Elevator connector with alignment feature

Abstract

An elevator connector having an alignment feature, the connector comprising: a body defining an interior cavity configured to receive a suspension member of an elevator system; and at least one suspension member alignment feature formed on the inner wall surface surrounding the inner cavity. The connector further includes a plurality of contact members establishing an electrically conductive connection with a tensioning member of the suspension members, with at least one suspension member alignment feature aligning the contact members with the tensioning member.

Description

Technical Field

[0001] The present invention relates to an elevator connector having an alignment feature. Background Art

[0002] Elevator systems are widely used to transport passengers between floors in a building, for example. Some elevator systems are traction-based, where a suspension assembly (sometimes called a rope) suspends the elevator car and counterweight. The suspension assembly also facilitates movement of the elevator car when needed. Traditional suspension assemblies include round steel ropes. More recently, elevator systems have included other types of suspension members, such as flat belts or other types of ropes having tensioning members wrapped in a compressible polymer sheath.

[0003] Conventional round steel ropes are typically inspected using a manual process involving manual and visual observation of the condition of the outer surface of the rope. Coated belts and other coated ropes cannot be inspected in that manner. Electrical inspection techniques have been developed that involve applying an electrical current to at least some of the tensioning members and measuring electrical properties, such as resistance, to obtain information indicative of the condition of the belt or coated rope. Connectors are used to connect the coated belt to a monitoring device. The electrical connection elements should be properly aligned relative to the connector. The connection is determined by the interaction of several dimensions, which can result in misaligned connections. Summary of the invention

[0004] An illustrative example connector includes: a body defining an internal cavity configured to receive a suspension member of an elevator system; at least one suspension member alignment feature formed on an inner wall surface surrounding the internal cavity; and a plurality of contact members establishing conductive connections with tension members in the suspension member, wherein at least one suspension member alignment feature aligns the contact members with the tension members.

[0005] In addition to or as an alternative to one or more of the features described above, at least one suspension member alignment feature includes at least one contact surface extending at an angle relative to the inner wall surface.

[0006] In addition to or alternatively to one or more of the features described above, at least one of the contact surfaces includes a key centered within the internal cavity.

[0007] In addition to or as an alternative to one or more of the features described above, at least one contact surface comprises at least one resilient finger.

[0008] In addition to or alternatively to one or more of the features described above, the internal cavity is defined by a width extending from a first end wall of the internal cavity to a second end wall of the internal cavity opposite the first end wall, and wherein at least one contact surface includes an inclined surface extending at an angle relative to the first end wall to provide the first end wall with a first end wall shape.

[0009] Additionally or alternatively to one or more of the features described above, the second end wall has a second end wall shape that is different than the first end wall shape.

[0010] In addition to one or more of the features described above, or as an alternative, the body has a first wall, a second wall opposite to the first wall, a first end wall connecting one end of the first wall to one end of the second wall, and a second end wall connecting the opposite end of the first wall to the opposite end of the second wall, and wherein one of the first wall and the second wall includes a plurality of openings, each of which receives a contact member.

[0011] An illustrative example elevator system includes: an elevator car; at least one suspension member that supports the elevator car and facilitates movement of the elevator car; a connector that defines an interior cavity surrounded by a plurality of walls, wherein a portion of at least one suspension member extends into the interior cavity; at least one alignment feature formed in the interior cavity, the at least one alignment feature being used to directly engage the at least one suspension member; and a plurality of contact members that establish a conductive connection with a tensioning member in the at least one suspension member, and wherein the at least one alignment feature aligns the contact members with the tensioning members.

[0012] In addition to or as an alternative to one or more of the features described above, at least one alignment feature includes at least one contact surface that extends at an angle relative to at least one wall surface of the plurality of walls defining the interior cavity.

[0013] In addition to or alternatively to one or more of the features described above, at least one of the contact surfaces includes a key centered within the internal cavity.

[0014] In addition to or as an alternative to one or more of the features described above, at least one contact surface comprises at least one resilient finger.

[0015] Additionally or alternatively to one or more of the features described above, the at least one resilient finger comprises at least a pair of resilient fingers, wherein one finger is located on one side of the interior cavity and the other finger is located on an opposite side of the interior cavity.

