Fiber-Reinforced Polymer Rope Terminal Assembly for Elevators
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Solution Overview
Problem
Existing elevator rope terminal assemblies are complex, heavy, and costly due to their metallic construction, which complicates mechanical attachment and increases production costs, especially when using non-metallic fiber-reinforced polymer composite materials, and lack effective damage detection mechanisms.
Innovation Solution
A lightweight, cost-effective rope terminal assembly made from fiber-reinforced polymer composite materials with a one-piece wedge housing designed using filament winding, incorporating a wedge element and rope end block for secure locking and integration with rope condition monitoring systems, allowing for efficient manufacturing and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic wedge housing with welded joints is used, then mechanical attachment is achieved, but device complexity and weight increase
Solution Approach 1:
The wedge housing is divided into multiple modular components (first wedge housing part, second wedge housing part, third wedge housing part) that can be separately manufactured and then assembled through welding or other connection methods. This segmentation allows each part to be optimized independently while maintaining overall structural integrity and strength for mechanical attachment.
Solution Approach 2:
The invention employs composite material construction for the wedge housing components, combining different materials (such as metal and polymer materials) to achieve both the required mechanical strength for secure attachment and reduced overall complexity. The composite structure allows each material to contribute its optimal properties to the assembly.
2Force
If multiple ropes are used, then load capacity increases, but number of rope terminals and production cost increase
Solution Approach 1:
The wedge housing assembly is designed as a universal component that can accommodate and secure multiple different types of ropes (suspension ropes, transmission ropes, compensating ropes) within the same structural framework. This multi-functional design allows a single standardized terminal assembly to handle various rope configurations, thereby maintaining load capacity while simplifying production and reducing the variety of specialized components needed.
3Weight of moving object
If fiber-reinforced polymer composite materials are used, then weight is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The composite material wedge housing is segmented into multiple parts that can be manufactured separately using precision composite manufacturing techniques (such as filament winding or resin transfer molding), then assembled together. This segmentation reduces the overall manufacturing precision requirement for each individual component while maintaining the weight advantages of composite materials.
Solution Approach 2:
The invention employs parameter optimization in the composite material construction, including fiber orientation, layer thickness, and resin content, to achieve the desired strength-to-weight ratio. By carefully controlling these parameters during manufacturing, the assembly achieves both reduced weight and sufficient structural integrity without requiring extreme manufacturing precision.
4Reliability
If welded joints are used in wedge housing, then structural integrity is achieved, but production cost and time increase
Solution Approach 1:
The wedge housing is segmented into standardized modules that can be pre-assembled and tested separately, then quickly connected to complete rope terminal assemblies on the production line. This modular segmentation maintains structural integrity through standardized connection interfaces while significantly improving assembly line efficiency and reducing production time.
Solution Approach 2:
Critical welding or connection operations are performed in advance during the manufacturing of individual wedge housing components, rather than during final assembly. This preliminary action ensures structural integrity is established early in the production process, allowing faster final assembly operations on the assembly line and improving overall productivity.
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
The solution provides a robust, lightweight, and cost-effective rope terminal assembly with improved manufacturing efficiency and damage detection capabilities, reducing production costs and enhancing the reliability of elevator rope connections while enabling easier handling and reduced weight in high-speed applications.
Implementation Method 1
The wedge housing is made with fiber reinforced polymer composite material comprising reinforcing fibers such as fiberglass or carbon fibers embedded in polymer matrix material, such as epoxy resin, vinylester resin or polyester resin
Implementation Method 2
The rope terminal assembly comprises a wedge element arranged to wedge between the rope and the wedge housing thus locking the rope in the gap
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The invention relates to a rope terminal assembly (1) of an elevator fixing an elevator rope (R) to a fixing base such as an elevator unit (2, CW), said elevator being suitable for transporting passengers and/or goods, which assembly (1) comprises at least the following components: an elevator rope (R), whose width is larger than its thickness in a rope transverse direction, with at least one end having an end face (R'), one or more wedge elements (8, 8'), and a wedge housing (7), the rope terminal assembly (1) comprising a rope gap through which said elevator rope (R) passes and said wedge element (8, 8') is arranged to wedge between said rope (R) and said wedge housing (7) thus locking said elevator rope (R) in the gap, and at least one component (7, 8, 8') of the rope terminal assembly (1) made of fiber reinforced polymer composite material, and an elevator.