Elevator machine

Abstract

A gearless elevator machine (1) comprising a first bearing housing (14) supporting a first bearing (48a), a second bearing housing (56) supporting a second bearing (48b), a shaft (30) supported by the first bearing (48a) and the second bearing (48b), and a motor (60) arranged to drive rotation of the shaft (30). The gearless elevator machine (1) further comprises at least one spacer (5) extending between the first bearing housing (14) and the second bearing housing (56) and removably attaching the first bearing housing (14) to the second bearing housing (56).

Description

Technical Field

[0001] This disclosure relates to a gearless elevator machine, an elevator system including the gearless elevator machine, a method for assembling the gearless elevator machine, and a kit for assembling the gearless elevator machine. Background Technology

[0002] It is known to provide gearless elevator machines to elevator systems, which are arranged to drive the movement of the tensioned components and thus move the elevator car. It is also known to provide different elevator machine constructions and designs with varying lengths and speeds to suit the different needs of various elevator systems. Furthermore, it is known to provide bearing housings in such systems to house bearings supporting a rotating shaft, wherein two bearing housings and an intermediate member between them are formed as a single integral piece. The dimensions and shape of this piece are specifically designed for a particular type and size of elevator machine.

[0003] This application seeks to provide an improved gearless elevator machine and a method for assembling the gearless elevator machine. Summary of the Invention

[0004] According to a first aspect of this disclosure, a gearless elevator machine is provided, comprising:

[0005] A first bearing housing and a first bearing, wherein the first bearing housing supports the first bearing.

[0006] The second bearing housing supports the second bearing.

[0007] The shaft is supported by a first bearing and a second bearing;

[0008] A motor, arranged to drive the shaft to rotate; and

[0009] At least one spacer extends between the first bearing housing and the second bearing housing, and removably attaches the first bearing housing to the second bearing housing.

[0010] The first and second bearing housings are removably attached together. It will be understood that the first and second bearing housings are not integrally formed as a single piece, but rather two separate individual pieces that are then attached together by one or more intermediate members (spacers). "Removably attached" will be understood as the possibility of removing one part from the other, in the sense that they are separable individual parts without having to disassemble a single integral piece into multiple parts. Removal does not necessarily have to be easy or require minimal force; for example, spacers may be glued or fixedly attached to one or both of the bearing housings.

[0011] Because the bearing housing is formed as a separate, independent part, the same (i.e., identical) bearing housing can be used with shafts of different lengths and spacers arranged between them to create gearless elevator machines of different lengths suitable for different applications. This allows for changes to only certain parts between different types or sizes of machines, while other parts (such as the bearing housing) can be used across a range of different machines, where other parts are interchangeable, thus providing modular gearless elevator machines.

[0012] The arrangement disclosed herein further has the advantage that a lighter material (or a variety of materials) can be selected for the spacer than for the bearing housing, thus reducing the overall weight of the gearless elevator machine compared to known arrangements in which the bearing housings are formed together as a single integral piece (including the connecting portion between them). It also allows the first and second bearing housings to be made of materials different from each other (and from the spacer material).

[0013] According to a second aspect of this disclosure, an elevator system is provided, comprising:

[0014] At least one tension member;

[0015] An elevator car suspended by tension components; and

[0016] A gearless elevator machine as described above and further described in detail below, wherein the shaft includes at least one pulley, and wherein at least one tension member engages with at least one pulley such that the movement of the elevator car is driven by the rotation of the shaft of the motor.

[0017] The elevator system may further include a counterweight, which is suspended by tension components.

[0018] In some examples, the gearless elevator machine further includes a brake coil arranged to engage and disengage a brake to brake rotation of the shaft, wherein the brake coil is received (i.e., housed) within a first bearing housing (e.g., within a recess defined by the first bearing housing). It will thus be understood that the brake coil is integrally integrated within the first bearing housing. Therefore, the first bearing housing may define a length (along the axial direction) and optionally also a height and depth along the vertical direction, and the brake coil may be received within the length of the first bearing housing (and optionally also the height and depth). In some examples, the first bearing housing is shaped to receive the recess (or cavity) of the brake coil. The first bearing housing may be referred to as a brake housing. In some examples, the gearless elevator machine further includes a brake.

[0019] In some examples, the gearless elevator machine (e.g., the braking assembly of the gearless elevator machine) includes a brake disc, a moving plate, and a fixed plate, wherein the brake disc is positioned between the moving plate and the fixed plate. A brake coil may be arranged to actuate movement of the moving plate (e.g., cooperating with one or more bias springs). In some examples, the moving plate and / or the fixed plate has a (substantially) square shape (i.e., in a plane perpendicular to the elongated axis of the gearless elevator machine). In some examples, the first bearing housing has a (substantially) square shape (i.e., in a plane perpendicular to the elongated axis of the gearless elevator machine). This allows the bushing for supporting the moving plate to be located in the corner of the substantially square shape, leaving a larger internal area that advantageously accommodates a larger brake disc.

[0020] It is advantageous to house the brake coil within the first bearing housing because it reduces the overall length (in the axial direction) of the gearless elevator machine, as the brake coil is located within the length of the first bearing housing and no separate length section is required therein. Furthermore, it reduces the volume of material required to form the first bearing housing, and thus reduces the weight of the required material.

[0021] This advantageous feature is itself considered novel and inventive, and therefore, according to the third aspect, a gearless elevator machine is provided, comprising:

[0022] A first bearing housing and a first bearing, wherein the first bearing housing supports the first bearing.