[0016] In addition to or alternatively to one or more of the features described above, the internal cavity is defined by a width extending from a first end wall of the plurality of walls to a second end wall of the plurality of walls opposite the first end wall, and wherein at least one contact surface includes an inclined surface extending at an angle relative to the first end wall to provide a first end wall shape, and wherein the second end wall has a second end wall shape that is different from the first end wall shape.

[0017] In addition to or alternatively to one or more features described above, at least one suspension member includes a first edge extending along the length of the at least one suspension member and a second edge opposite the first edge, and wherein the first edge has a first edge shape that matches the first end wall shape, and the second edge has a second edge shape that matches the second end wall shape.

[0018] In addition to or alternatively to one or more of the features described above, at least one suspension member comprises a flat band comprising a tensioning member wrapped in a sheath, wherein at least one of the plurality of walls comprises a plurality of openings to receive a contact member that directly engages the at least one suspension member through the plurality of openings.

[0019] Additionally or alternatively to one or more of the features described above, a center contact member of the plurality of contact members is aligned with a center of at least one suspension member at a location between two adjacent tensioning members.

[0020] An illustrative example method for aligning a suspension member within an internal cavity of a connector includes: forming at least one alignment feature on an inner wall surface surrounding the internal cavity; directly engaging a surface of the suspension member on the at least one alignment feature to provide a properly aligned position of the suspension member within the internal cavity; and aligning a contact member with a tensioning member in response to the at least one alignment feature to establish a conductive connection between a plurality of contact members and a tensioning member in the suspension member.

[0021] In addition to or alternatively to one or more of the features described above, the suspension member includes a flat band, the flat band includes a tensioning member wrapped in a sheath, and the method includes: passing the contact member through the wall of the connector so that when in a properly aligned position, a center contact member of the plurality of contact members is aligned with the center of the suspension member at a position between two adjacent tensioning members.

[0022] In addition to or alternatively to one or more of the features described above, the method includes: forming a first end wall of the internal cavity to have a first end wall shape to provide at least one alignment feature; forming a second end wall of the internal cavity to have a second end wall shape different from the first end wall shape; forming a first longitudinal edge of the suspension member to have a first edge shape matching the first end wall shape; and forming a second longitudinal edge of the suspension member to have a second edge shape matching the second end wall shape.

[0023] In addition to or as an alternative to one or more of the features described above, the method includes forming at least one key or finger to extend outwardly from the inner wall surface to provide at least one alignment feature.

[0024] The various features and advantages of the exemplary embodiments will become apparent to those skilled in the art from the following detailed description.The drawings that accompany the detailed description can be briefly described as follows. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 Selected portions of an elevator system are shown schematically.

[0026] Figure 2 A portion of an example suspension member is schematically shown.

[0027] Figure 3A An example of a cross section of a connector is schematically shown.

[0028] Figure 3B A cross section of a suspension member is schematically shown.

[0029] Figure 3C Schematic diagram showing the installation Figure 3A The connector inside Figure 3B Cross section of a suspension member.

[0030] Figure 3D Schematically shows Figure 3C A top view of a suspension member and connector with a portion of the connector removed.

[0031] Figure 4A Another example of a cross section of a connector is schematically shown.

[0032] Figure 4B A cross section of a suspension member is schematically shown.

[0033] Figure 4C Schematic diagram showing the installation Figure 4A The connector inside Figure 4B Cross section of a suspension member.

[0034] Figure 4D Schematically shows Figure 4C A top view of a suspension member and connector with a portion of the connector removed.

[0035] Figure 5A A cross section of another example of a suspension member installed within a connector is schematically shown.

[0036] Figure 5B Schematically shows Figure 5A A top view of a suspension member and connector with a portion of the connector removed.

[0037] Figure 6 is a flow chart of an example implementation of an alignment method. DETAILED DESCRIPTION

[0038] Embodiments of the present disclosure provide a connector having an internal cavity configured to receive a suspension member and alignment features formed on an inner wall surface surrounding the internal cavity. The connector includes a contact member that establishes a conductive connection with a tensioning member in the suspension member, wherein the alignment features align the contact member with the tensioning member through a common reference. By creating a single common reference from which all tensioning members and contact members are sized and controlled, dependencies on connector slot width, band width, and cable-to-edge positioning can be eliminated from the tolerance stack.

