Elevator Digital Twins via UAV for Retrofit-Free Maintenance
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Solution Overview
Problem
Existing methods for predictive maintenance of elevators, particularly for old equipment, are economically infeasible due to the high cost of retrofitting sensors, and there is a lack of effective monitoring solutions for components like suspension ropes.
Innovation Solution
Utilizing an unmanned aerial vehicle (UAV) equipped with sensors to generate digital twins of elevator components, comparing parameter values and trends against predefined thresholds, and automatically triggering maintenance requests when thresholds are met or exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are retrofitted to old elevator equipment for data collection, then predictive maintenance capability is improved, but installation cost increases significantly
Solution Approach 1:
The patent introduces an intermediary system consisting of a UAV (drone) and external sensors that collect data about elevator components without requiring permanent installation on the equipment. The UAV acts as a mobile intermediary platform that can access hard-to-reach components like suspension ropes, transferring measurement information to the monitoring system without physical attachment to the elevator infrastructure.
Solution Approach 2:
The system creates a digital twin (virtual copy) of the elevator system that replicates the physical elevator's behavior and parameters. By monitoring the digital twin instead of directly instrumenting the physical system, the patent avoids the need for extensive sensor installation while maintaining full predictive maintenance capability through simulation and comparison of the copied system.
2Loss of information
If comprehensive sensor coverage is implemented for all elevator components, then data collection completeness is improved, but device complexity increases
Solution Approach 1:
The system transitions from a static sensor network to a dynamic mobile measurement platform. The UAV can dynamically position itself to access different components of the elevator system as needed, adjusting its location and measurement focus based on the specific component being monitored, thereby achieving comprehensive coverage without permanent installations at every location.
Solution Approach 2:
The UAV platform serves multiple functions: it can monitor different elevator components (suspension ropes, guide rails, landing doors), perform visual inspections, and collect various types of data (dimensional, visual, operational) using a single multi-functional system rather than dedicated sensors for each component.
3Productivity
If manual inspection methods are used for elevator maintenance, then implementation simplicity is maintained, but productivity and detection accuracy decrease
Solution Approach 1:
The patent replaces manual mechanical inspection methods with automated UAV-based measurement systems equipped with sensors and imaging devices. The system automatically navigates, captures data, and processes measurements, eliminating the need for manual inspection while significantly improving both productivity and measurement precision through consistent, repeatable automated measurements.
Solution Approach 2:
The system implements continuous monitoring with automated feedback loops that compare measured parameters against threshold values and historical data. When anomalies are detected, the system automatically generates alerts and maintenance requests, providing real-time feedback that enables proactive maintenance decisions without requiring continuous manual assessment.
Data Source
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AI summary
The present invention relates to a method, a system and a computer program product for detecting and/or predicting need for elevator maintenance. A first digital twin of the elevator is generated using data collected by one or more sensors of an unmanned aerial vehicle (UAV) operating within the elevator shaft. One or more threshold values are defined for parameters associated with one or more components of the elevator appearing in the first digital twin. At least one second digital twin of the elevator is generated using data collected by one of more sensors of an unmanned aerial vehicle (UAV) within the elevator shaft. Each parameter of the elevator in the at least one second digital twin is compared to the respective one or more first threshold values. A request for maintenance of the one or more components of the elevator is automatically triggered if any one of the compared parameters meets or goes beyond the respective first threshold value.