[0023] The shaft is supported by a first bearing;

[0024] A motor, arranged to drive the shaft to rotate; and

[0025] A brake coil, arranged to engage and disengage the brake to brake the rotation of the shaft, wherein the brake coil is housed within a first bearing housing.

[0026] In some examples of this, the gearless elevator machine further includes a second bearing housing and a second bearing, the second bearing housing supporting the second bearing. The shaft may also be supported by the second bearing.

[0027] In some examples (i.e., any aspect described herein), the braking coil comprises copper (or is made of copper).

[0028] In some examples, the first bearing housing comprises steel (or is made of steel). This is advantageous, especially when the first bearing housing houses the brake coil, because steel is compatible with copper coils.

[0029] In some examples, the motor includes a rotor and a stator, the stator being arranged to selectively drive the rotation of the rotor. The rotor may be connected to a shaft such that the rotation of the rotor drives the shaft to rotate. In some examples, the stator is attached (i.e., mounted to) a second bearing housing. The second bearing housing may be referred to as a motor housing. The stator may be attached to the second bearing housing by one or more screws. Therefore, the stator and / or the second bearing housing may include threaded holes to receive screws. Thus, the second bearing housing advantageously provides convenient mounting for the stator. Furthermore, by precisely and accurately mounting the stator to the second bearing housing (e.g., through precise positioning via threaded holes) and precisely positioning the rotor, it is ensured that the rotor is concentrically located within the stator without the need for additional positioning portions, such as flanges.

[0030] The rotor can be mounted to (i.e., around) a shaft. This shaft can be supported within (i.e., through) a second bearing. Therefore, the precise positioning of the bearing relative to the second bearing housing will control the position of the shaft, and thus the position of the rotor, ensuring its concentricity relative to the stator.

[0031] The first bearing housing may include a recess (of the first bearing) to receive the first bearing. The second bearing housing may include a recess (of the second bearing) to receive the first bearing. The recesses may be centered relative to the corresponding bearing housings (e.g., aligned along the axis of a gearless elevator machine).

[0032] In some examples, the second bearing housing comprises cast iron or forged steel (or is made of cast iron or forged steel). The first and second bearings may have (substantially) the same outer diameter and / or inner diameter.

[0033] The shaft is supported (i.e., rotatably) by a first bearing and a second bearing. The shaft may be supported within the bearings, i.e., pass through the bearings. The shaft extends (at least) between the first and second bearings, and therefore between the first and second bearing housings. The shaft may comprise steel (or be made of steel). The shaft may extend through (i.e., all the way through) the stator.

[0034] In some examples, the shaft includes a motor key recess. In some examples, the gearless elevator machine includes a motor key, which is (at least partially) received within the motor key recess. The motor key may be arranged to engage with a motor (e.g., with the motor's rotor). This helps ensure that the rotation of the motor drives the rotation of the shaft. The motor key recess, and therefore the motor key, may extend along the axial length of the shaft, i.e., along the axial length of the gearless elevator machine. This helps improve the engagement of the motor key with the motor.

[0035] In some examples, the gearless elevator machine further includes at least one pulley for engaging with the elevator tension member, wherein the at least one pulley is arranged about an axis. The elevator tension member may be an elevator rope or an elevator belt.

[0036] While it is possible to integrally form one or more pulleys with the shaft, in some advantageous examples, the pulleys and shaft are separate (i.e., provided as a separate part). In some examples, at least one pulley is interference-fitted around the shaft. Since the pulley is not manufactured as part of the shaft, this reduces the diameter of the shaft portion that must be manufactured. This is particularly advantageous in cases where the shaft is machined, as machining of the smaller diameter portion reduces waste and simplifies the manufacturing process. Furthermore, because the pulley is interference-fitted to the shaft, different numbers of pulleys can be introduced onto the shaft for different machines using the same shaft, making the machine more suitable for different applications (e.g., accommodating different belt widths). Additionally, as described above, the same pulley can be used for different shaft lengths, each compatible with a particular machine. The interference fit also allows different types of pulleys to be mounted on the same shaft to suit a specific application. For example, different (groups of) pulleys can be fitted where they are intended to engage with elevator ropes rather than elevator belts.

[0037] In some examples, the shaft includes a keyway, wherein the gearless elevator machine further includes (at least partially) a pulley key received within the keyway. In some examples, each of at least one pulley includes an inner groove, wherein the pulley key is arranged to engage with the inner groove. This pulley key improves the engagement between the shaft and the pulley, ensuring this engagement even if the interference fit itself is insufficient to keep the pulley rotating with the shaft. The keyway, and therefore the pulley key, can extend along the axial length of the shaft, i.e., along the axial length of the gearless elevator machine. This facilitates engagement of the pulley key with all pulleys.

[0038] In some examples, the gearless elevator machine further includes a guard extending between a first bearing housing and a second bearing housing, wherein the guard is formed as a single integral (i.e., monolithic) piece. The guard may be aligned above the shaft (and therefore above the pulley, and in use above the tensioned components of the elevator). The guard may be a hollow semi-cylinder. The elongated axis of the semi-cylinder may extend parallel to the axial length of the shaft (i.e., the gearless elevator machine).

[0039] The cover can be removably attached (e.g., screwed) to the first and / or second bearing housings. Therefore, the cover can be removed to allow the elevator tension components to be mounted to the pulleys. The cover can also be removed for maintenance on components of the gearless elevator machine or on the tension components. In some examples, the cover comprises (or is made of) plastic.

