Elevator Brake Testing with Balance-Verified Test Load

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Solution Overview

Problem

Existing methods for testing elevator brakes are flawed due to incorrect balancing, leading to insufficient test loads and potential failure of brakes to stop the elevator car properly, especially during downward movement with a full load.

Innovation Solution

A method that calculates an actual test load based on a balance check, comparing it to predetermined criteria, and only allows brake testing if the balance check meets these criteria, ensuring the brakes are tested with the correct load to ensure safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a brake test is performed without verifying elevator balance, then the brake test can be conducted, but the test load may be insufficient leading to unreliable brake safety verification

Engineering Contradiction:

Improvebrake safety verification reliabilityVSAvoidtest procedure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by performing a balance check before the brake test. The control unit verifies that the elevator car is properly balanced (within acceptable tolerance, e.g., 50% ± 5%) before allowing the brake test to proceed. This ensures that the test load is sufficient and the brake safety verification is reliable, while preventing unnecessary delays by automatically verifying balance rather than requiring manual inspection.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the brake test is allowed to proceed with incorrect balance, then the test can be completed quickly, but the brake may not be adequately tested leading to safety risks

Engineering Contradiction:

Improvetest execution speedVSAvoidbrake safety assurance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements feedback by having the control unit continuously monitor the balance status of the elevator and provide feedback before allowing the brake test to proceed. The control unit compares the actual balance (determined by measuring the weight difference between the car and counterweight) against acceptable tolerance ranges and either permits or prevents the brake test accordingly. This automated feedback mechanism ensures brake safety assurance without significantly impacting test execution speed, as the balance verification is performed automatically rather than manually.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If manual balance verification is performed before brake testing, then the test load accuracy can be ensured, but the testing process time increases

Engineering Contradiction:

Improvetest load accuracyVSAvoidtesting process time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical balance verification with an automated electronic measurement and control system. The control unit automatically determines the balance status by measuring the weight difference between the elevator car and counterweight using existing elevator sensors and communication systems. This substitution of manual mechanical verification with automated electronic control maintains high measurement precision for test load accuracy while significantly reducing the time required, as the automated system performs balance verification instantaneously rather than requiring manual inspection procedures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3901079B1A method for testing safety characteristics of an elevator

Publication Date: 2026.04.01 KONE OYJ

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AI summary

The method for testing safety characteristics of an elevator comprises performing a balance check of the elevator according to a request.