[0039] Figure 1 Schematically illustrated are selected portions of an elevator system 20. An elevator car 22 is supported by a rope arrangement or suspension assembly 24 that includes a plurality of suspension members 26. The elevator car 22 is coupled to a counterweight 28 via the suspension members 26. The suspension members 26 move about pulleys 38 as the elevator car 22 moves between landings or floors.

[0040] The suspension member monitoring device includes at least one processor 30 configured to determine the condition of each suspension member 26. The processor 30 in the illustrated example includes a computing device and associated memory. The processor 30 is programmed or otherwise configured to use a combination of different types of information and criteria indicative of the respective conditions of the suspension members 26 to determine when it is desirable or necessary to remove any of the suspension members 26 from service.

[0041] The electrical-based monitor 32 uses electrical inspection techniques and generates or provides corresponding indications regarding the condition of each suspension component 26. The processor 30 receives the indications from the electrical-based monitor 32.

[0042] In some example embodiments, the electrical-based monitor 32 is configured to apply electricity to at least one tension member (such as a wire rope) of each suspension member 26 and detect or measure the resistance of the tension member. Changes in resistance indicate changes in the state of the suspension member 26. Such resistance-based inspection techniques are known and need not be further described herein.

[0043] Figure 2 A portion of an example suspension member 26 is schematically shown. In the illustrated embodiment, the suspension member 26 is a flat belt that includes a plurality of tension members 34 that are encased in a sheath 36 of a compressible material such as polyurethane. In many embodiments, the tension members 34 include steel cables. Other embodiments include tension members made of different materials. The electrical inspection technique takes advantage of the conductive properties of the tension members 34.

[0044] Connector 40 is used to connect the electrical based monitor 32 to the associated suspension member 26 ( Figure 1 In one example, the electrical-based monitor 32 wirelessly transmits the resistance information to the processor 30 .

[0045] In one example, the connector 40 defines an interior cavity 42 surrounded by a plurality of walls. Figure 3A In one example shown, the plurality of walls include a first wall 44, a second wall 46 opposite the first wall 44, a first end wall 48 connecting one end of the first wall 44 to one end of the second wall 46, and a second end wall 50 connecting the opposite end of the first wall 44 to the opposite end of the second wall 46. The plurality of walls 44, 46, 48, 50 cooperate to completely surround and enclose the interior cavity 42. A portion 52 of the suspension member 26 extends into the interior cavity 42, as shown in FIG. Figure 3D shown.

[0046] Figures 3A-3C An example of an alignment feature 54 formed within the interior cavity 42 is shown. At least one alignment feature 54 is configured to directly engage the suspension member 26. The connector 40 further includes a plurality of contact members 56 ( Figure 3C ), which establishes a conductive connection with the tension members 34 in the suspension member 26. The alignment features 54 align the contact members 56 and the tension members 34 to a common reference R to reduce potential misalignment between the suspension member 26 and the contact members 56. If there is misalignment, one of the tension members 34 may not have a conductive connection with one of the contact members 56, which means that there will be no resistance information for that tension member 34.

[0047] In one example, the alignment feature 54 includes at least one contact surface that extends at an angle relative to at least one wall surface of the plurality of walls 44, 46, 48, 50 defining the interior cavity 42. In one example, the contact surface includes a small portion of the wall surface that extends at an angle relative to the main wall surface. In one example, the alignment feature 54 includes a contact surface formed as at least one protrusion or depression within at least one wall surface of the plurality of walls defining the interior cavity 42.

[0048] Figures 3A-3C An example is disclosed in which the contact surface of the alignment feature 54 includes a key 58 protruding outward from the wall 46. In one example, the key 58 has a first surface extending at an angle relative to the inner wall surface 88 of the second wall 46, a second surface extending at an angle relative to the inner wall surface 88 of the second wall 46, and a third surface connecting the first surface and the second surface. The alignment feature 54 further includes a receiver area 60 formed in the suspension member 26, such as Figure 3BIn one example, the cross-sectional shape of the receiver area 60 corresponds or matches the cross-sectional shape of the key 58. In one example, the receiver area 60 is formed within the sheath 36 during the production of the strap to extend along the entire length of the suspension member 26. This will allow the connector 40 to be used anywhere on the suspension member 26.