[0040] At least one spacer extends between a first bearing housing and a second bearing housing and is removably attached to both bearing housings. In some examples, each spacer includes a screw or bolt. In some examples, each spacer includes a housing. The screw or bolt can be positioned within the housing. Thus, in some examples, the first and second bearing housings can be removably attached together by screws or bolts. In some examples, each spacer is an elongated cylinder.

[0041] This disclosure extends to a method for assembling a gearless elevator machine. Therefore, according to a fourth aspect of this disclosure, a method for assembling a gearless elevator machine is provided, comprising:

[0042] Select an axis with a first axis length from a plurality of axes, wherein at least two of the plurality of axes have different axis lengths;

[0043] At least one spacer having a first spacer length is selected from a plurality of spacers, wherein at least two of the plurality of spacers have different spacer lengths, and the first spacer length corresponds to a first shaft length.

[0044] The shaft is arranged to be supported by a first bearing in a first bearing housing and a second bearing in a second bearing housing; and

[0045] At least one spacer is arranged to extend between the first bearing housing and the second bearing housing so as to removably attach the first bearing housing to the second bearing housing.

[0046] It will be understood that the shaft can be arranged to be supported by the bearing housings before or after (or simultaneously with) the arrangement of spacers to extend between the bearing housings and to removably attach the bearing housings. Similarly, the selection steps do not need to be performed in the order they are described.

[0047] According to a fifth aspect of this disclosure, a kit for assembling a gearless elevator machine is provided, comprising:

[0048] Multiple axes, wherein at least two of the multiple axes have different axis lengths;

[0049] Multiple spacers, wherein at least two of the multiple spacers have different spacer lengths, the spacer lengths corresponding to the shaft lengths;

[0050] A first bearing housing and a first bearing, wherein the first bearing housing supports the first bearing.

[0051] The second bearing housing supports the second bearing.

[0052] The first and second bearings are configured to support any selected one (i.e., each) of a plurality of shafts; and

[0053] The first and second bearing housings are configured to be removably attached together by any one of a plurality of spacers (i.e., each one).

[0054] It will be recognized that, in the case of assembling multiple spacers to form a gearless elevator machine, each of these spacers will have a length that is (substantially) the same as all the other spacers. Therefore, multiple spacers are selected, each having a first spacer length.

[0055] The length of the first spacer corresponds to the length of the first shaft. It can be understood that the lengths are compatible, such that when they are used together to form a gearless elevator machine, both are of appropriate length to achieve their respective functions. Therefore, there is a correspondence between the spacer length and the shaft length, but the two lengths are not necessarily the same. A one-to-one pairing of the corresponding first shaft length and first spacer length is possible.

[0056] It will be recognized that any of the above-described components having any of the described features may exist in the kit, and similarly, the method may include assembling any of the above-described components having any of the described features into a gearless elevator machine (within the described location).

[0057] In some examples, the kit further includes multiple motors, with at least two of the motors having different motor lengths (i.e., axial lengths). In some examples, a second bearing housing may be attached to any selected one of the multiple motors. Thus, all motors are compatible with the same bearing housing. All motors in the multiple motors may have (substantially) the same outer diameter (or envelope diameter) (i.e., perpendicular to the axial direction).

[0058] Similarly, in some examples, the method further includes selecting a motor having a first motor length from a plurality of motors. The method may include attaching a second bearing housing to the selected motor. This allows for the selection of a motor with suitable power output for a particular gearless elevator machine, thereby selectively driving the shaft at a desired speed. Motor length may refer to the length of the motor's stator, or the length of the motor's rotor, or both. Therefore, motors may all have different stator lengths but the same rotor length, or different rotor lengths and the same stator length, or both the stator length and motor length may differ for each motor length (e.g., in each motor with a given motor length, the stator length and rotor length may correspond).

[0059] In some examples, the kit further includes multiple belt guards, wherein at least two of the belt guards have different belt guard lengths (i.e., axial lengths), each belt guard length corresponding to the spacer length and / or shaft length. In some examples, the method includes selecting a belt guard having a first belt guard length from the multiple belt guards. The method may further include arranging the belt guard to extend between a first bearing housing and a second bearing housing. This may be the final stage in the assembly of a gearless elevator machine (e.g., possibly after the elevator tension components have been positioned above the pulleys). Therefore, in the case of selecting spacers and shafts of different lengths, appropriate belt guards of corresponding lengths can also be selected for assembly within the gearless elevator machine. Attached Figure Description

[0060] Certain preferred embodiments of this disclosure will now be described by way of example only, with reference to the accompanying drawings, in which:

[0061] Figure 1 An exploded view of an elevator machine according to an example of this disclosure is shown;

[0062] Figure 2 The fully assembled structure is shown. Figure 1 An external view of the elevator machine;

[0063] Figure 3a yes Figure 1 An end view of the braking assembly of the elevator machine;

[0064] Figure 3b It is along Figure 3a The line AA is intercepted Figure 1 A cross-sectional view of the braking assembly of the elevator machine;

[0065] Figure 4 This shows a portion (left) of the braking assembly of a conventional elevator machine. Figure 1 A cross-sectional view of the braking assembly of the elevator machine (right) compared to the previous view;

[0066] Figure 5 yes Figure 1 An exploded view of the shaft assembly of the elevator machine;

[0067] Figure 6 It is in a fully assembled structure Figure 5 A perspective view of the axis component;

[0068] Figure 7 It is shown Figure 1 An end cross-sectional view of the elevator machine with the protective assembly and one of the bearing housings.

