Encapsulated Electromagnet Assembly for Elevator Actuator Fatigue

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Solution Overview

Problem

Existing electronic safety actuators in elevator systems face challenges in surviving thousands of actuations due to wear and fatigue, particularly in electromagnet assemblies and their components.

Innovation Solution

The implementation of encapsulated electromagnet and magnet assemblies, where the components are housed within a non-magnetic encapsulating body, such as a plastic shell, to protect them from stress and fatigue.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If electromagnet assemblies are used in electronic safety actuators, then the actuator can perform repeated actuations, but wear and fatigue occur in coils and lead wire connectors

Engineering Contradiction:

Improvenumber of actuationsVSAvoidfatigue failures in coils and lead wire connectors

Core Design Contradiction:

Duration of action of moving objectVSReliability

Solution Approach 1:

The patent combines the electromagnet assembly and magnet assembly into a single integrated unit with a common non-magnetic support structure. This merging eliminates separate mounting configurations and reduces the number of discrete components that can fail, thereby improving reliability while maintaining the capability for repeated actuations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent introduces a non-magnetic support structure as an intermediary element that holds both the electromagnet assembly and magnet assembly. This intermediary component isolates the magnetic components from direct mechanical stress and wear, reducing fatigue failures in coils and lead wire connectors while enabling sustained repeated actuations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If mounting configurations are used to attach components, then components can be secured, but shearing of metal flanges or other static components occurs due to wear and environment

Engineering Contradiction:

Improvemounting strengthVSAvoidshearing of metal flanges

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces traditional mechanical mounting configurations with magnetic attraction forces. The electromagnet assembly and magnet assembly attract each other magnetically, eliminating the need for metal flanges and mechanical fasteners that are susceptible to shearing. This substitution maintains strong component attachment while eliminating wear-related failures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The non-magnetic support structure serves as an intermediary that holds the electromagnet and magnet assemblies without requiring direct mechanical connection between them. This intermediary approach eliminates the shearing stresses that would otherwise be transmitted through metal flanges and mounting hardware.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If traditional electromagnet assemblies are used, then the actuator can operate, but components are exposed to stress and fatigue from repeated operations

Engineering Contradiction:

Improveactuator operationVSAvoidwear and fatigue from repeated operations

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent merges the electromagnet assembly and magnet assembly into a unified structure with shared support, reducing the number of separate components subject to wear and fatigue. This integrated design maintains full operational capability while minimizing the points of failure from repeated actuations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The non-magnetic support structure acts as an intermediary that protects the electromagnet and magnet assemblies from direct exposure to operational stresses. This intermediary structure absorbs and distributes mechanical loads, reducing fatigue accumulation in the critical magnetic components during repeated operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution enhances the durability and longevity of the electromechanical actuator components, reducing the risk of failures in coils, lead wire connectors, and metal flanges, thereby ensuring reliable operation over thousands of actuations.

Implementation Method 1

an electromagnet assembly (506) housed within the encapsulating body (516), the electromagnet assembly (506) configured to magnetically engage with the magnet assembly (508)

Methodology Applied

Scientific EffectElectromagnet: Electromagnet

Implementation Method 2

a magnet assembly (508) disposed adjacent to the electromagnet assembly (506), the magnet assembly (508) configured to magnetically engage with the electromagnet assembly (506)

Methodology Applied

Scientific EffectMagnetism: Magnetism

Data Source

PatentEP3915922B1Encapsulated components of electromechanical actuators for elevator systems

Publication Date: 2025.05.28 OTIS ELEVATOR CO

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AI summary

Electromagnetic actuators (500) for an elevator systems and encapsulated components thereof are described. The encapsulated components include an encapsulating body (516) and a component assembly (506) is arranged within the encapsulating body (516), wherein at least some parts of the component assembly (506) are contained within a material of the encapsulating body (516).