004] An illustrative example embodiment of an elevator sheave assembly includes a plurality of polymer rings secured together. The plurality of polymer rings includes at least two polymer rings each having an outer circumferential surface defining a portion of a belt guide surface adjacent a flange at a longitudinal end of the sheave assembly. The at least two polymer rings each include a bearing supported inside the ring.

[0005] In addition to one or more of the features described above, or as an alternative, the at least two polymer rings are a first polymer end ring at a first longitudinal end of the sheave assembly, the first polymer end ring having an outer circumferential surface with a first profile defining a first portion of a first belt guide surface, and a second polymer end ring at a second longitudinal end of the sheave assembly, the second polymer end ring having an outer circumferential surface with a second profile defining a first portion of a second belt guide surface, the plurality of polymer rings including at least one polymer intermediate ring positioned between and connected to the first and second polymer end rings, and the at least one polymer intermediate ring including an outer circumferential surface with a profile defining a second portion of the first belt guide surface and a second portion of the second belt guide surface.

[0006] In addition to one or more of the above features, or as an alternative, the at least one polymer intermediate ring includes a plurality of polymer intermediate rings including a first intermediate ring received adjacent to and connected to the first polymer end ring and a second intermediate ring received adjacent to and connected to the second polymer end ring, a profile of the outer circumferential surface of the first intermediate ring defines a second portion of the first guide surface, and a profile of the outer circumferential surface of the second intermediate ring defines a second portion of the second guide surface.

[0007] In addition to one or more of the above features, or as an alternative, the first intermediate ring is connected to the second intermediate ring, a profile of the outer circumferential surface of the first intermediate ring defines a first portion of the third guide surface, and a profile of the outer circumferential surface of the second intermediate ring defines a second portion of the third guide surface.

[0008] In addition to one or more of the above features, or as an alternative, a profile of the outer circumferential surface of the first intermediate ring is the same as a profile of the outer circumferential surface of the second intermediate ring.

[0009] In addition to one or more of the above features, or as an alternative, the plurality of polymer intermediate rings includes at least one third intermediate ring between and connected to the first and second intermediate rings, a profile of the outer circumferential surface of the first intermediate ring defines a first portion of the third guide surface, a profile of the outer circumferential surface of the second intermediate ring defines a first portion of the fourth guide surface, and a profile of the outer circumferential surface of the at least one third intermediate ring defines a second portion of the third guide surface and a second portion of the fourth guide surface.

[0010] In addition to one or more of the above features, or as an alternative, the at least one third intermediate ring includes two third intermediate rings connected together at a longitudinal center of the elevator sheave assembly, and a profile of the outer circumferential surface of the two third intermediate rings defines a fifth guide surface at the longitudinal center of the elevator sheave assembly.

[0011] In addition to one or more of the above features, or as an alternative, the polymer of each of the at least two polymer rings is overmolded onto a portion of the bearing to retain the bearing within the ring.

[0012] In addition to one or more of the above features, or as an alternative, each of the rings includes only a single bearing.

[0013] In addition to one or more of the above features, or as an alternative, the single bearing is positioned at a location corresponding to a concentration of load on the ring.

[0014] In addition to one or more of the above features, or as an alternative, the elevator sheave assembly includes a connector securing the at least one polymer intermediate ring to the first polymer end ring and the second polymer end ring.

[0015] In addition to one or more of the above features, or as an alternative, the connector includes a separate piece at least partially received in a lateral surface on the polymer ring.

[0016] In addition to one or more of the above features, or as an alternative, the connector is formed as part of the polymer ring.

[0017] In addition to one or more of the above features, or as an alternative, the first and second polymer end rings include at least one of a protrusion extending from a lateral surface and a recess in a lateral surface, the at least one polymer intermediate ring includes at least one of a recess in a lateral surface on the at least one polymer intermediate ring and a protrusion extending from a lateral surface on the at least one polymer intermediate ring, and the protrusion and recess cooperate to connect the at least one polymer intermediate ring to the first and second polymer end rings.

[0018] An illustrative example embodiment of a method of manufacturing an elevator sheave assembly includes positioning a first polymer end ring at a first longitudinal end of the sheave assembly, the first polymer end ring including an outer circumferential surface having a first profile defining a first portion of a first guide surface; connecting at least one polymer intermediate ring to the first polymer end ring, the at least one polymer intermediate ring including an outer circumferential surface having a profile defining a second portion of the first guide surface; and connecting a second polymer end ring to the at least one polymer intermediate ring to position the second polymer end ring at a second longitudinal end of the sheave assembly, the second polymer end ring including an outer circumferential surface having a second profile defining a first portion of a second guide surface, the at least one polymer intermediate ring profile defining a second portion of the second guide surface.

