Elevator Car Monocoque Corner Elements for Compact Shafts
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Solution Overview
Problem
Elevator shafts occupy valuable space and restrict architectural design due to the need for large dimensions to accommodate traditional car frames, which also limit loadable floor space and are costly to produce with complex, non-modular designs.
Innovation Solution
An elevator car design featuring single-shell corner elements connected between the floor and roof, using fiber-reinforced materials with a monocoque structure, where corner elements form a belt or column to transmit vertical forces, and filling elements with varying widths allow for efficient production of cars with different capacities, enabling space savings and modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional car frame surrounding the elevator car on three or four sides is used, then structural strength and stability are ensured, but the shaft dimensions increase and loadable floor space decreases
Solution Approach 1:
The invention extracts the car frame from its traditional form surrounding the car on multiple sides and reduces it to only the necessary corner elements. This extraction removes unnecessary structural components while maintaining the essential function of supporting the car and absorbing forces during acceleration and braking.
Solution Approach 2:
The car frame is segmented into discrete corner elements positioned at the four corners of the elevator car. Each corner element independently supports the car structure and absorbs forces, eliminating the need for continuous side frames while maintaining overall structural integrity.
2Strength
If a massive car frame is used to ensure structural integrity, then strength and stability are improved, but manufacturing cost increases and production complexity increases
Solution Approach 1:
The frame is divided into standardized corner elements that can be manufactured independently using the same production process. This segmentation allows for economies of scale and simplified manufacturing compared to producing a custom massive frame structure.
Solution Approach 2:
The invention changes the dimensional parameters of the frame elements from massive continuous structures to compact corner elements with specific geometries. This parameter optimization reduces material consumption and manufacturing complexity while maintaining the necessary structural properties.
3Strength
If a car frame with many different individual parts is used, then structural requirements are met, but manufacturing complexity increases and modular design becomes difficult
Solution Approach 1:
The frame is segmented into corner elements that are identical or similar in design, allowing for standardized production. This contrasts with traditional designs that require numerous different parts to achieve the same structural function.
Solution Approach 2:
The corner elements serve multiple functions: providing structural support, absorbing forces during acceleration and braking, and forming the basic geometry of the car. This multi-functionality reduces the need for additional specialized components.
4Quantity of substance
If corner elements with thin walls are used, then material consumption decreases, but the walls tend to bulge and vibrate
Solution Approach 1:
The corner elements utilize composite material structures that provide high strength-to-weight ratios. This allows the walls to be thin enough to reduce material consumption while maintaining sufficient stiffness to prevent bulging and vibration through the material's inherent properties.
Solution Approach 2:
The corner elements feature curved transitions and rounded corners instead of sharp angles. This curvature distributes stress more evenly throughout the structure, preventing stress concentration that would cause thin walls to bulge or vibrate under load.
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 design reduces space requirements, allows for efficient manufacturing, and enables the production of elevator cars with varying capacities, adapting to different floor plans, while minimizing noise and vibration, and providing a visually appealing interior without additional paneling.
Implementation Method 1
the corner elements consist of a fiber material including fiber-reinforced plastic or fiber composite material. These materials are characterized by their high strength and comparatively low weight, even with thicker walls, as well as their inherent damping.
Implementation Method 2
These materials are characterized by their high strength and comparatively low weight, even with thicker walls, as well as their inherent damping.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A lift with a car 1 that moves up and down vertically along guide rails 8 is described. The car 1 is characterized by the fact that the car floor 5 and the car roof 6 are connected by single-shell corner elements 18, 18a, which are not directly connected to each other along their vertical side edges and through which the entire vertical force flow that can occur between the car roof 6a and the car floor 5 is transmitted to the car floor 5.