Apparatus and method for aligning guide rails in an elevator shaft

The apparatus includes a positioning unit and an alignment unit. The positioning unit extends across the elevator shaft in a second direction and comprises at each end a first attachment mechanism movable in the second direction for supporting the positioning unit on opposite wall structures in the elevator shaft. The alignment unit extends across the elevator shaft in the second direction and is supported with support parts on each end portion of the positioning unit. Each end portion of the alignment unit is individually movable in relation to the positioning unit in a third direction perpendicular to the second direction. The alignment unit includes further at each end a second attachment mechanism movable in the second direction for supporting the alignment unit on opposite guide rails in the shaft. The second attachment mechanism includes a gripper for gripping on the guide rail.

FIELD OF THE INVENTION

The invention relates to an apparatus for aligning guide rails in an elevator shaft, a lifting machinery moving an elevator car in a first direction upwards and downwards in the vertically extending elevator shaft being restricted by wall structures, the elevator car being guided by guide rails supported on the wall structures in the elevator shaft.

The invention relates further to a method for aligning guide rails in an elevator shaft including using the apparatus of the invention.

BACKGROUND ART

An elevator comprises an elevator car, lifting machinery, ropes, and a counter weight. The elevator car is supported on a transport frame being formed by a sling or a car frame. The transport frame surrounds the elevator car. The lifting machinery comprises a traction sheave, a machinery brake and an electric motor being connected via a shaft. The electric motor is used to rotate the traction sheave and the machinery brake is used to stop the rotation of the traction sheave. The lifting machinery is situated in a machine room. The lifting machinery moves the car upwards and downwards in a vertically extending elevator shaft. The transport frame and thereby also the elevator car is carried by the ropes, which connect the elevator car over the traction sheave to the counter weight. The transport frame of the elevator car is further supported with gliding means at guide rails extending in the vertical direction in the elevator shaft. The gliding means can comprise rolls rolling on the guide rails or gliding shoes gliding on the guide rails when the elevator car is mowing upwards and downwards in the elevator shaft. The guide rails are supported through fish plates on fastening brackets that are supported at the side wall structures of the elevator shaft. The gliding means engaging with the guide rails keep the elevator car in position in the horizontal plane when the elevator car moves upwards and downwards in the elevator shaft. The counter weight is supported in a corresponding way on guide rails supported on the wall structure of the elevator shaft. The elevator car transports people and/or goods between the landings in the building. The elevator shaft can be formed so that the wall structure is formed of solid walls or so that the wall structure is formed of an open steel structure.

The guide rails are formed of guide rail elements of a certain length. The guide rail elements are connected in the installation phase end-on-end one after the other in the elevator shaft. When aligning elevator guide rails every bracket and fish plate associated with the bracket needs to be adjusted and the straightness of the guide rail is measured locally. Such a prior art system requires a lot of manual adjustment work and it may require multiple adjustment passes. The quality of the alignment will vary depending on the mechanic who is doing the alignment.

BRIEF DESCRIPTION OF THE INVENTION

An object of the present invention is to present a novel apparatus and method for aligning guide rails of an elevator.

The apparatus for aligning guide rails in an elevator shaft according to the invention has lifting machinery that moves an elevator car in a first direction upwards and downwards in the vertically extending elevator shaft, which is restricted by wall structures. The elevator car is guided by guide rails supported on the wall structures in the elevator shaft. The apparatus comprises:

A lifting machinery moves an elevator car in a first direction upwards and downwards in the vertically extending elevator shaft being restricted by wall structures. The elevator car is guided by guide rails supported on the wall structures in the elevator shaft. The apparatus comprises:

a positioning unit extending horizontally across the elevator shaft in a second direction and comprising first attachment means movable in the second direction at each end of the positioning unit for supporting the positioning unit on opposite wall structures in the elevator shaft,

an alignment unit extending across the elevator shaft in the second direction and being movably supported with support parts on each end portion of the positioning unit and comprising second attachment means movable in the second direction at each end of the alignment unit for supporting the alignment unit on opposite guide rails in the shaft, means for moving the attachment means in the second direction, and means for moving each support part separately horizontally in relation to the positioning unit in a third direction being perpendicular to the second direction, said second attachment means comprising gripping means for gripping on the guide rail, whereby

opposite guide rails can be adjusted in relation to each other and in relation to the elevator shaft so that the opposite guide rails extend in a common vertical plane, and so that the opposite guide rails are at the same distance from the back of the shaft.

