Elevator Brake Torque Testing for Proactive Maintenance
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Solution Overview
Problem
Conventional elevator brake testing methods require reactive maintenance, leading to frequent shutdowns and inconvenience when brakes fail, as they only detect faults after the brake has failed, rather than proactively identifying impending failures.
Innovation Solution
A method that continually increases motor torque until the elevator car moves, storing the torque value representative of the brake's capacity, allowing for comparison with a reference value set during calibration to determine if the brake meets regulatory loading conditions, and sending proactive maintenance requests if the brake is nearing failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional brake testing methods are used with predetermined test torque, then the testing process is simple, but the brake failure is detected only after it occurs, causing elevator shutdowns
Solution Approach 1:
The patent applies preliminary action by progressively increasing motor torque before actual brake failure occurs, allowing the system to detect declining brake capacity in advance. The torque is increased in steps and held at each level to monitor for car movement, enabling proactive identification of brake deterioration before it leads to complete failure and elevator shutdown.
2Ease of operation
If predetermined test torque is applied to detect brake failure, then the testing method is straightforward, but maintenance is reactive rather than proactive
Solution Approach 1:
The system performs preliminary torque increases at scheduled intervals to assess brake health before failure occurs. By progressively applying torque and monitoring for car movement, the system enables proactive maintenance planning, allowing elevator operators to schedule maintenance during off-peak hours rather than experiencing unexpected shutdowns.
Solution Approach 2:
The patent implements feedback by continuously monitoring whether the elevator car moves at each torque level. This feedback mechanism provides real-time information about brake capacity, allowing the system to detect gradual deterioration and trigger maintenance alerts before complete brake failure occurs, thus reducing unexpected downtime.
3Device complexity
If brake capacity is tested with fixed torque values, then the test procedure is simple, but it cannot detect gradual brake deterioration
Solution Approach 1:
The patent applies dynamics by transitioning from fixed torque values to a progressive torque increase approach. The motor torque is dynamically adjusted in incremental steps, with each level held long enough to observe car movement. This dynamic testing method accurately captures gradual brake deterioration while maintaining manageable procedural complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the frequency of elevator shutdowns by proactively identifying brakes about to fail, enabling scheduled maintenance and keeping the elevator operational, thus minimizing user inconvenience and extending brake lifespan.
Implementation Method 1
at least one brake is employed in association with the motor or the traction sheave to stop the elevator and to keep the elevator stationary within the hoistway
Data Source
AI summary
A method for operating an elevator having a car driven by a motor and at least one brake to stop the car, the method including closing a brake, increasing a torque of the motor until the car moves, and registering a value indicative of the motor torque at which the car moves.