[0019] In addition to one or more of the above features, or as an alternative, the at least one polymer intermediate ring includes a plurality of polymer intermediate rings including a first intermediate ring and a second intermediate ring. The method further includes connecting the first intermediate ring to the first polymer end ring, connecting the second intermediate ring to the second polymer end ring, and connecting the first intermediate ring to the second intermediate ring.

[0020] In addition to one or more of the features described above, or as an alternative, the profile of the outer circumferential surface of the first intermediate ring defines a second portion of the first guide surface; the profile of the outer circumferential surface of the first intermediate ring defines a first portion of the third guide surface; the profile of the outer circumferential surface of the second intermediate ring defines a second portion of the second guide surface; and the profile of the outer circumferential surface of the second intermediate ring defines a second portion of the third guide surface.

[0021] In addition to one or more of the features described above, or as an alternative, the first profile is the same as the second profile, and the profile of the outer circumferential surface of the first intermediate ring is the same as the profile of the outer circumferential surface of the second intermediate ring.

[0022] In addition to one or more of the features described above, or as an alternative, the method further includes overmolding the material of the first polymer end ring onto the bearing and overmolding the material of the second polymer end ring onto the bearing.

[0023] In addition to one or more of the features described above, or as an alternative, the method further includes positioning the bearing of each of the polymer end rings in a location corresponding to a concentration of load on the polymer end ring.

[0024] Various features and advantages of at least one disclosed example embodiment will become apparent to those skilled in the art from the following detailed description, taken in conjunction with the accompanying drawings. The drawings accompanying the detailed description can be briefly described as follows. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 schematically illustrates selected portions of an elevator system.

[0026] Figure 2 is a cross-sectional view schematically illustrating an example embodiment of an elevator sheave assembly.

[0027] Figure 3A and Figure 3B is a cross-sectional view schematically illustrating an example embodiment of an elevator sheave assembly including a polymer intermediate ring.

[0028] Figure 4 is a cross-sectional view schematically illustrating an embodiment of an elevator sheave assembly including two polymer intermediate rings.

[0029] Figure 5 is a cross-sectional view schematically illustrating another example elevator sheave assembly including three polymer intermediate rings.

[0030] Figure 6 is a cross-sectional view schematically illustrating another elevator sheave assembly including four polymer intermediate rings.

[0031] Figure 7is a partially exploded view of an example embodiment of a polymer end ring.

[0032] Figure 8 is a partially exploded view of an embodiment of a connector for connecting polymer rings.

[0033] Figure 9 is a partially exploded view of another set of connectors.

[0034] Figure 10 is a partially exploded view of an example embodiment of a connector including a portion of a ring formed as a rope wheel assembly.

[0035] Figure 11 is a cross-sectional view schematically illustrating an elevator rope wheel assembly including three rings that collectively form a single belt guide surface.

[0036] Figure 12 is a flowchart diagram outlining an example method of assembling an elevator rope wheel assembly. DETAILED DESCRIPTION

[0037] Figure 1 A selected portion of an elevator system 20 is schematically illustrated. An elevator car 22 is coupled to a counterweight 24 by a rope 26. Although not shown in detail, the rope 26 includes a plurality of tension members, which in this case include flat belts. The rope 26 follows a path that is at least partially defined by rope wheels 30. At least one of the rope wheels 30 is a traction sheave associated with a machine 32 that selectively causes movement of the rope 26 to control movement and position of the elevator car 22 to provide elevator service to passengers. Another of the illustrated rope wheels 30 is an idler sheave that rotates as the rope 26 moves during movement of the elevator car 22.

[0038] Figure 2 An elevator rope wheel assembly is shown that can be used, for example, as an idler sheave 30. The elevator rope wheel assembly includes a plurality of polymer rings that are secured together to form at least one belt guide surface. Figure 2 The plurality of polymer rings in the example embodiment of FIG. 1 includes two polymer rings, one of which is a first polymer end ring 40 at a first longitudinal end of the rope wheel assembly. The first polymer end ring 40 includes an outer circumferential surface 42 having a first profile that defines a portion 44 of the belt guide surface. A flange 46 is positioned along an outer lateral edge of the first polymer end ring 40. The flange 46 forms one end of the belt guide surface.