The method for aligning guide rails in an elevator shaft is characterized by the steps of:

using an apparatus comprising

a positioning unit extending horizontally across the elevator shaft in a second direction and comprising first attachment means movable in the second direction at each end of the positioning unit for supporting the positioning unit on opposite wall structures or other support structures in an elevator shaft, and

an alignment unit extending across the elevator shaft in the second direction and being supported with support parts on each end portion of the positioning unit so that each end portion of the alignment unit is individually movable in relation to the positioning unit in a third direction perpendicular to the second direction, and comprising second attachment means movable in the second direction at each end of the alignment unit for supporting the alignment unit on opposite guide rails in the shaft, said second attachment means comprising gripping means for gripping on the guide rail,

for aligning opposite guide rails in an elevator shaft, whereby

the alignment unit is used to align the two opposite guide rails in relation to each other and the positioning unit is used to align the two opposite guide rails in relation to the elevator shaft.

The mechanic moves during the alignment of the guide rails typically upwards and downwards in the elevator shaft on a working platform attached to the transport frame. The transport frame is moved by lifting means connected to the transport frame. The inventive apparatus can be supported on the transport frame when the mechanic moves between the support bracket locations in the elevator shaft. The mechanic stops the lifting means at each support bracket location and uses the inventive apparatus to align the guide rail at said bracket location. Each end of the alignment unit in the apparatus can be supported on the two opposite guide rails. Each end of the positioning unit can on the other hand be supported on opposite wall constructions and/or on dividing beams and/or on brackets in the shaft. This makes it possible to align the two opposite guide rails in relation to the direction between the guide rails (DBG) and in relation to the direction between the back wall construction and the front wall construction of the shaft (BTF).

The inventive apparatus will speed up the process-step of aligning the elevator guide rails compared to prior art methods. The inventive apparatus will also eliminate variations in the quality of the alignment. The quality of the alignment will be less dependent on the person performing the alignment. A trained technician can easily make a high quality alignment with the help of the inventive apparatus.

The inventive apparatus can be used in aligning the guide rails in a new installation and in re-adjusting the alignment of the guide rails in an existing elevator.

The length of the inventive apparatus can in one embodiment be adapted to elevator shafts of different dimensions.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

FIG. 1shows a vertical cross section of an elevator. The elevator comprises an elevator car10, lifting machinery40, ropes41, and a counter weight42. The elevator car10is supported on a transport frame11surrounding the elevator car10. The lifting machinery40comprises a traction sheave43, a machinery brake46and an electric motor44being connected via a shaft45. The electric motor44is used to rotate the traction sheave43and the machinery brake46is used to stop the rotation of the traction sheave43. The lifting machinery40is situated in a machine room30. The lifting machinery40moves the car10in a first direction S1upwards and downwards in a vertically extending elevator shaft20. The transport frame11and thereby also the elevator car10are carried by the ropes41, which connect the elevator car10over the traction sheave43to the counter weight42. The transport frame11of the elevator car10is further supported with gliding means70at guide rails50extending in the vertical direction in the elevator shaft20. The figure shows two guide rails50at opposite sides of the elevator car10. The gliding means70can comprise rolls rolling on the guide rails50or gliding shoes gliding on the guide rails50when the elevator car10is mowing upwards and downwards in the elevator shaft20. The guide rails50are supported with fish plates at fastening brackets60and the support brackets60are attached to the side wall structures21or other support structures in the elevator shaft20. The figure shows only two fastening brackets60, but there are several fastening brackets60along the height of each guide rail50. The gliding means70engaging with the guide rails50keep the elevator car10in position in the horizontal plane when the elevator car10moves upwards and downwards in the elevator shaft20. The counter weight42is supported in a corresponding way on guide rails supported on the wall structure21of the elevator shaft20. The elevator car10transports people and/or goods between the landings in the building. The elevator shaft20can be formed so that the wall structure21is formed of solid walls or so that the wall structure21is formed of an open steel structure.

