Dual Elevator Machine Layout With Synchronized Split Capacity

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Solution Overview

Problem

Elevator machine material costs significantly increase with capacity and decrease in volume, especially in high-rise and heavy-duty applications, requiring large investments and posing challenges in sourcing and manufacturing.

Innovation Solution

A dual machine arrangement for elevator systems, comprising two small cantilever machines aligned in reverse directions with a flexible coupling and drive circuitry for synchronization, effectively functioning as a single large machine with double capacity at a lower cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a large machine is developed with 200% capacity increase, then the elevator capacity is improved, but the material costs increase by up to 300% or more

Engineering Contradiction:

Improveelevator capacityVSAvoidmaterial costs

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The patent divides a single large machine into two separate smaller machines, each handling 50% of the total load. This segmentation allows each machine to be manufactured at a smaller scale with lower material costs, while collectively achieving the required double capacity. The cost analysis shows that two smaller machines together cost significantly less than one large machine with equivalent total capacity.

Inventive Principle:

Principle #1Segmentation

2Power

If the machine capacity is increased, then the elevator can handle heavier loads, but the machine volume increases making sourcing and manufacture challenging

Engineering Contradiction:

Improvemachine capacityVSAvoidmachine volume

Core Design Contradiction:

PowerVSVolume of moving object

Solution Approach 1:

By splitting the required capacity into two separate machines, each machine maintains a compact, manageable volume that is easier to source and manufacture. The patent specifically notes that smaller machines are easier to manufacture and install, and the modular approach allows for standardization and economies of scale in production.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If two small machines are used instead of one large machine, then the material costs are reduced, but the system complexity increases due to synchronization requirements

Engineering Contradiction:

Improvematerial costsVSAvoidsynchronization system

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent implements encoder feedback systems on each machine that continuously monitor position and speed, allowing the control system to detect and correct asynchronous conditions. This feedback mechanism ensures that both machines operate in sync, eliminating the complexity concern by providing automatic correction capabilities.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces complex mechanical synchronization mechanisms with electronic control and software-based synchronization algorithms. This substitution reduces mechanical complexity while achieving precise synchronization through digital communication and control between the two machines.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP4464638A1Dual machine arrangement

Publication Date: 2024.11.20 OTIS ELEVATOR CO

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AI summary

A dual machine arrangement (201) is provided for a hoist assembly of an elevator system (101). The dual machine arrangement includes dual machines (210), each comprising a motor (2110, 2120) and a sheave (2111, 2121), which is rotatable by the motor, a coupling (220) by which respective ends (2112, 2122) of the sheaves of the dual machines are connected and drive circuitry (230) configured to synchronize reverse operations of the dual machines to raise or lower a load.