Elevator Wire Rope Diameter Reduction Prediction
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Solution Overview
Problem
The current methods for predicting the replacement time of elevator wire ropes are inaccurate, leading to either premature or delayed replacements, as they rely solely on manual or non-contact diameter measurements without considering the rope's usage history, resulting in unplanned maintenance and procurement delays.
Innovation Solution
A non-contact rope diameter measuring device is installed in the elevator shaft to measure the rope diameters at multiple points during initial and follow-up inspections, calculating the diameter reduction over time, allowing for the prediction of when the rope will reach a predetermined threshold, enabling planned replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wire ropes are replaced based on manual diameter measurements alone, then measurement simplicity is maintained, but replacement timing accuracy deteriorates leading to premature or delayed replacements
Solution Approach 1:
The system performs preliminary actions by conducting multiple diameter measurements at different positions along the wire rope (including contact and non-contact portions with the drive sheave) before determining replacement timing. Historical measurement data is collected and stored over time, allowing the system to predict future diameter reduction trends and determine optimal replacement timing in advance, rather than relying on single-point measurements.
Solution Approach 2:
The invention transitions from one-dimensional measurement (single diameter value) to multi-dimensional analysis by measuring diameter at multiple positions along the wire rope's length, both in contact and non-contact zones with the drive sheave. This spatial dimensionality enables more accurate assessment of overall rope condition and wear patterns, leading to better replacement timing decisions.
2Loss of time
If wire ropes are replaced based on current diameter only, then immediate measurement simplicity is maintained, but planning capability deteriorates causing unplanned elevator downtime
Solution Approach 1:
The system implements feedback by continuously collecting and storing historical diameter measurement data from multiple inspection points along the wire rope. This historical data serves as feedback on the rope's degradation trend, allowing the system to predict future replacement needs and plan maintenance activities in advance, thereby minimizing unplanned elevator downtime.
Solution Approach 2:
By analyzing historical measurement data and predicting future diameter reduction trends, the system performs preliminary action in determining replacement timing. This allows maintenance planning to be done in advance, ensuring replacement parts are procured and scheduled appropriately, avoiding last-minute emergencies and unplanned downtime.
3Measurement precision
If multiple diameter measurements are taken at multiple positions, then replacement timing prediction accuracy is improved, but measurement time and complexity increase
Solution Approach 1:
The measurement system is segmented into multiple independent measurement positions along the wire rope, including both contact and non-contact portions with the drive sheave. Each position provides independent data about local rope condition. This segmentation allows comprehensive assessment without requiring continuous measurement along the entire rope length, balancing accuracy with inspection efficiency.
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 method allows for precise prediction of the rope replacement time, ensuring timely maintenance and reducing downtime by accurately tracking the rope's diameter reduction based on usage history, thereby optimizing maintenance schedules and procurement processes.
Implementation Method 1
a non-contact rope diameter measuring device is provided at a predetermined position in an elevator shaft along a path of the wire ropes
Data Source
AI summary
During a maintenance inspection, an optical rope diameter measuring device is provided at a predetermined position along a path of a wire rope, rope diameter is measured at multiple measuring points while the elevator is driven in test mode, and diameter reduction at each measuring point is determined and stored as a first diameter reduction (S2_S6). During a subsequent maintenance inspection, rope diameter is similarly measured at each measuring point to determine diameter reduction constituting a second diameter reduction (S7_S11). Based on these two diameter reductions, the time at which diameter reduction will reach a predetermined threshold value is predicted for each measuring point, and the earliest time is displayed as a rope replacement time (S12_S14).