The cross section of the guide rails50has normally the form of a letter T. The horizontal branch of the letter T is attached to fish plates being attached to the support brackets60, which are attached to the wall structure21or other support structure in the elevator shaft20. The vertical branch of the letter T forms three gliding surfaces for the gliding means70comprising rolls or gliding shoes. There are thus two opposite side gliding surfaces and one front gliding surface in the guide rail. The horizontal cross-section of the gliding means70has the form of a letter U so that the inner surface of the gliding means70sets against the three gliding surfaces of the guide rail50. The gliding means70is attached to the transport frame11.

The guide rails50extend vertically along the height of the elevator shaft20. The guide rails50are thus formed of guide rail elements of a certain length e.g. 5 m. The guide rail elements are connected in the installation phase end-on-end one after the other. It is time consuming to install the guide rails50so that they are properly aligned along the whole height of the elevator shaft20. The quality of the alignment will vary depending on the mechanic who is doing the alignment.

Variations in the alignment of the guide rails50will result in lateral forces acting on the gliding means70when the car10moves upwards and downwards in the elevator shaft20. These lateral forces might cause vibrations to the gliding means70and thereby also to the elevator car10. The vibrations acting on the elevator car10will also cause noise disturbing the passengers in the elevator car10.

The mechanic moves during the alignment of the guide rails50typically upwards and downwards S1in the elevator shaft20on a working platform attached to the transport frame11. The transport frame11is moved by lifting means connected to the transport frame11. The apparatus can be supported on the transport frame11when the mechanic moves between the support bracket60locations in the elevator shaft20. The mechanic stops the lifting means at each support bracket60location and uses the inventive apparatus to align the guide rails50at said bracket60location.

FIG. 2shows a horizontal cross section of the elevator shaft. The figure shows the wall structures21of the shaft20forming a rectangular cross section. There are first guide rails51,52at the opposite side wall structures21of the shaft20guiding the elevator car10. There are further second guide rails53,54at the back wall structure21of the shaft20guiding the counterweight42. The figure shows also a second direction S2i.e. the direction between the guide rails (DBG) and a third direction S3i.e. the direction from the back to the front (BTF). The second direction S2is perpendicular to the third direction S3.

FIG. 3shows an axonometric view of an apparatus for aligning guide rails in an elevator according to the invention. The apparatus500for aligning guide rails50comprises a positioning unit100and an alignment unit200.

The positioning unit100comprises a longitudinal support structure with a middle portion110and two opposite end portions120,130. The two opposite end portions120,130are mirror images of each other. There could be several middle portions110of different lengths in order to adjust the length of the positioning unit100to different elevator shafts20. The positioning unit100comprises further first attachment means140,150at both ends of the positioning unit100. The first attachment means140,150are movable in the second direction S2i.e. the direction between the guide rails (DBG). The positioning unit100extends across the elevator shaft20in the second direction S2. The first attachment means140,150are used to lock the positioning unit100between the wall structures21and/or dividing beams and/or brackets60in the elevator shaft20. An actuator141,151(position shown only schematically in the figure) e.g. a linear motor in connection with each of the first attachment means140,150can be used to move each of the first attachment means140,150individually in the second direction S2.

The alignment unit200comprises a longitudinal support structure with a middle portion210and two opposite end portions220,230. The two opposite end portions220,230are mirror images of each other. There could be several middle portions210of different lengths in order to adjust the length of the alignment unit200to different elevator shafts20. The alignment unit comprises further second attachment means240,250at both ends of the alignment unit200. The second attachment means240,250are movable in the second direction S2. An actuator241,251e.g. a linear motor can be used to move each of the second attachment means240,250individually in the second direction S2. Each of the second attachment means240,250comprises further gripping means in the form of jaws245,255positioned at the end of the second attachment means240,250. The jaws245,255are movable in the third direction S3perpendicular to the second direction S2. The jaws245,255will thus grip on the opposite side surfaces of the guide rails50. An actuator246,256e.g. a linear motor can be used to move each of the jaws245,255individually in the third direction S3. The alignment unit200is attached to the positioning unit100at each end of the positioning unit100with support parts260,270. The support parts260,270are movable in the third direction S3in relation to the positioning unit100. The alignment unit200is attached with articulated joints J1, J2to the support parts260,270. An actuator261,271e.g. a linear motor can be used to move each of the support parts260,270individually in the third direction S3. The articulated joints J1, J2make it possible to adjust the alignment unit200so that it is non-parallel to the positioning unit100.