[0039] In this example embodiment, the other of the two polymer rings is a second polymer end ring 50 located at a second, opposite longitudinal end of the elevator sheave assembly. The second polymer end ring 50 includes an outer circumferential surface 52 that defines another portion 54 of the belt guide surface. A flange 56 at an outer lateral edge of the second polymer end ring 50 forms another outer edge of the belt guide surface.

[0040] Each of the two polymer end rings 40, 50 includes a bearing 70 supported within the ring. The polymer material of the polymer rings 40, 50 overmolds onto the respective bearing 70 such that the bearing is held within an externally molded groove 71 around the bearing 70.

[0041] Figure 2 Embodiments of the present application are configured to accommodate a single belt on the belt guide surface including portions 44 and 54. Other embodiments are configured to accommodate multiple belts.

[0042] Figure 3A An example embodiment configured to accommodate two belts is shown in FIG. 4, where the outer circumferential surface 42 defines a first portion 44 of a first belt guide surface, and the outer circumferential surface 52 defines a first portion 54 of a second belt guide surface. At least one polymer intermediate ring 60 is positioned between and connected to the first polymer end ring 40 and the second polymer end ring 50. The polymer intermediate ring 60 includes an outer circumferential surface 62 having a profile that includes a rib 64. The profile of the outer circumferential surface 62 defines a second portion 66 of the first belt guide surface and a second portion 68 of the second belt guide surface. The rib 64 separates the first belt guide surface 44, 66 from the second belt guide surface 54, 68.

[0043] The first polymer end ring 40 is connected to the polymer intermediate ring 60 along adjacent lateral edges of those rings. Similarly, the second polymer end ring 50 is connected to the polymer intermediate ring 60 along adjacent lateral edges of those rings. All of the polymer rings 40, 50, and 60 are fixed together such that they rotate in unison during movement of the flat belts of the rope 26.

[0044] In this embodiment, the first polymer end ring 40 and the second polymer end ring 50 each include a bearing 70. The polymer material of each ring is overmolded onto the bearing 70 such that the bearing is held fixed in a desired position between the lateral edges of the ring. Overmolding the polymer material onto the bearing 70 of each ring allows for strategic placement of the bearing 70 in a position where load on the ring will be concentrated when the sheave 30 engages the rope 26, which is suspending the load of the elevator car 22 and the counterweight 24.

[0045] As Figure 3AAs shown in FIG. 1, the retaining ring 72 is received in a notch in a shaft 74 that defines the axis of rotation of the rope pulley 30. The bearing 70 rotates about the shaft 74 to facilitate rotation of the rope pulley 30.

[0046] In Figure 3A In the embodiment shown in FIG. 1, the intermediate ring 60 does not include its own bearing 70. In Figure 3B Another example embodiment is shown in FIG. 2, in which the intermediate ring 60 includes its own bearing 70. As with the embodiment shown in FIG. 1, Figure 3A The belts used with the rope pulley 30 shown in FIG. 1 are narrower than the belts used with Figure 3B The embodiment in FIG. 1 is configured to accommodate belts having a wider width. In Figure 3B In the embodiment shown in FIG. 1, the additional width of the belt guide surface is accommodated by the larger longitudinal dimension of the polymer intermediate ring 60.

[0047] Figure 4 Another embodiment of an elevator rope pulley assembly is shown that includes a plurality of polymer intermediate rings. A first polymer intermediate ring 80 is received against and connected to the inner lateral edge of the first polymer end ring 40. The first polymer intermediate ring 80 has an outer circumferential surface 82 that has a profile that defines a second portion 84 of a first belt guide surface. The outer circumferential surface 82 also defines a first portion 86 of a third belt guide surface. A rib 88 separates the second portion 84 of the first belt guide surface from the first portion 86 of the third belt guide surface.

[0048] A second polymer intermediate ring 90 has one lateral edge that is received against the inner lateral surface of the second polymer end ring 50. The other lateral edge of the second polymer intermediate ring 90 is received against an adjacent lateral surface on the first polymer intermediate ring 80. All of the rings 40, 50, 80, and 90 are fixedly connected together to rotate in unison.

[0049] The second polymer intermediate ring 90 includes an outer circumferential surface 92 that defines a second portion 94 of the second belt guide surface and a second portion 96 of the third belt guide surface. A rib 98 separates the portions of the second polymer intermediate ring 90 that contribute to the second and third belt guide surfaces, respectively.