[0069] Figure 8 yes Figure 1An exploded view of the motor assembly of the elevator machine, which does not show the rotor;

[0070] Figure 9 This shows a portion (left) of the motor assembly of a conventional elevator machine. Figure 1 A cross-sectional view of the motor assembly of the elevator machine (right) compared to the previous view;

[0071] Figure 10 It is in a fully assembled structure Figure 1 A cross-sectional view of the elevator machine;

[0072] Figure 11 This is a schematic diagram of an elevator system according to an example of this disclosure;

[0073] Figure 12 This is an external perspective view showing examples of three different gearless elevator machines manufactured according to this disclosure; and

[0074] Figure 13 This is a flowchart illustrating an example of a method according to this disclosure. Detailed Implementation

[0075] Figure 1 A gearless elevator machine 1 according to the present disclosure is shown. The gearless elevator machine 1 includes a cover 2, a brake assembly 4, a shaft assembly 6, a shielded assembly 8, a motor assembly 10, and a motor cover 12, which will be described in more detail below. A spacer 5 extends between the brake assembly 4 and the motor assembly 10.

[0076] These components are Figure 2 It can also be seen in the external view.

[0077] As described in more detail below, the gearless elevator machine 1 has an advantageous design that allows for the modular provision of various types (e.g., speeds) of machines based on this single structure, making different machines suitable for different needs. Furthermore, the features of this design result in a lighter weight and a smaller axial profile, which also facilitates easier maintenance and replacement of component parts.

[0078] The shaft assembly 6 is selectively rotated by the rotor within the motor assembly 10 to drive the movement of a rope or belt in contact with a portion of the shaft assembly 6. The braking assembly 4 selectively brakes the rotation of the shaft assembly 6 to prevent the movement of the elevator driven by the rope or belt in contact with the shaft assembly. The operation of each component of the gearless elevator machine 1 is described in more detail below.

[0079] Cover 2 is a cover that covers the braking assembly 4 and prevents foreign objects such as dust from entering the braking assembly 4 and potentially interfering with its function. It also protects electrical components located on this side of the gearless elevator machine 1, such as encoders or brake monitoring switches.

[0080] Figure 3a and 3b Braking component 4 is shown. Figure 3b It shows along Figure 3a The cross-section of the brake assembly 4 along line AA is shown. For clarity, Figure 3a In the view, certain components located behind the fixing plate 24 are shown in dashed lines.

[0081] The braking assembly 4 includes a first bearing housing 14, which may be referred to as a brake bearing housing. The first bearing housing 14 includes a recess 16 arranged to receive a bearing of the shaft assembly 6, which is further described below. The first bearing housing 14 also includes a brake coil 18 integrally integrated (i.e., received therein). In this example, the brake coil 18 is a copper coil. Receiving the brake coil within the first bearing housing is advantageous because it reduces the overall length (in the axial direction) of the gearless elevator machine 1 and reduces the volume (and therefore weight) of the material (e.g., steel) required to form the first bearing housing 14.

[0082] Braking assembly 14 further includes a movable plate 20, the movable plate 20 being arranged to move axially relative to the gearless elevator machine 1 (i.e., relative to...). Figure 3b (Views to the left and right). The movable plate 20 is magnetic, such that its axial movement is controlled by activating or deactivating the brake coil 18 as appropriate, depending on the bias voltage and polarity of the movable plate 20. In this example, the movable plate 20 is moved by... Figure 3a The spring 21 seen in the picture is oriented towards Figure 3b The view is offset to the left. These springs 21 are in... Figure 3b They are not visible in the cross-section because they are located on the outer circumference toward the moving plate 20, rather than along the axis AA of the cross-section.

[0083] The braking assembly 4 further includes a brake disc 22, which engages with (and thus moves with) the shaft 30 of the shaft assembly 6. The braking assembly 4 also includes a retaining plate 24.

[0084] In this example, the brake coil 18 is de-energized to allow movement of the brake shaft 30. As a result, the spring 21 actuates the moving plate 20 to move to the left toward the fixed plate 24 (see reference). Figure 3bThis brings the brake disc 22 into contact with both the fixed plate 24 and the movable plate 20. Friction from the contact between the fixed plate 24, the movable plate 20, and the brake disc 22 slows the rotation of the brake disc 22 and eventually brings it to a stop. Since the brake disc is connected to the shaft 30, this stop is transmitted to the shaft 30 and ultimately stops the movement of the elevator car driven by the gearless elevator machine 1. When the elevator needs to move again, the controller sends a signal, and current is sent to the brake coil 18 to pull the movable plate 20 away from the brake disc 22 and the fixed plate 24, allowing rotational movement of the brake disc 22 and the shaft 30, and thus allowing the car to move.

[0085] Figure 4 This shows a portion (left) of the braking assembly of a conventional elevator machine. Figure 1 A cross-sectional view of a portion (right) of the braking assembly 4 of the elevator machine is shown to illustrate the advantages of the braking assembly 4 disclosed herein.

[0086] In the prior art arrangement, the brake disc 22' has a radius of 28'. This extends only as far as the retaining device 20', which is required to attach the brake assembly to the bearing housing.

