Linear Stator Beam Segmentation for Elevator Weight Reduction

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Solution Overview

Problem

Existing elevator systems with linear motors are expensive and heavy, particularly for high-rise applications, due to the cost and weight of linear stators with windings and/or permanent magnets, which pose challenges for efficient and cost-effective operation in tall buildings.

Innovation Solution

The elevator system incorporates a vertical stator beam with ferromagnetic poles, where the stator beam supports the linear stator and the mover forms a magnetic bearing, eliminating the need for separate guide means like guide rollers or rails, allowing the stator beam and mover to function as both the drive and guide for the elevator car, using ferromagnetic poles and electromagnetic components to maintain a constant air gap and reduce horizontal forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a linear stator with windings and permanent magnets is used in the elevator shaft, then the elevator motor can provide sufficient driving force, but the weight and cost of the system increases considerably

Engineering Contradiction:

Improvemotor forceVSAvoidweight of linear stator

Core Design Contradiction:

ForceVSWeight of stationary object

Solution Approach 1:

The linear stator is divided into multiple segments mounted on separate beams that can be distributed along the elevator shaft. Each beam carries a portion of the stator, allowing the total weight to be distributed and managed more effectively while maintaining the required motor force through multiple mover-stator interactions.

Inventive Principle:

Principle #1Segmentation

2Length of stationary object

If the elevator shaft height increases to 50 m or more, then the elevator can serve more floors, but the weight and cost of the linear stator adds up considerably

Engineering Contradiction:

Improveelevator shaft lengthVSAvoidweight of linear stator

Core Design Contradiction:

Length of stationary objectVSWeight of stationary object

Solution Approach 1:

The elevator shaft is divided into multiple zones with stator segments distributed throughout. Each segment is mounted on a separate beam structure, allowing the system to scale to great heights without requiring a single continuous heavy stator. The modular approach enables the elevator to serve more floors while managing weight through distributed architecture.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stator beams are arranged in multiple horizontal dimensions around the shaft perimeter rather than a single vertical arrangement. This spatial distribution in multiple dimensions allows the system to achieve the required motor force for high-rise applications while reducing the concentration of weight in any single location.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Weight of stationary object

If ferromagnetic poles are formed on the side face of a stator rod, then the stator beam can be made more lightweight, but the motor force generation must be maintained

Engineering Contradiction:

Improveweight of stator beamVSAvoidmotor force

Core Design Contradiction:

Weight of stationary objectVSForce

Solution Approach 1:

Ferromagnetic poles are formed locally on the side faces of stator rods rather than using a solid ferromagnetic beam throughout. This localized approach reduces the overall weight of the stator beam while maintaining the necessary magnetic properties for force generation at the critical interaction points between stator and mover.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The stator beam combines non-ferromagnetic structural materials with localized ferromagnetic pole formations. This composite approach allows the beam to achieve sufficient mechanical strength and stiffness while minimizing weight, as the ferromagnetic material is only present where needed for electromagnetic force generation.

Inventive Principle:

Principle #40Composite materials

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 configuration reduces the weight and cost of the elevator system, enabling efficient operation in high-rise buildings by doubling the motor force and eliminating the need for ropes or separate guide systems, while maintaining smooth movement and increased transport capacity through multiple elevator cars in a closed loop system.

Implementation Method 1

The elevator has at least one elevator motor comprising at least one linear stator located vertically along the elevator shaft and at least one mover located in connection with the elevator car and co-acting with the stator

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Implementation Method 2

the stator beam and the mover of the elevator car form guide means for the travel of the elevator car in the elevator shaft

Methodology Applied

Scientific EffectMagnetic bearing: Electrodynamic Bearing

Data Source

PatentUS11524875B2Elevator with linear motor

Publication Date: 2022.12.13 KONE OYJ

AI summary

An elevator includes at least one elevator shaft and at least one elevator car traveling in the elevator shaft. The elevator has at least one elevator motor including at least one linear stator located vertically along the elevator shaft and at least one mover located in connection with the elevator car and co-acting with the stator. The elevator includes a vertical stator beam supporting at least one stator, which stator beam has at least one side face carrying ferromagnetic poles of said stator spaced apart by a pitch. The mover includes at least one counter-face facing the side face(s) of the stator beam, in which electro-magnetic components of the mover are located.