Modular Elevator Sills Segmentation for Customization
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Solution Overview
Problem
Custom elevator sills require significant time and cost due to the need for custom design, engineering, and manufacturing as single-piece components, leading to longer lead times and higher costs compared to standard sills.
Innovation Solution
A modular sill assembly comprising a top layer, a bottom layer, and fasteners, where the top layer includes blind bores and the bottom layer includes through bores, allowing for secure threading and assembly, enabling customization without extensive machine setup or programming, and allowing for the use of different materials and constructions for central and extension sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If custom elevator sills are manufactured as single-piece components, then structural integrity is maintained, but production time and cost increase significantly
Solution Approach 1:
The sill is divided into multiple segments including a base segment, top segment, and intermediate segments that can be manufactured separately and assembled together. This segmentation allows each component to be produced independently using standard manufacturing processes, significantly reducing production time and cost while maintaining the overall structural integrity through proper connection mechanisms between segments
2Strength
If custom elevator sills are manufactured as single-piece components, then structural integrity is maintained, but manufacturing cost increases significantly
Solution Approach 1:
The sill structure is segmented into standardized components that can be manufactured using existing production capabilities rather than requiring custom single-piece machining. This approach leverages economies of scale and standard manufacturing processes, reducing the cost of custom sills to near-standard prices while achieving the required structural performance through properly designed connections
Solution Approach 2:
The segmented sill design uses standardized base segments, top segments, and connection elements that can serve multiple configurations and applications. These universal components can be adapted to various sill lengths, styles, and specifications through different assembly arrangements, eliminating the need for entirely custom manufacturing and reducing overall production costs
3Adaptability or versatility
If custom elevator sills are manufactured as single-piece components, then design flexibility is achieved, but lead time increases significantly
Solution Approach 1:
The sill is divided into modular segments that can be independently manufactured and stored. When a custom sill is needed, the appropriate segments are selected and assembled, dramatically reducing lead time from weeks of custom machining to days or hours of assembly. This modular approach maintains design flexibility because segments can be reconfigured for different applications
Solution Approach 2:
Standardized sill segments are pre-manufactured and prepared in advance using standard processes. The base segments, top segments, and connection elements are produced ahead of time and can be kept in inventory or readily available for quick assembly. This preliminary preparation eliminates the need for time-consuming custom machining when orders are received
Data Source
AI summary
A modular sill assembly includes a top layer, a bottom layer, a first fastener, and a second fastener. The top layer includes a first top plate and a second top plate. The first and second top plates define a door channel therebetween. Each of the first and second top plates includes a top surface, a bottom surface, and a blind bore. The blind bore is defined in the bottom surface and extends towards the top surface. The blind bore is threaded. The bottom layer includes a first base plate that defines a through bore. The first fastener extends through the first base plate and is threadably received in the blind bore of the first top plate to secure the first top plate to the first base plate. The second fastener extends through the first base plate and is threadably received in the blind bore of the second top plate to secure the second top plate to the first base plate.