[0087] In contrast, in the brake assembly 4 of this disclosure, the brake disc 22 has a radius 28, which is larger than the achievable brake disc radius 28' of prior art arrangements. This larger radius 28 is achieved because the brake assembly 4 (particularly the moving plate 22, the fixed plate 24, and the first bearing seat 14) has a square cross-sectional shape, compared to the prior art arrangements which have circular shapes. Consequently, the bushing 23 used for supporting and guiding the moving plate 20 (… Figure 3a As seen in the image, the brake disc 22 can be positioned towards the corners of the moving plate 22 and the fixed plate 24, leaving a larger inner diameter available for the brake disc 22. Since the brake disc 22 has a relatively large area compared to brake discs in prior art elevator machines, its heat dissipation is improved. Furthermore, due to the increased braking area, the force required by the springs is reduced, and therefore the size (and thus the weight) of the brake coils 18 acting on these springs must be reduced, thus reducing the weight of copper required for the gearless elevator machine 1.

[0088] Figure 5 An exploded view of shaft assembly 6 is shown. Shaft assembly 6 includes shaft 30. Shaft 30 includes a first keyway 34 and a second keyway 36 (from...). Figure 1 (The view shown is not visible).

[0089] The motor key 38 is (at least partially) accommodated within the second keyway 36. The motor key 38 engages with the rotor 68 of the motor assembly 10 such that when the rotor 68 rotates, this causes the shaft 30 to rotate.

[0090] The shaft assembly 6 further includes a pulley key 40, which is partially received within a first key recess 34 such that it still extends beyond the outer surface of the shaft 30. Each of the pulleys 32a and 32b includes inner recesses 42a and 42b (i.e., on their inner surfaces), the shape and position of which are configured to receive and engage the pulley key 40 when the pulleys 32a and 32b are positioned about the shaft 30. Because the pulley key 40 engages with the inner recesses 42a and 42b, it drives the rotation of the pulleys 32a and 32b when the shaft 30 rotates. Each of the pulleys 32a and 32b also includes outer recesses 44a and 44b. These outer recesses 44a and 44b are arranged to receive corresponding belts or ropes (not shown) for raising and lowering the elevator car.

[0091] Pulleys 32a and 32b are independent of shaft 30; that is, they are separate, non-integral parts. Pulleys 32a and 32b are mounted to shaft 30 via an interference fit. Although in Figure 5 The example shows two pulleys 32a and 32b, but it will be appreciated that the advantage of separating pulleys 32a and 32b from shaft 30 is that any number of pulleys 32a and 32b can be provided on shaft 30, as desired for a particular gearless elevator machine 1. Shafts 30 of different lengths can be selected from a certain range of available shafts with the same diameter to accommodate the desired number of pulleys 32 and 32b for a particular application. Since each shaft has the same diameter, all will be able to accommodate the same pulleys. Because spacer 5 is used to attach brake assembly 4 (i.e., brake bearing housing 14) and motor assembly 10 (i.e., motor bearing housing 56 discussed below) together, rather than forming the two parts integrally, different spacer lengths can be selected to match (i.e., correspond to) the length of the selected shaft 30, allowing the same bearing housing to be used to accommodate shafts 30 of different lengths. It is also advantageous that, since pulleys 32a and 32b are independent of the shaft, the diameter of the machined shaft portion is smaller.

[0092] Shaft 30 and pulleys 32a, 32b may be made of, for example, cast iron or steel. It will be appreciated that, since the parts are independent, they may be made of different materials, but alternatively they may be made of the same material.

[0093] Shaft 30 includes a brake engagement portion 46. (As in...) Figure 5 As can be seen in the view, this part includes radially extending teeth or splines configured to engage with brake disc 22 to ensure that brake disc 22 and shaft 30 rotate together (or stop rotating).

[0094] The shaft assembly 6 also includes two bearings 48a and 48b. The first bearing 48a is received within a recess 16 of the bearing housing 14 described above. As further described below, the second bearing 48b is received within a second bearing recess 17 of the motor assembly 10. In this example, bearings 48a and 48b are identical to each other. Bearings 48a and 48b are circular and define an inner circular opening through which the shaft 30 is inserted. Advantageously, these identical bearings 48a and 48b are suitable for supporting shafts 30 of various lengths, selectable for use in gearless elevator machines 1 as described above.

[0095] The shaft assembly 6 further includes a ring 50. The ring 50 is metallic (e.g., made of steel) to provide sufficient rigidity to support axial forces from the second bearing 48b and the second pulley 32b. The ring 50 serves to guide the axial force from the second pulley 32b to the inner ring of the bearing (i.e., the rotating portion of the second bearing 32b).

[0096] Figure 6 The image shown is in an assembled configuration (not an exploded view). Figure 5 The part. In Figure 6 The inner pulley key 40 is shown as a dashed line in the view.

[0097] like Figure 1 China and also Figure 7 As shown in the side view, the shielded assembly 8 is positioned above the shaft assembly 6. Figure 7 The first bearing housing 14 is visible in the view, as is the case with one of the pulleys 32a and 32b. It will be appreciated that, due to its symmetry, this view of the shrouded assembly 8 will be substantially the same as that seen along the same axis in opposite directions, but instead of the first bearing housing 14, the second bearing housing (e.g., a motor bearing housing) discussed below is shown.

[0098] The shielded assembly 8 includes a shield 52. For example... Figure 1 As seen, the protective cover 52 is a hollow semi-cylinder, shaped to cover the upper half of the shaft 30 without contacting the pulleys 32a and 32b. Two screws 54a and 54b attach the protective cover 52 to the bearing housing 4. Similarly, at another axial end (not visible), two more screws attach the protective cover to another bearing housing.