[0050] Figure 4 The embodiment of FIG. 1 is configured to accommodate three belts. Figure 5Another embodiment is shown configured to accommodate four belts. In this example embodiment, a third polymer intermediate ring 100 is positioned between the first polymer intermediate ring 80 and the second polymer intermediate ring 90. The third polymer intermediate ring 100 also has an outer circumferential surface 102. The profile of the outer surface 102 defines a second portion 104 that cooperates with the portion 86 of the first polymer intermediate ring 80 to form a third belt guide surface. Another portion 106 of the outer surface 102 cooperates with the portion 96 of the second polymer intermediate ring 90 to form a fourth belt guide surface. A rib 108 separates the portions 104 and 106 and forms an inner edge of each of the third and fourth belt guide surfaces.

[0051] Figure 6 The embodiment in FIG. 1 1 includes another polymer intermediate ring and is configured to accommodate five belts. In this embodiment, the polymer intermediate ring 100A includes an outer circumferential surface 102A having a profile that includes a portion 104A that defines a third belt guide surface with the portion 86 of the first polymer intermediate ring 80. The polymer intermediate ring 100B has an outer circumferential surface 102B that includes a portion 104B that defines a fourth belt guide surface with the portion 96 of the second polymer intermediate ring 90. Portions 106A and 106B define a fifth belt guide surface at the longitudinal center of the sheave assembly.

[0052] As can be appreciated from the drawings, the first polymer end ring 40 and the second polymer end ring 50 have the same configuration with the same profile on the outer circumferential surfaces 42 and 52. In other words, the polymer end rings 40 and 50 are interchangeable in that they are identical components. Similarly, the first polymer intermediate ring 80 and the second polymer intermediate ring 90 are identical components. The polymer intermediate rings 100, 100A, and 100B are identical. With just those three configurations of polymer rings, a wide variety of elevator sheave assembly configurations are possible to accommodate the desired number of belts. Moreover, different belt widths can be accommodated depending on the polymer ring selected for each location in the elevator sheave assembly.

[0053] The intermediate ring shown in FIG. 1 1 includes a polymer intermediate ring 60 that is identical to the polymer intermediate ring 90 shown in FIG. 1. The intermediate ring shown in FIG. 1 1 also includes a polymer intermediate ring 100 that is identical to the polymer intermediate ring 90 shown in FIG. 1. The intermediate ring shown in FIG. 1 1 also includes a polymer intermediate ring 100A that is identical to the polymer intermediate ring 90 shown in FIG. 1. The intermediate ring shown in FIG. 1 1 also includes a polymer intermediate ring 100B that is identical to the polymer intermediate ring 90 shown in FIG. 1. Figure 2 The intermediate ring shown in FIG. 1 1 includes a polymer intermediate ring 60 that is identical to the polymer intermediate ring 90 shown in FIG. 1. The intermediate ring shown in FIG. 1 1 also includes a polymer intermediate ring 100 that is identical to the polymer intermediate ring 90 shown in FIG. 1. The intermediate ring shown in FIG. 1 1 also includes a polymer intermediate ring 100A that is identical to the polymer intermediate ring 90 shown in FIG. 1. The intermediate ring shown in FIG. 1 1 also includes a polymer intermediate ring 100B that is identical to the polymer intermediate ring 90 shown in FIG. 1.

[0054] One way in which the example elevator sheave assembly differs from conventional metal sheave constructions is that the bearings 70 are strategically placed at selected locations along the entire length of the sheave assembly. With conventional metal sheave constructions, bearings can only be press fit into the end portions of the sheave, but are not present in the central portion of the sheave. With separate polymer rings each having a bearing, it is possible to strategically distribute the load on the bearings along the entire length of the sheave. The location of the bearings 70 within each ring can be selected to align with the concentration of load on that ring when the elevator sheave assembly is used in an elevator system 20.

[0055] In some embodiments, the polymer material used to manufacture the rings is a plastic material that includes nylon. One example material is referred to in the industry as nylon 66, and includes a glass fiber content of approximately 30% to 60%. Such a polymer material provides some flexibility or resiliency along the length of the elevator sheave assembly. This aspect of the polymer material helps enable the bearings to be strategically positioned at locations where the load on the rings is most concentrated when the elevator sheave assembly is used in an elevator system.

