Elevator Master Controller for Dynamic Brake Force Control
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Solution Overview
Problem
Current elevator systems require separate braking systems for operational, unintended movement, and free fall brakes, leading to binary actuation and abrupt stopping, necessitating shutdown for maintenance and failing to ensure a level stop.
Innovation Solution
A master controller is introduced to selectively control a plurality of brakes, incorporating sensing units to detect freefall and unintended movement, allowing for varied braking forces and continuous operation by distributing braking functions among available brakes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate braking systems are used for operational, unintended movement, and free fall brakes, then each braking function can be independently controlled, but the device complexity increases and maintenance requires entire elevator shutdown
Solution Approach 1:
The patent combines multiple separate braking systems (operational brake, unintended movement brake, free fall brake) into a single integrated braking system controlled by one controller. This consolidation reduces device complexity while maintaining all necessary braking functions through unified control logic that selectively activates appropriate brake forces based on operational needs.
Solution Approach 2:
The single braking system is designed to perform multiple braking functions universally. The controller can selectively activate different braking forces (operational, unintended movement, free fall) using the same physical brake infrastructure, allowing one system to fulfill multiple safety and operational roles without requiring separate dedicated systems for each function.
2Ease of operation
If binary actuation of brakes is used, then the control system is simple, but abrupt stopping conditions occur and the elevator car cannot be leveled during braking
Solution Approach 1:
The patent transitions from static binary brake actuation (on/off) to dynamic brake force control. The controller selectively activates brakes with varied force levels, enabling gradual and controlled deceleration. This dynamic approach allows the system to modulate braking intensity to achieve smooth stopping and proper car leveling while maintaining relatively simple control architecture.
3Loss of time
If one braking system is used for multiple functions, then maintenance time is reduced, but the reliability of individual braking functions may be compromised
Solution Approach 1:
The patent uses parameter changes to differentiate braking functions within a single system. By varying the force characteristics and activation parameters of the brake based on the required function (operational, unintended movement, or free fall braking), the system maintains high reliability for each function while using shared hardware infrastructure, thus reducing maintenance requirements.
Data Source
AI summary
A system and method for controlling the movement of an elevator is provided. The elevator controller directs the operation of the elevator and receives information from the elevator system to calculate a brake profile. The elevator system transmits the brake profile to a master controller. The master controller selectively actuates the brakes to apply a braking force configured to generate the brake profile. The system and method may include local controllers, each configured to actuate a respective brake, wherein the master controller selectively directs the local controllers to generate a brake force commensurate with the braking profile.