[0099] Figure 8 This is an exploded view showing a portion of the motor assembly 10. The motor assembly 10 includes a motor 60, which includes a stator 64 and a rotor 68. Figure 10 (As seen in the image). The rotor 68 is connected to the shaft 30, concentrically positioned within the stator 64, and rotates by the operation of the stator 64, causing the shaft 30 to rotate. Figure 8 The rotor is not shown.

[0100] The stator 64 includes a stator coil 61 wound around a stator tooth 63. The stator coil 61 and the stator tooth 63 are located within a stator housing 62, which is part of the stator 64.

[0101] Motor assembly 10 includes a second bearing housing 56, referred to as the motor housing. Although in Figure 8 Not visible in the view, but the second bearing housing 56, like the first bearing housing 14, includes a (second) bearing recess 17 to receive the bearing supporting the shaft 30, in this case, the second bearing 48b. The second bearing recess 17 is in Figure 9 and Figure 10 As seen in the image, the second bearing 48b is positioned within it. The bearing recess 17 is precisely formed (i.e., at a precisely defined location) within the second bearing housing 56, ensuring that the second bearing 48b, the shaft 30 supported on the second bearing 48b, and the rotor 68 arranged on the shaft 30 (as described below) are all concentrically aligned around the central (axial) axis of the second bearing housing 56 and therefore precisely relative to the inner diameter of the stator 64 (i.e., stator coil 61). This precise alignment guarantees a constant rotor / stator air gap (the thin radial clearance between the rotor 68 and the stator 64), and thus ensures proper motor performance.

[0102] The second bearing housing 56 also includes a circular stator recess 58, which is arranged to receive the end turns of the stator coil 61 of the stator 64.

[0103] The stator 64 (particularly the housing 62 of the stator 64) is attached to the second bearing housing 56 by four screws 66a, 66b, 66c, and 66d, which are positioned at corresponding corners of the stator housing 62. Accurate concentric alignment of the stator 64 around the rotor 68 is achieved through precise alignment of the screw holes (e.g., during machining) and by machining the circular bearing housing recess 17 at its precise center position relative to the inner diameter of the stator 64, without the need for additional positioning elements such as flanges.

[0104] The difference is Figure 9 The image shows a portion of the prior art motor assembly 10' on the left side and a portion on the right side. Figure 8 The motor assembly 10.

[0105] The prior art motor assembly 10' includes a rotor flange 90', which is used to ensure the concentric alignment of the stator 64' around the rotor by connecting to the bearing housing 56'. In contrast, in this example, the second bearing recess 17 is precisely centered in the second bearing housing 56. Once the stator housing 62 and therefore the stator 64 are mounted to the second bearing housing 56 by four screws 66a, 66b, 66c, 66d, precise machining is performed in the bearing recess 17 with reference to the inner diameter of the stator 64 to ensure concentricity between the two diameters. Since the rotor 68 is mounted to the shaft 30, which itself is supported by a second bearing 48b housed within the second bearing recess 17, the precise placement of the second bearing recess 17 ensures the precise centering of the rotor 68 relative to the stator 64, and thus provides a constant air gap between them.

[0106] exist Figure 10 All parts of the gearless elevator machine 1 can be seen together in the cross-sectional view.

[0107] like Figure 10 As seen in the image, the gearless elevator machine 1 further includes an encoder 26 positioned within the shaft 30. The encoder 26 rotates with the shaft 30 and monitors this rotation to track the position of the rope or belt in contact with the shaft assembly 6, and thus track the position of the elevator moved by the rope or belt.

[0108] In this cross-section, pulley key 40 is visible, engaging with two of pulleys 32a and 32b, with the pulleys press-fitted around shaft 30. Motor key 38 is also visible. This motor key engages with rotor 68, which is concentrically positioned within stator 64.

[0109] As described above, the stator 64 causes the rotor 68 within it to rotate by generating a changing magnetic field. Since the motor key 38 provides engagement between the shaft 30 and the rotor 68, the shaft 30 rotates together with the rotor 68. This causes the pulleys 32a and 32b to rotate.

[0110] Figure 10 Recesses 70a and 70b are visible. In use, the elevator belt (which may be a rope in an alternative example) is arranged in these recesses 70a and 70b, in the outer grooves 44a and 44b of the corresponding pulleys 32a and 32b, and is therefore driven in a specific direction (upward or downward) depending on the direction of rotation of the shaft 30. Alternative pulleys 32a and 32b may be provided, in which ropes are used instead of belts, for example, pulleys with deeper and rounder grooves. These elevator belts suspend the elevator car (not shown) and optionally also suspend the elevator counterweight, such that when the motor 60 drives the movement of the belt in the manner described, this causes the elevator car to move upward or downward.

[0111] In this example, four spacers 5a, 5b, 5c, and 5d extend between the corresponding corners of bearing housings 14 and 56, respectively. All four of these spacers 5a, 5b, 5c, and 5d are located between... Figure 2 As can be seen, and two of these are in Figure 10 Seen in the cross-sectional side view. Each spacer 5a, 5b, 5c, 5d includes an outer cylinder or housing and a bolt contained within the outer cylinder. The bolt extends between bearing housings 14, 56 (e.g., from the brake bearing housing 14 side to the motor bearing housing 56) and removably attaches the bearing housings 14, 56 together by screwing them in and out through corresponding threaded holes in the first bearing housing 14 and engaging with corresponding threaded nut portions 57 on the second bearing housing 56.

