Elevator Junction Box Pre-Assembly and Factory Testing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing method of installing elevator shaft signalization bundles requires extensive disassembly and reassembly during field installation, which is labor-intensive and inefficient, especially for low-rise elevators with 2-4 floors.
Innovation Solution
The method involves pre-assembling and testing the junction box with integrated PCB boards and a multi-conductor coil at the factory, which includes hoistway access control, floor control, and floor option boards, and then affixing it to the elevator hoistway with integrated box flaps, allowing for electrical connections via a serial data bus, reducing the need for on-site disassembly and simplifying the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shaft signalization bundle is assembled and tested in the factory then disassembled for field installation, then the complete bundle can be tested before installation, but the installation process becomes labor-intensive and time-consuming
Solution Approach 1:
The shaft signalization bundle including PCB boards, multi-conductor coil, and wiring is completely assembled and tested at the factory before delivery. The junction box is pre-configured with knock-out portions for cable access. This preliminary assembly and testing eliminates the need for disassembly during field installation, resolving the contradiction between ensuring testing completeness and maintaining installation efficiency.
2Ease of operation
If PCB boards are installed in separate metallic boxes at each floor, then each location has dedicated control, but the installation process requires extensive work
Solution Approach 1:
Multiple PCB boards (hoistway access control, floor control, floor option boards) are merged into a single junction box located in the elevator shaft. The junction box contains all necessary control circuits and connects to multiple floors through a multi-conductor coil. This merging reduces installation complexity while maintaining distributed control capability through the modular PCB board design within the unified junction box.
Solution Approach 2:
The junction box serves as an intermediary device in the elevator shaft that consolidates multiple control functions. It acts as a central hub connecting various PCB boards and the multi-conductor coil, simplifying the installation process while maintaining the ability to control multiple floors independently through its modular internal structure.
3Reliability
If the junction box includes integrated PCB boards and multi-conductor coil, then factory testing can be performed on the complete assembly, but the device complexity increases
Solution Approach 1:
The junction box is designed with modular PCB boards that can be independently installed and replaced. Each PCB board (hoistway access control, floor control, floor option) is a separate module within the junction box. This segmentation allows for factory testing of the complete assembly while maintaining manageable complexity through modular design, as each module can be tested and replaced independently if needed.
Data Source
AI summary
A method for installing at least one junction box in an elevator hoistway of an elevator includes providing at least one junction box, the junction box including a plurality of knock-out portions, knocking out at least one of the plurality of knock-out portions of the at least one junction box to form a respective aperture, and affixing at least one PCB board to the respective aperture. An elevator includes at least one junction box, including at least one PCB board affixed to an aperture of at least one junction box via holders and an integrated multi-conductor coil wired to each PCB board; a duct connector connected to the at least one junction box; and a plurality of wiring ducts connected to the duct connector.