Elevator Safety Spring I-Beam Cross Section Manufacturing
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Solution Overview
Problem
Elevator safety spring manufacturing is inefficient due to the need for various spring sizes and thicknesses based on load and deflection requirements, leading to increased material and equipment costs, as well as cumbersome manufacturing processes.
Innovation Solution
The method involves determining and selecting dimensional parameters for an elevator safety spring with an I-beam cross-section, using advanced manufacturing processes like die forging or additive manufacturing, such as electron beam wire additive manufacturing, to create a single, unitary structure with optimized spring characteristics based on maximum load and normal load conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different spring sizes and thicknesses are used based on load and deflection requirements, then the spring performance is optimized for specific applications, but the manufacturing cost and equipment tonnage requirements significantly increase
Solution Approach 1:
The patent applies universality by designing a single standardized spring geometry that can serve multiple applications with different load and deflection requirements. By optimizing the dimensions of a universal spring design, the same basic spring structure replaces multiple specialized springs, reducing manufacturing complexity and cost while maintaining appropriate performance for various elevator safety applications.
Solution Approach 2:
The patent applies parameter changes by systematically varying the dimensional parameters (such as wire diameter, mean coil diameter, and number of active coils) of a standardized spring geometry to achieve different performance characteristics. This allows a single spring design family to cover multiple application requirements without needing completely different spring structures, thereby reducing manufacturing complexity while maintaining optimized performance.
2Reliability
If multiple spring sizes and thicknesses are manufactured, then specific application requirements are met, but the number of manufacturing steps and tools increases
Solution Approach 1:
The patent reduces manufacturing process complexity by establishing a universal spring geometry that can be produced using the same manufacturing tools and processes. Instead of requiring different forming equipment and tooling for various spring sizes, the standardized design allows a single manufacturing setup to produce springs for multiple applications by simply adjusting dimensional parameters within the standardized geometry.
Solution Approach 2:
The patent applies segmentation by dividing the range of required spring performances into discrete dimensional variants of a standardized geometry. Rather than creating entirely different spring structures for each application, the design segments the performance requirements into manageable dimensional variations (such as different wire diameters or coil counts) that can all be produced through the same manufacturing process.
3Strength
If spring wall thickness exceeds a certain dimension, then the spring can handle higher loads, but the material cost and equipment tonnage requirements significantly increase
Solution Approach 1:
The patent applies parameter changes by optimizing the dimensional parameters of the standardized spring geometry to achieve high load capacity without increasing wall thickness beyond economical limits. By adjusting parameters such as wire diameter, mean coil diameter, and number of active coils, the spring can handle higher loads while maintaining a wall thickness that avoids the need for expensive heavy-duty forming equipment.
Solution Approach 2:
The patent applies dimensionality change by resolving the load capacity requirement through dimensional variations (such as increasing wire diameter or adjusting coil geometry) rather than simply increasing wall thickness. This allows the spring to achieve higher strength through optimized proportions and geometry in multiple dimensions, avoiding the need for excessively thick walls that would require high-tonnage forming equipment.
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 approach reduces manufacturing costs and complexity by unifying spring designs, minimizing tooling needs, and achieving lighter weight springs with improved deformation characteristics, thereby reducing operational costs and energy requirements.
Implementation Method 1
the additive manufacturing process comprises electron beam wire additive manufacturing
Data Source
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AI summary
A method of manufacturing an elevator safety spring (20) is provided. The method includes determining a plurality of dimensional parameters (P1-P9) of the elevator safety spring (20). The method also includes selecting a plurality of dimensions (D1-D7) within the dimensional parameters (P1-P9). The method further includes manufacturing the elevator safety spring (20) based on the selected parameters, the elevator safety spring (20) having an I-beam cross-section.