[0112] As explained above, different lengths of shaft 30 can be selected for different types and sizes of machines, i.e., for different applications. A spacer 5 of the corresponding length will be selected so that the bearing housings 14 and 56 are separated by an appropriate length to accommodate the selected shaft length.

[0113] exist Figure 10 As can also be seen, although the lengths of the shaft 30 and the spacer 5 are not the same, their lengths are corresponding. This means that when the first bearing housing 14 and the second bearing housing 56 are separated by the distance defined by the spacer 5, their lengths allow the shaft 30 to extend through both the first bearing housing 14 and the second bearing housing 56. If the spacers were longer or shorter, i.e., not the same length as the shaft 30, they would either not cover the required distance between the housings, thus leaving no space to accommodate the shaft portion that needs to be accommodated between the bearing housings 14 and 56, or they would create too large a gap, preventing the shaft 30 from extending far enough into the brake assembly 4 or the motor assembly 10.

[0114] Figure 11 This is a schematic diagram of an example of an elevator system 100 including the gearless elevator machine 1 described above. The elevator system 100 includes an elevator car 102, a counterweight 104, and a tension member 106 extending between the elevator car 102 and the counterweight 104 and suspending both the elevator car 102 and the counterweight 104. The tension member 106 may be located in... Figure 10 The recessed portions 70a and 70b shown are illustrated.

[0115] The tension member 106 engages with the gearless elevator machine 1 and specifically passes over pulleys 32a, 32b (optionally via multiple separate belts, each housed in a corresponding pulley). The tension member 106 also passes over a deflection pulley 108. Driving the gearless elevator machine 1 moves the tension member 106 to raise and lower the elevator car 102 and correspondingly lower or raise the counterweight 104.

[0116] Figure 12 This is an external perspective view showing three different gearless elevator machines 1a, 1b, 1c manufactured according to this disclosure using multiple identical modular parts. All gearless elevator machines 1a, 1b, 1c in the examples shown are formed using the same bearing housings 14, 56 and covers 2, 12, although this is not necessarily required.

[0117] like Figure 12 As seen in the diagram, each of the three gearless elevator machines 101a, 101b, and 101c has a different length along the axial direction. Therefore, different sets of spacers 105a, 105b, and 105c are used in each gearless elevator machine 101a, 101b, and 101c, with each set of spacers having a different spacer length. Similarly, different shafts 130a, 130b, and 130c, each with different lengths, are used, and each shaft can have a different number of pulleys suited to it. The lengths of the spacers used in a given gearless elevator machine correspond to the lengths of the selected shafts. This means that the lengths are compatible, such that when they are used together to form a gearless elevator, both have appropriate lengths to achieve their respective functions, rather than being the same length.

[0118] To correspond to the different lengths of spacers 105a, 105b, 105c and shafts 130a, 130b, 130c, different lengths of protective covers 152a, 152b, 152c are used in each of the corresponding gearless elevator machines 101a, 101b, 101c.

[0119] Each of the different gearless elevator machines 101a, 101b, 101c also includes motors 160a, 160b, 160c of different (axial) lengths. It will be understood that each motor 160a, 160b, 160c has substantially (or precisely) the same diameter so that they can each be housed in the same bearing housing 56, but each motor has a different axial range (e.g., for longer motors, the rotor 68 and / or stator 64 extend further in the axial direction). This allows for stators with different power levels. The power of the stator affects its ability to drive the motor and thus the speed at which the corresponding shaft is located.

[0120] Figure 13 This is a flowchart illustrating an example of a method according to this disclosure.

[0121] First, at stage 200, an axis 30 with a first axis length is selected from a plurality of axes 130a, 130b, 130c, wherein at least two of the plurality of axes have different axis lengths. The axis 30 may be selected based on the desired width of the elevator belt or rope to be accommodated.

[0122] Next, at stage 202, a spacer or a plurality of spacers 5 having a first spacer length corresponding to (i.e. compatible with) the length of the first shaft is selected from a plurality of spacers 105a, 105b, 105c, wherein at least two of the plurality of spacers have different spacer lengths. A first bearing 48a and a second bearing 48b are configured to support any one of the plurality of shafts (i.e., each of the plurality of shafts). A first bearing housing 14 and a second bearing housing 56 are configured to be removably attached together via any one of the plurality of spacers (i.e., each).

[0123] At stage 204, a belt cover 52 is selected from a plurality of belt covers 152a, 152b, 152c of different lengths, wherein the belt cover has a first belt cover length compatible with (i.e., corresponding to) the length of the first shaft and the length of the first spacer. The first belt cover length may be the same as the length of the first spacer (because both the spacer and the belt cover extend between the first bearing housing 14 and the second bearing housing 56). Each belt cover 152a, 152b, 152c is compatible with the first bearing housing and the second bearing housing 14, 56.

[0124] Next, at stage 206, a motor 60 is selected from a plurality of motors 160a, 160b, 160c, wherein at least two of the motors have different motor lengths (i.e., axial lengths). A second bearing housing 56 may be attached to (i.e., each) any one of the plurality of motors 160a, 160b, 160c (i.e., compatible with it). Motors 160a, 160b, 160c may have different power output levels (e.g., due to their respective lengths).

[0125] At stage 208, the selected components and any other required components are assembled to form the gearless elevator machine 1. This stage may include arranging the shaft 30 to be supported by a first bearing 48a and a second bearing 48b, and arranging at least one spacer 5 to extend between the first bearing housing 14 and the second bearing housing 56 to removably attach the first bearing housing 14 to the second bearing housing 56. This stage may include attaching the second bearing housing 56 to a selected motor 68 (e.g., to a stator 64). This stage may include arranging a shroud 52 to extend between the first bearing housing 14 and the second bearing housing 56.