[0056] The polymer rings of the illustrated example embodiments can have an entire profile of an outer circumferential surface that is formed during a molding process in which the rings are molded. Alternatively, as shown in FIGS. 6A and 6B, separate flanges 46 can be affixed to the outer lateral edges of the polymer end rings. Figure 7

[0057] The above-described elevator sheave assembly can be manufactured or assembled by connecting selected polymer rings together. Figure 8 An example arrangement is shown in which the polymer rings include recesses 110 on at least one lateral surface of the rings. Connectors 112 are received in the recesses for affixing two adjacent rings together. Figure 9 Another example embodiment is shown in which spring pins 114 are used as the connectors.

[0058] Figure 10 Embodiments are illustrated in which the rings include recesses 116 and protrusions 118 on at least one lateral surface. The arrangement of the recesses 116 and protrusions 118 is the same on each of the illustrated rings 40 and 50. The protrusions 118 are configured to be at least partially received within the recesses 116 for affixing two adjacent rings together. Depending on the construction of the connectors 112, 114 or protrusions 118, an adhesive can be used to form a permanent connection between adjacent rings.

[0059] Figure 11 ​An embodiment is illustrated that includes a first polymer end ring 40 and a second polymer end ring 50 with an intermediate ring 60 between the end rings. The rings 40, 50, and 60 collectively form a single belt guide surface with portions 44, 54, and 64. Each of the rings 40, 50, and 60 includes a bearing 70 within the ring. The single belt guide surface has three associated bearings 70, which can be useful, for example, when the expected load on the corresponding belt requires such support.

[0060] Example embodiments include a number of rings and a number of bearings 70 for each belt guide surface. In some of the disclosed embodiments, the number of bearings is equal to the number of rings, and there are at least two bearings for each belt guide surface because each ring has an associated bearing. In other embodiments, there are more than two bearings for each belt guide surface or fewer than two bearings for each belt guide surface.

[0061] Figure 12 A flowchart diagram 120 is included that outlines a method of manufacturing an elevator sheave assembly consistent with the embodiments discussed above. In Figure 12 the case where at least one polymer intermediate ring is included between the first polymer end ring 40 and the second polymer end ring 50. The example method includes, at 122, positioning the first polymer end ring 40 at a first longitudinal end of the sheave assembly. At 124, the polymer intermediate ring 60 is connected to the first polymer end ring 40. At 126, the polymer intermediate ring 60 is connected to the second polymer end ring 50 to position the second polymer end ring at a second longitudinal end of the sheave assembly.

[0062] The use of polymer rings of the type illustrated in the drawings and described above allows for accommodating a variety of sheave requirements in a variety of elevator system configurations. Having four basic polymer ring components allows for accommodating any number of belts, and allows for forming a belt guide surface that can accommodate belts of different widths.

[0063] The foregoing description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples can become apparent to those skilled in the art upon access to the teachings provided herein. Such variations and modifications do not necessarily depart from the spirit of the present application. The legal scope of the invention is set by the appended claims.

Claims

1. An elevator sheave assembly comprising a plurality of polymer rings secured together, the plurality of polymer rings including at least two polymer rings each having an outer circumferential surface defining a portion of a belt guide surface adjacent a flange at a longitudinal end of the sheave assembly, the at least two polymer rings each including a bearing supported inside the ring, wherein the at least two polymer rings are a first polymer end ring and a second polymer end ring; the first polymer end ring is at a first longitudinal end of the sheave assembly; the outer circumferential surface of the first polymer end ring has a first profile defining a first portion of a first belt guide surface; the second polymer end ring is at a second longitudinal end of the sheave assembly; the outer circumferential surface of the second polymer end ring has a second profile defining a first portion of a second belt guide surface; the plurality of polymer rings includes at least one polymer intermediate ring positioned between and connected to the first polymer end ring and the second polymer end ring; and the at least one polymer intermediate ring includes an outer circumferential surface having a profile defining a second portion of the first belt guide surface and a second portion of the second belt guide surface.

2. The elevator sheave assembly of claim 1, wherein the at least one polymer intermediate ring includes a plurality of polymer intermediate rings including a first intermediate ring received adjacent and connected to the first polymer end ring and a second intermediate ring received adjacent and connected to the second polymer end ring; the profile of the outer circumferential surface of the first intermediate ring defines the second portion of the first belt guide surface; and the profile of the outer circumferential surface of the second intermediate ring defines the second portion of the second belt guide surface.

