Escalator Step Strain Sensing for Overload Shutdown and Maintenance

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Solution Overview

Problem

Escalators require routine maintenance and are prone to component damage during overloading, necessitating quick shutdown to prevent further damage and scheduling maintenance based on loading conditions.

Innovation Solution

Equipping escalator steps with strain sensors and a master-slave sensor configuration for real-time monitoring, allowing for predictive maintenance and emergency shutdown when loading exceeds a threshold, utilizing strain gauges, pressure gauges, and accelerometers to determine loading and stress, and employing virtual sensors for data analytics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If routine scheduled maintenance is performed, then escalator reliability is maintained, but maintenance costs and downtime increase

Engineering Contradiction:

Improveescalator reliabilityVSAvoidmaintenance downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary monitoring of loading conditions and component stress levels to predict potential failures before they occur. By detecting strain and load patterns that indicate impending component failure, the system enables maintenance to be scheduled at optimal times, reducing unexpected downtime while maintaining reliability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors loading conditions, strain levels, and component stress, providing real-time feedback about escalator health. This feedback loop allows dynamic adjustment of maintenance schedules based on actual component conditions rather than fixed time intervals, optimizing both reliability and minimizing unnecessary maintenance downtime.

Inventive Principle:

Principle #23Feedback

2Strength

If overloading is detected and escalator is shut off quickly, then component damage is minimized, but operational continuity is disrupted

Engineering Contradiction:

Improvecomponent damage resistanceVSAvoidoperational continuity

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The system applies preliminary anti-action by detecting loading conditions that approach dangerous thresholds and taking preventive action before actual overloading and component damage occur. The strain sensors and load cells identify stress patterns indicating impending overload, allowing the system to reduce load or shut down before critical damage happens, minimizing both component damage and disruption duration.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The system dynamically adjusts escalator operation based on real-time loading conditions. Rather than fixed shutdown thresholds, the system continuously monitors strain and load levels, adjusting operational parameters dynamically to prevent component damage while maintaining maximum safe productivity. This dynamic approach optimizes the balance between protection and operational continuity.

Inventive Principle:

Principle #15Dynamics

3Measurement precision

If multiple load sensors are installed on escalator steps, then measurement precision of loading conditions is improved, but device complexity increases

Engineering Contradiction:

Improveloading condition measurement precisionVSAvoidsensor system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The sensor system is segmented into modular units with each escalator step containing its own load sensor and strain sensors. Each modular sensor unit independently measures local loading conditions, and the data from multiple segments is aggregated to provide comprehensive precision measurement of overall escalator loading while keeping individual sensor units simple and manageable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The load sensors and strain sensors are designed with multi-functionality, serving multiple purposes: measuring vertical load, detecting strain levels, monitoring component stress, and identifying abnormal usage patterns. This universal approach improves measurement precision across multiple parameters while avoiding the complexity of separate dedicated sensors for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables real-time response to loading conditions, prolongs component life, reduces maintenance costs, and optimizes maintenance schedules by predicting component lifetimes and reducing the risk of damage.

Implementation Method 1

the at least one load sensor includes one or more of a strain gauge, pressure gauge and an accelerometer

Methodology Applied

Scientific EffectStrain gauge: Piezoresistive Effect

Implementation Method 2

the at least one load sensor includes one or more of a strain gauge, pressure gauge and an accelerometer

Methodology Applied

Scientific EffectPressure gauge:

Implementation Method 3

the at least one load sensor includes one or more of a strain gauge, pressure gauge and an accelerometer

Methodology Applied

Scientific EffectAccelerometer: Accelerometer

Data Source

PatentEP3915927B1Escalator steps with strain sensors

Publication Date: 2025.11.12 OTIS ELEVATOR CO

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AI summary

Disclosed is an escalator system that has: an escalator step; and load sensors secured to the escalator step, wherein the load sensors are configured to: sense an escalator loading; and transfer, to an escalator controller, sensor data indicative of the escalator loading.