[0126] It will be recognized by those skilled in the art that this disclosure has been shown by describing one or more specific aspects, but the disclosure is not limited to these aspects; many variations and modifications are possible within the scope of the appended claims.

Claims

1. A gearless elevator machine (1), comprising: A first bearing housing (14) and a first bearing (48a), wherein the first bearing housing (14) supports the first bearing (48a). The second bearing housing (56) and the second bearing (48b), wherein the second bearing housing (56) supports the second bearing (48b). A shaft (30) is supported by the first bearing (48a) and the second bearing (48a); A motor (60) arranged to drive the shaft (30) to rotate; and At least one spacer (5) extends between the first bearing housing (14) and the second bearing housing (56) and removably attaches the first bearing housing (14) to the second bearing housing (56).

2. The gearless elevator machine (1) according to claim 1 further includes a brake coil (18) arranged to engage and disengage brakes (20, 22) to brake rotation of the shaft (30), wherein the brake coil (18) is housed within the first bearing housing (14).

3. The gearless elevator machine (1) according to claim 1 or claim 2, wherein, The first bearing housing comprises steel.

4. The gearless elevator machine (1) according to any of the preceding claims, wherein, The motor (60) includes a rotor (68) and a stator (64), wherein the stator (64) is arranged to selectively drive the rotation of the rotor (68), wherein the rotor (68) is connected to the shaft (30) such that the rotation of the rotor drives the shaft (30) to rotate, and wherein the stator (64) is attached to the second bearing housing (56).

5. The gearless elevator machine (1) according to any of the preceding claims, wherein, The second bearing housing comprises cast iron or forged steel.

6. The gearless elevator machine (1) according to any of the preceding claims further includes a guard (52) extending between the first bearing housing (14) and the second bearing housing (56), wherein the guard (52) is formed as a single integral piece.

7. The gearless elevator machine (1) according to any of the preceding claims, wherein, The shaft includes a keyway (34), wherein the gearless elevator machine (1) further includes a pulley key (40) at least partially housed within the keyway (34).

8. The gearless elevator machine (1) according to any of the preceding claims further includes at least one pulley (32a, 32b) for engaging with the elevator tension member (106), wherein the at least one pulley (32a, 32b) is arranged around the shaft (30).

9. The gearless elevator machine (1) according to claim 8, wherein, The at least one pulley (32a, 32b) is interference-fitted around the shaft (30).

10. The gearless elevator machine (1) according to claim 8 or claim 9, when further dependent on claim 7, wherein, Each of at least one pulley (32a, 32b) includes an inner groove (42a, 42b), wherein the pulley key (40) is arranged to engage with the inner groove (42a, 42b).

11. An elevator system (100), comprising: At least one tension member (106); The elevator car (102) is suspended by the tension member (106); as well as According to any one of claims 8 to 10, the gearless elevator machine (1) wherein the at least one tension member (106) engages with the at least one pulley (32a, 32b) such that the movement of the elevator car (102) is driven by the rotation of the shaft (30) of the motor (60).

12. A method for assembling a gearless elevator machine (1), comprising: A shaft (30) with a first shaft length is selected from a plurality of shafts (130a, 130b, 130c), wherein at least two of the plurality of shafts have different shaft lengths; At least one spacer (5a, 5b, 5c, 5d) having a first spacer length is selected from a plurality of spacers (105a, 105b, 105c), wherein at least two of the plurality of spacers have different spacer lengths, and the first spacer length corresponds to the first shaft length. The shaft (30) is arranged to be supported by a first bearing (48a) of a first bearing housing (14) and a second bearing (48b) of a second bearing housing (56); and The at least one spacer (5a, 5b, 5c, 5d) is arranged to extend between the first bearing housing (14) and the second bearing housing (56) so as to removably attach the first bearing housing (14) to the second bearing housing (56).

13. A kit for assembling a gearless elevator machine (1), comprising: Multiple axes (130a, 130b, 130c), wherein at least two of the multiple axes have different axis lengths; A plurality of spacers (105a, 105b, 105c), wherein at least two of the plurality of spacers have different spacer lengths, the spacer lengths corresponding to the shaft length; A first bearing housing (14) and a first bearing (48a), wherein the first bearing housing (14) supports the first bearing (48a). The second bearing housing (56) and the second bearing (48b), wherein the second bearing housing (56) supports the second bearing (48b). The first bearing (48a) and the second bearing (48b) are configured to support any one of the plurality of shafts (130a, 130b, 130c); and The first bearing housing (14) and the second bearing housing (56) are configured to be removably attached together by any one of the plurality of spacers (105a, 105b, 105c).

14. The kit of claim 13, further comprising a plurality of motors (160a, 160b, 160c), wherein at least two of the plurality of motors have different motor lengths; wherein the second bearing housing is attachable to any selected one of the plurality of motors (160a, 160b, 160c).

15. A gearless elevator machine (1), comprising: A first bearing housing (14) and a first bearing (48a), wherein the first bearing housing (14) supports the first bearing (48a). Shaft (30), which is supported by the first bearing (48a); A motor (60) arranged to drive the shaft (30) to rotate; and A brake coil (18) is arranged to engage and disengage the brakes (20, 22) to brake the rotation of the shaft (30), wherein the brake coil (18) is housed within the first bearing housing (14).

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