3. The elevator sheave assembly of claim 2, wherein the first intermediate ring is connected to the second intermediate ring; the profile of the outer circumferential surface of the first intermediate ring defines a first portion of a third belt guide surface; and the profile of the outer circumferential surface of the second intermediate ring defines a second portion of the third belt guide surface.

4. The elevator sheave assembly of claim 3, wherein, the profile of the outer circumferential surface of the first intermediate ring is the same as the profile of the outer circumferential surface of the second intermediate ring.

5. The elevator sheave assembly of claim 2, wherein the plurality of polymer intermediate rings includes at least one third intermediate ring between and connected to the first intermediate ring and the second intermediate ring; the profile of the outer circumferential surface of the first intermediate ring defines a first portion of a third belt guide surface; the profile of the outer circumferential surface of the second intermediate ring defines a first portion of a fourth belt guide surface; and the profile of the outer circumferential surface of the at least one third intermediate ring defines a second portion of the third belt guide surface and a second portion of the fourth belt guide surface.

6. The elevator sheave assembly of claim 5, wherein the at least one third intermediate ring comprises two third intermediate rings; the two third intermediate rings are connected together at a longitudinal center of the elevator sheave assembly; and the profile of the outer circumferential surface of the two third intermediate rings defines a fifth belt guide surface at the longitudinal center of the elevator sheave assembly.

7. The elevator sheave assembly of claim 1, wherein, a polymer of each of the at least two polymer rings is overmolded onto a portion of the bearing to retain the bearing within the ring.

8. The elevator sheave assembly of claim 7, wherein, each of the rings includes only a single bearing.

9. The elevator sheave assembly of claim 8, wherein, the single bearing is positioned at a location corresponding to a concentration of load on the ring.

10. The elevator sheave assembly of claim 1, comprising a connector securing the at least one polymer intermediate ring to the first and second polymer end rings.

11. The elevator sheave assembly of claim 10, wherein, the connector comprises a separate piece at least partially received into a lateral surface on the polymer ring.

12. The elevator sheave assembly of claim 10, wherein, the connector is formed as part of the polymer ring.

13. The elevator sheave assembly of claim 12, wherein the first and second polymer end rings comprise at least one of a protrusion extending from a lateral surface and a recess in the lateral surface; the at least one polymer intermediate ring comprises at least one of a recess in a lateral surface on the at least one polymer intermediate ring and a protrusion extending from the lateral surface on the at least one polymer intermediate ring; and the protrusion and recess cooperate to connect the at least one polymer intermediate ring to the first and second polymer end rings.

14. A method of manufacturing an elevator sheave assembly, the method comprising: positioning a first polymer end ring at a first longitudinal end of the sheave assembly, the first polymer end ring comprising an outer circumferential surface having a first profile defining a first portion of a first belt guide surface; connecting at least one polymer intermediate ring to the first polymer end ring, the at least one polymer intermediate ring comprising an outer circumferential surface having a profile defining a second portion of the first belt guide surface; and connecting a second polymer end ring to the at least one polymer intermediate ring to position the second polymer end ring at a second longitudinal end of the sheave assembly, the second polymer end ring comprising an outer circumferential surface having a second profile defining a first portion of a second belt guide surface, the at least one polymer intermediate ring profile defining a second portion of the second belt guide surface.

15. The method of claim 14, wherein, the at least one polymer intermediate ring comprises a plurality of polymer intermediate rings, the plurality of polymer intermediate rings comprising a first intermediate ring and a second intermediate ring; and the method comprises connecting the first intermediate ring to the first polymer end ring, connecting the second intermediate ring to the second polymer end ring, and connecting the first intermediate ring to the second intermediate ring.

16. The method of claim 15, wherein the profile of the outer circumferential surface of the first intermediate ring defines the second portion of the first belt guide surface; the profile of the outer circumferential surface of the first intermediate ring defines a first portion of a third guide surface; the profile of the outer circumferential surface of the second intermediate ring defines the second portion of the second guide surface; and the profile of the outer circumferential surface of the second intermediate ring defines a second portion of the third guide surface.

17. The method of claim 15, wherein the first profile is the same as the second profile; and the profile of the outer circumferential surface of the first intermediate ring is the same as the profile of the outer circumferential surface of the second intermediate ring.

18. The method of claim 14, comprising overmolding material of the first polymer end ring onto a bearing; and overmolding material of the second polymer end ring onto a bearing.

19. The method of claim 18, comprising positioning the bearing of each of the polymer end rings in a location corresponding to a concentration of load on the polymer end ring.

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