[0049] exist Figure 3A In the example shown, the key 58 has a trapezoidal cross-section; however, other cross-sectional shapes may also be used. For example, the key 58 may have a triangular cross-section, a square cross-section, or any other polygonal shape. In addition, the key 58 may have a curved cross-section or a cross-section having a combination of curved and linear shapes.

[0050] In one example, the key 58 is centered within the interior cavity 42, as shown in FIG. Figures 3A-3C When the suspension member 26 is received in the interior cavity 42, the key 58 is inserted into the receiver area 60, as shown. Figure 3C Thus, this example uses features created during production of the strap that mate with features on connector 40 to align to a common reference R.

[0051] In one example, proper alignment includes a configuration in which each tensioning member 34 contacts one of the contact members 56, such as Figure 3D As shown. In one example, the contact members 56 include screws or other similar fastening elements. In one example, there are twelve tension members 34 and seven contact members 56. When properly aligned, the center contact member 56a is aligned with the center of the suspension member 26 at a position between two adjacent tension members 34a, 34b located in the middle of the suspension member 26. Therefore, one side of the center contact member 56a contacts the tension member 34a, and the opposite side of the center contact member 56a contacts the tension member 34b. The edge tension members 34c, 34d each directly and respectively engage only with the end contact members 56c, 56d. The remaining contact members 56 are aligned between adjacent tension members 34 so that one side of the contact member 56 contacts one tension member 34 and the opposite side of the contact member 56 contacts the other tension member 34. It should be understood that the twelve tension members 34 and the seven contact members 56 are shown as an example, and the number of tension members and contact members can be changed as needed.

[0052] Figures 4A-4DAnother example of an alignment feature 54 is disclosed. In this example, the inclined contact surface of the alignment feature 54 includes a contoured portion of one of the end walls 48, 50, the contoured portion defining an asymmetric feature. The internal cavity 42 is defined by a width extending from the first end wall 48 to the second end wall 50. The contact surface includes at least one inclined surface 70 that extends at an angle relative to the first end wall 48 to provide a first end wall shape. In the example shown, the contact surface includes two inclined surfaces 70 that are interconnected via a flat surface portion of the end wall 48. The inclined surfaces 70 extend at a non-parallel and non-perpendicular angle relative to the flat surface portion. The second end wall 50 has a second end wall shape that is different from the first end wall shape.

[0053] The suspension member 26 includes a first edge 72 extending along the length of the suspension member 26 and a second edge 74 opposite the first edge 72. In one example, the first edge 72 has a first edge shape that matches the shape of the first end wall, and the second edge 74 has a second edge shape that matches the shape of the second end wall. This means that the suspension member 26 can only be installed in the connector 40 in one orientation. In one example, the first edge 72 has an inclined surface 76 connected to each other by a straight surface 80 to form a shape common to the shape of the first end wall. In one example, the second edge 74 has a square shape to match the square end of the second end wall 50. It should be understood that other shapes can also be used.

[0054] In one example, at least one resilient finger 62 additionally functions as a compliant feature to allow the first edge 72 of the suspension member to directly engage the first end wall 48 to achieve proper alignment. Thus, in this example, the alignment feature 54 comprises an asymmetric feature added to the suspension member 26 that allows only one installation orientation and is combined with the use of a compliant feature to align to a common reference R.

[0055] Figure 5A-5B Another example of an alignment feature 54 is disclosed. In this example, the inclined contact surface of the alignment feature 54 includes at least one resilient finger 62. In this example, the resilient finger 62 is formed in one of the first end wall 48 and the second end wall 50. In one example, the at least one finger 62 includes at least a pair of resilient fingers 62, one of which is located on one side of the interior cavity 42 and the other of which is located on the opposite side of the interior cavity 42, such as Figure 5B shown.

