Elevator Hazard Warning Sensing for Car-Counterweight Inspection Safety
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Solution Overview
Problem
Elevator systems lack effective safety measures to prevent mechanics from accidentally contacting the counterweight during inspection mode, particularly when the elevator car is within a predetermined distance from the counterweight.
Innovation Solution
An approaching hazard warning system with a range finding sensor and controller that detects the distance between the elevator car and counterweight, executing responsive actions such as slowing or stopping the elevator car and providing audible alerts when the distance falls below certain thresholds, and using a relay to stop the elevator car if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an approaching hazard warning system is implemented to prevent mechanics from contacting the counterweight, then safety is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical safety systems with electronic sensing and control components. A range finding sensor (optical/electronic) detects the distance between the elevator car and counterweight, and a controller processes this data to trigger warnings or stop the elevator, substituting mechanical interlocks with electronic hazard warning system
Solution Approach 2:
The controller acts as an intermediary between the range finding sensor and the elevator motor/brake system. It receives sensor data, processes the distance information, and executes responsive actions (visual/audible warnings, slowing, or stopping the elevator), thereby mediating the safety function without requiring direct mechanical connection between components
2Reliability
If a range finding sensor and controller are added to detect distance and execute responsive actions, then safety is improved, but cost increases
Solution Approach 1:
The controller serves multiple functions: it processes range finding sensor data, determines when the elevator is in inspection mode, executes visual and audible warnings, controls motor power removal, and manages brake application. This multi-functionality consolidates what could be separate safety systems into a single controller, reducing overall system cost
Solution Approach 2:
The system uses the elevator's existing motor and brake mechanisms to execute safety actions. When the controller detects a hazard, it removes power from the motor and activates the brake, utilizing components already present in the elevator system rather than requiring additional dedicated stopping mechanisms
3Reliability
If power is removed from the motor and brake is applied to stop the elevator, then safety is improved, but operation time increases
Solution Approach 1:
The system applies a graduated response based on distance thresholds. Instead of immediately stopping the elevator at any detected hazard, it first issues visual and audible warnings, then removes motor power, and only applies the brake when necessary. This partial action approach maintains safety while minimizing disruption to operation
Solution Approach 2:
The controller executes preliminary warnings (visual and audible signals) before removing power from the motor or applying the brake. This preliminary action gives the mechanic time to react and stop the elevator manually if possible, reducing the need for forced stopping and minimizing operation time loss
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
Ensures the safety of mechanics by preventing accidental contact with the counterweight through controlled deceleration and alerts, providing a low-cost, easily installable solution for elevator systems.
Implementation Method 1
a range finding sensor, operationally coupled to the warning system controller, and mounted to one of the elevator car, the counterweight and the hoistway wall
Data Source
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AI summary
An elevator system having: a hoistway; an elevator car movable within the hoistway; a controller operationally coupled to the elevator car; a counterweight coupled to the elevator car and movable within the hoistway; and an approaching-hazard-warning-system that has: a warning system controller; a range finding sensor, operationally coupled to the warning system controller, and mounted to one of the elevator car, the counterweight and the hoistway wall, wherein, while operating in an inspection mode, the warning system controller is configured to receive sensor data from the range finding sensor, detect when a distance between the elevator car and the counterweight is less than a stop distance while the elevator car and the counterweight are moving toward each other, and execute a first responsive action including one or more of slowing the elevator car by communicating with the car controller, stopping the elevator car and sounding a first audible alert.