Elevator Belt Wear Monitoring by Segment Bend Tracking
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Solution Overview
Problem
Elevator belt inspection methods, such as resistance-based inspection (RBI), are inadequate for monitoring residual strength, and physical devices have limited effectiveness in assessing belt wear.
Innovation Solution
A system and method that utilizes a processor to track historical data and real-time data of elevator car movements to identify segments of the tension member experiencing excessive bends, generating a heatmap to guide inspectors to areas of high wear for visual inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If resistance-based inspection (RBI) is used to monitor belt strength, then inspection capability is provided, but it is not feasible to accurately monitor residual strength
Solution Approach 1:
The patent replaces physical/mechanical inspection devices with a computational system that uses processor-based analysis of operational data (traffic patterns, usage history, real-time sensor data) to assess belt health. This substitution enables accurate residual strength monitoring without relying on feasible but imprecise physical measurement devices.
2Measurement precision
If physical devices are deployed to monitor belt strength, then monitoring capability is provided, but effectiveness in assessing wear is limited
Solution Approach 1:
The patent replaces complex physical monitoring devices with a computational approach using processors to analyze operational data. This eliminates the need for complex physical wear assessment devices while improving wear assessment accuracy through comprehensive data analysis including traffic patterns and usage history.
Solution Approach 2:
The patent introduces sensors as intermediary elements that indirectly measure belt condition through parameters like tension, speed, and operational patterns. These sensors feed data to the processor which then assesses wear, providing an effective wear assessment mechanism without direct physical contact with the belt.
3Measurement precision
If comprehensive belt inspection is performed, then wear detection accuracy is improved, but maintenance time increases
Solution Approach 1:
The patent performs preliminary wear assessment continuously during elevator operation by analyzing traffic patterns and usage data. This ongoing preliminary inspection identifies high-wear areas before maintenance is needed, allowing targeted inspections that reduce overall maintenance time while maintaining high detection accuracy.
Solution Approach 2:
The patent applies different inspection intensities to different belt segments based on their wear risk. High-traffic areas receive more frequent and detailed monitoring, while low-traffic areas receive less intensive inspection. This localized approach maintains high wear detection accuracy for critical areas while reducing overall maintenance time.
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
A system for monitoring wear of a tension member, having: a hoistway; a car; an elevator motor having a first sheave; a processor configured to: access historical data including at least one of prior usage data of the tension member and historical traffic pattern of the car; track real time data indicative of bends of segments of the tension member; determine from historical data and real time data a health condition of the segments of the tension member; issue a service alert when bends in one or more segments of the tension member exceeds a threshold; and control the car to transport an inspector to one or more locations along the hoistway that provide for visual inspection of at least one segment of the one or more segments that has a greater amount of bends relative to another segment of the one or more segments.