Robotic Hoistway Mapping for Precise Elevator Installation

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Solution Overview

Problem

Manually mapping and inspecting elevator shafts for elevator systems is time-consuming and imprecise, requiring significant manual effort.

Innovation Solution

An elevator inspection system utilizing a robotic platform equipped with sensors and a controller to create a three-dimensional hoistway model, enabling precise installation and maintenance by defining virtual elevator guide rails and installation locations, and allowing for automated inspection and maintenance using SLAM and CAD models.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual mapping and inspection methods are used, then flexibility and adaptability are maintained, but time consumption and imprecision increase significantly

Engineering Contradiction:

Improveinspection precisionVSAvoidtime consumption

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical inspection methods with an automated robotic system equipped with sensors (laser scanners, cameras, LIDAR) that can autonomously map and inspect hoistways. The robotic platform moves along guide rails and collects spatial data without human intervention, eliminating the time-consuming nature of manual inspection while achieving high measurement precision through advanced sensing technologies.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates a digital 3D model (copy) of the physical hoistway structure through laser scanning and photogrammetry. This digital replica allows for precise measurement and inspection without requiring physical manual measurement, significantly reducing time consumption while maintaining or improving measurement accuracy compared to manual methods.

Inventive Principle:

Principle #26Copying

2Productivity

If automated robotic inspection systems are implemented, then time efficiency and precision improve, but system complexity increases

Engineering Contradiction:

Improveinstallation efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The robotic inspection platform is designed as a multi-functional system that can perform various inspection tasks (laser scanning, photography, LIDAR measurement) and adapt to different hoistway configurations. The same robotic platform can be used for both initial mapping and ongoing inspection, reducing the need for multiple specialized systems and managing complexity through consolidation of functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system introduces a centralized control system and processing unit that acts as an intermediary between the various sensors, robotic movement mechanisms, and data output. This intermediary layer coordinates the complex interactions between components, managing system complexity by providing a unified control interface and centralized data processing rather than requiring direct coordination between all components.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If detailed three-dimensional hoistway modeling is performed, then installation precision and component alignment improve, but data processing requirements and time increase

Engineering Contradiction:

Improveinstallation precisionVSAvoiddata processing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system performs preliminary mapping and creates the 3D hoistway model during the initial installation phase or during scheduled maintenance when the hoistway is idle. This preliminary action captures all spatial data and structural characteristics upfront, allowing for precise installation planning without requiring time-consuming data collection during actual installation operations. The model is prepared in advance to guide subsequent installation activities.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system creates a detailed digital 3D model (virtual copy) of the hoistway that can be used repeatedly for installation planning and simulation without requiring additional physical measurement time. This digital replica allows multiple iterations of installation planning and component positioning to be performed virtually, reducing the time needed for actual on-site adjustments while maintaining high installation precision.

Inventive Principle:

Principle #26Copying

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

Reduces manual effort, increases precision, and enhances the efficiency of elevator installation and maintenance processes, providing a competitive advantage with faster installation times and improved ride quality.

Implementation Method 1

a LIDAR sensor; a camera; a laser sensor, a photogrammetry sensor, and a time of flight sensor

Methodology Applied

Scientific EffectTime of flight: Time of Flight

Data Source

PatentEP3882204B1Elevator inspection system with robotic platform configured to develop hoistway model data from sensor data

Publication Date: 2025.08.06 OTIS ELEVATOR CO

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AI summary

Disclosed is an elevator inspection system (200), having: a sensor implement (210); a robotic platform (220) supporting the sensor (210), the robotic platform (220) configured to inspect a hoistway; a controller (230) operationally connected to the robotic platform (220) and the sensor (210), wherein the controller (230) is configured to define hoistway model data for the hoistway, from sensor data, corresponding to locations and shape boundaries of the hoistway and doorway openings formed in the hoistway.