[0056] In one example, a recess 64 for each finger 62 is formed in the associated end wall 48, 50 to associate with the corresponding finger 62. In one example, the finger 62 has a first end 66 that is retained in the recess 62 and extends to a cantilevered distal end 68 that is movable between an uninstalled position and an installed position. When the suspension member 26 is in the uninstalled position, the finger 62 is resiliently biased to an outward position within the interior cavity 42. When the suspension member 26 is in the installed position ( Figure 5B ), the fingers 62 are pressed outwardly away from each other and toward their respective recesses 64 by the opposing edges 72, 74 of the suspension member 26. Thus, in this example, the fingers 62 include a compliant feature that resiliently grips the suspension member 26 and centers it in a properly aligned position relative to the common reference R. In this position, the contact member 56 is aligned relative to the tensioning member 34 in a manner similar to that described above with respect to Figure 3D The way of description.

[0057] Figure 6 is a flow chart of an example implementation of an alignment method. In one example, a method of aligning a suspension member 26 within an internal cavity 42 of a connector 40 includes forming at least one alignment feature 54 on an inner wall surface surrounding the internal cavity 42, as indicated at step 100. Next, a suspension member surface is directly engaged with the at least one alignment feature 54 to provide a properly aligned position of the suspension member 26 within the internal cavity 42, as indicated at step 200. Next, a contact member 56 is aligned with a tension member 34 in response to the at least one alignment feature 54, and a conductive connection is established between the contact member 56 and the tension member 34 in the suspension member 26, as indicated at step 300.

[0058] In one example, one of the plurality of walls 44, 46, 48, 50 is formed with an opening 78 to receive a contact member 56 that directly engages the tensioning member 34. In one example, step 300 of the method further includes inserting the contact member 56 through the wall of the connector 40 such that a center contact member 56a of the plurality of contact members 56 is aligned with the center of the suspension member 26 at a location between two adjacent tensioning members 34a, 34b when in a properly aligned position.

[0059] In one example, forming at least one alignment feature 54 includes forming an asymmetric feature, as set forth at step 110. In one example, step 110 includes: forming a first end wall of the interior cavity to have a first end wall shape to provide at least one alignment feature; forming a second end wall of the interior cavity to have a second end wall shape different from the first end wall shape; forming a first longitudinal edge of the suspension member to have a first edge shape matching the first end wall shape; and forming a second longitudinal edge of the suspension member to have a second edge shape matching the second end wall shape.

[0060] In another example, forming at least one alignment feature 54 includes forming a raised feature, as set forth at step 120. In one example, step 120 includes forming at least one key or finger to extend outwardly from the inner wall surface to provide the at least one alignment feature.

[0061] Current resistance-based inspection connector and strap production process capabilities present a narrow design window to ensure that the connector's contact member is properly mated with the tensioning member. The success of the connection is determined by the interaction of several dimensions. Future designs may further narrow the window, which will require additional measures to improve alignment. The present subject disclosure provides several methods for reducing potential misalignment between the contact member and the tensioning member. These methods include using mating male / female features on the connector and the suspension member, using compliant features inside the connector to center the suspension member, or adding features to ensure one installation orientation while aligning to a common reference using compliant features. By creating a single common reference against which all tensioning members on the suspension member and the contact member on the connector are sized and controlled, dependencies on dimensions such as connector slot width, suspension member width, and tensioning member-to-edge positioning can be eliminated from the cumulative tolerances.

[0062] The foregoing description is exemplary rather than limiting in nature. Those skilled in the art may appreciate variations and modifications to the disclosed examples that do not necessarily depart from the spirit of the invention. The scope of legal protection afforded to this invention can only be determined by studying the appended claims.

Claims

1. A connector, comprising: a body defining an interior cavity configured to receive a suspension member of an elevator system; at least one suspension member alignment feature formed on an interior wall surface surrounding the interior cavity; as well as A plurality of contact members establish conductive connections with tension members in the suspension member, wherein the at least one suspension member alignment feature aligns the contact members with the tension members.

2. The connector according to claim 1, wherein: The at least one suspension member alignment feature includes at least one contact surface extending at an angle relative to the inner wall surface.

3. The connector according to claim 2, wherein: The at least one contact surface includes a key centered within the interior cavity.

