Dual Elevator Machine Coupling for High-Capacity Hoists
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Solution Overview
Problem
Elevator machine material costs increase significantly with capacity increases and volume decreases, particularly in high-rise and heavy-duty applications, leading to high investment costs and 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, allowing for double capacity at a lower cost by integrating two low-cost machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large machine is developed with 200% capacity increase, then the machine capacity is improved, but the material costs increase by up to 300% or more
Solution Approach 1:
The patent divides a single large-capacity machine into two separate smaller machines, each with standard capacity. This segmentation allows both machines to be manufactured using conventional, cost-effective processes while achieving the combined capacity of a large machine, thereby avoiding the exponential cost increase associated with developing a single large-capacity machine.
Solution Approach 2:
The patent combines two smaller machines into a unified dual-machine arrangement that functions as a single large-capacity system. The machines are mechanically coupled through sheaves and belts, and controlled through synchronized drive circuitry, effectively merging their capabilities to achieve the capacity of a large machine without incurring the high material costs of developing one.
2Power
If machine capacity is increased, then the power output is improved, but the machine volume decreases leading to higher material costs
Solution Approach 1:
Instead of compressing a large-capacity machine into a small volume, the patent segments the capacity across two separate standard-sized machines. Each machine maintains its standard volume, avoiding the need to reduce individual machine volumes, which would otherwise drive up material costs.
Solution Approach 2:
The patent transitions from a single-machine vertical capacity scaling to a multi-machine horizontal arrangement. By distributing capacity across multiple machines arranged in parallel with mechanical coupling, the system achieves large capacity without requiring extreme volume reduction of individual components.
3Ease of manufacture
If two small machines are used instead of one large machine, then the manufacturing cost is reduced, but the synchronization complexity increases
Solution Approach 1:
The patent incorporates drive circuitry with feedback mechanisms that monitor and synchronize the operation of the two machines. This feedback system automatically adjusts the timing and coordination of the machines, eliminating the need for complex manual synchronization while maintaining cost-effective manufacturing of individual machine units.
Solution Approach 2:
The patent introduces an intermediary control system (drive circuitry) that manages the coordination between the two machines. This intermediary handles the synchronization complexity, allowing the individual machines to remain simple and cost-effective to manufacture while the control system manages the coordination overhead.
4Power
If a dual machine arrangement is implemented, then the capacity is doubled, but the mechanical structure complexity increases
Solution Approach 1:
The patent employs universal, standard components for both machines (motors, sheaves, belts) that perform multiple functions. The mechanical coupling structure serves both to transmit power between machines and to provide structural support, reducing overall complexity despite the doubled capacity.
Solution Approach 2:
The patent uses flexible belts as coupling elements between the sheaves of the two machines. These flexible belts provide a simple, adaptable mechanical connection that accommodates minor misalignments and reduces the complexity of rigid mechanical linkages while maintaining synchronized operation.
Data Source
AI summary
A dual machine arrangement is provided for a hoist assembly of an elevator system. The dual machine arrangement includes dual machines, each comprising a motor and a sheave, which is rotatable by the motor, a coupling by which respective ends of the sheaves of the dual machines are connected and drive circuitry configured to synchronize reverse operations of the dual machines to raise or lower a load.