4. The connector according to claim 2, wherein: The at least one contact surface includes at least one resilient finger.

5. The connector according to claim 2, wherein: The interior cavity is defined by a width extending from a first end wall of the interior cavity to a second end wall of the interior cavity opposite the first end wall, and wherein the at least one contact surface includes an inclined surface extending at an angle relative to the first end wall to provide the first end wall with a first end wall shape.

6. The connector according to claim 5, wherein: The second end wall has a second end wall shape that is different from the first end wall shape.

7. The connector according to claim 1, wherein: The body has a first wall, a second wall opposite to the first wall, a first end wall connecting one end of the first wall to one end of the second wall, and a second end wall connecting the opposite end of the first wall to the opposite end of the second wall, and wherein one of the first wall and the second wall includes a plurality of openings, each of which receives a contact member.

8. An elevator system, comprising: Elevator car; at least one suspension member that supports the elevator car and facilitates movement of the elevator car; a connector defining an interior cavity surrounded by a plurality of walls, wherein a portion of the at least one suspension member extends into the interior cavity; at least one alignment feature formed within the interior cavity, the at least one alignment feature configured to directly engage the at least one suspension member; as well as A plurality of contact members establish conductive connections with a tension member of the at least one suspension member, and wherein the at least one alignment feature aligns the contact members with the tension member.

9. The elevator system according to claim 8, wherein: The at least one alignment feature includes at least one contact surface extending at an angle relative to at least one wall surface of the plurality of walls defining the interior cavity.

10. The elevator system according to claim 9, wherein: The at least one contact surface includes a key centered within the interior cavity.

11. The elevator system according to claim 9, wherein: The at least one contact surface includes at least one resilient finger.

12. The elevator system according to claim 11, wherein: The at least one resilient finger includes at least a pair of resilient fingers, with one finger located on one side of the interior cavity and the other finger located on an opposite side of the interior cavity.

13. The elevator system according to claim 9, wherein: The internal cavity is defined by a width extending from a first end wall among the plurality of walls to a second end wall among the plurality of walls opposite the first end wall, and wherein the at least one contact surface includes an inclined surface extending at an angle relative to the first end wall to provide a first end wall shape, and wherein the second end wall has a second end wall shape that is different from the first end wall shape.

14. The elevator system according to claim 13, wherein: The at least one hanging member includes a first edge extending along the length of the at least one hanging member and a second edge opposite the first edge, and wherein the first edge has a first edge shape that matches the first end wall shape, and the second edge has a second edge shape that matches the second end wall shape.

15. The elevator system according to claim 8, wherein: The at least one suspension member comprises a flat band including a tensioning member encased in a sheath, wherein at least one wall of the plurality of walls comprises a plurality of openings to receive a contact member that directly engages the at least one suspension member via the plurality of openings.

16. The elevator system according to claim 15, wherein: A central contact member among the plurality of contact members is aligned with a center of the at least one suspension member at a position between two adjacent tensioning members.

17. A method of aligning a suspension member within an internal cavity of a connector, the method comprising: forming at least one alignment feature on an inner wall surface surrounding the inner cavity; causing a suspension member surface to directly engage the at least one alignment feature to provide a properly aligned position of the suspension member within the interior cavity; as well as In response to the at least one alignment feature aligning the contact members with the tension members, an electrically conductive connection is established between the plurality of contact members and the tension members in the suspension member.

18. The method according to claim 17, wherein: The suspension member comprises a flat belt including a tensioning member encased in a sheath, and the method comprises: The contact members are inserted through the wall of the connector such that a center contact member of the plurality of contact members is aligned with the center of the suspension member at a location between two adjacent tensioning members when in the properly aligned position.

19. The method according to claim 17, comprising: forming a first end wall of the interior cavity to have a first end wall shape to provide at least one alignment feature; forming a second end wall of the internal cavity to have a second end wall shape different from the first end wall shape; forming a first longitudinal edge of the suspension member to have a first edge shape matching the first end wall shape; and forming a second longitudinal edge of the hanging member to have a second edge shape matching the shape of the second end wall.

20. The method of claim 17 including forming at least one key or finger to extend outwardly from the inner wall surface to provide the at least one alignment feature.

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