The two second attachment means240,250are moved with the actuators241,251only in the second direction S2. It would, however, be possible to add a further actuator to one of the second attachment means240,250in order to be able to turn said second attachment means240,250in the horizontal plane around an articulated joint. It seems that such a possibility is not needed, but such a possibility could be added to the apparatus500if needed.

The apparatus500can be operated by a mechanic through a control unit400. The control unit400can be attached to the apparatus500or it can be a separate entity that is connectable with a cable to the apparatus500. There can naturally also be a wireless communication between the control module400and the apparatus500. The control unit400is used to control all the actuators141,142moving the first attachment means140,150, the actuators241,242moving the second attachment means240,250, the actuators246,256moving the gripping means245,255and the actuators261,271moving the support parts260,270.

FIG. 4shows a first phase of the operation of the apparatus ofFIG. 3. The figure shows the bracket61at one side and the fish plates65,66on both sides of the shaft20. The guide rails51,52are attached to the fish plates65,66and the fish plates65,66are attached to the brackets60. The apparatus500can be supported on the transport frame11and lifted with the transport frame11to a first bracket60location during the alignment of the guide rails50. The mechanic is travelling on the working platform attached to the transport frame11. The mechanic operates then the apparatus500through the control unit400and attaches the alignment unit200with the jaws245,255at the ends of the second attachment means240,250to the two opposite guide rails51,52. The second attachment means240,250are movable in the second direction S2and the jaws245,255are movable in the third direction S3so that they can grip on the opposite vertical side surfaces of the guide rails51,52. The bracket60bolts and the fish plate65,66bolts are then opened at both sides of the shaft20so that the guide rails51,52can be moved. The guide rails51,52on opposite sides of the shaft20are then adjusted relative to each other with the alignment unit200. The frame of alignment unit200is stiff so that the two opposite guide rails51,52will be positioned with the apexes facing towards each other when the gripping means245,255grips the guide rails50. There is thus no twist between the opposite guide rails50after this. The distance between the two opposite guide rails50in the direction (DBG) is also adjusted with the alignment unit200. The position of each of the second attachment means240,250in the second direction S2determines said distance.

There is a plump line formed in the vicinity of each guide rail51,52(not shown in the figure). There is further a contact-free measurement system measuring the distance i.e. in the DBG and the BFT direction from the guide rail51,52to the plumb line that is in the vicinity of said guide rail51,52. The system calculates further the difference to a predetermined target value. Based on the differences of each guide rail51,52from the target value, the needed control values (DBG, BTF and twist) are calculated. The control values are then transformed into incremental steps, which are fed as control signals to the control units of the linear motors in the apparatus500. The DBG can also be measured based on the motor torque, which indicates when the second attachment means240,250have reached their end position and are positioned against the guide rails50. The position of the linear motors can then be read from the display of the control unit400. The apparatus500can thus calculate the DBG based on the distance of the guide rails51,52to the plumb lines and based on the position of each of the second attachment means240,250in the second direction S2.

FIG. 5shows a second phase of the operation of the apparatus ofFIG. 3. The positioning unit100is locked to the wall constructions21or other support structures in the elevator shaft20with the attachment means260,270. The alignment unit200is in a floating mode in relation to the positioning unit100when the positioning unit100is locked to the wall construction21of the elevator shaft20. The guide rails51,52can now be adjusted with the alignment unit200and the positioning unit100in relation to the shaft20. The bracket60bolts and the fish plate65,66bolts are then tightened. The apparatus500can now be transported to the next bracket60location where the first phase and the second phase of the operation of the apparatus is repeated.

The use of the invention is naturally not limited to the type of elevator disclosed in the figures, but the invention can be used in any type of elevator e.g. also in elevators lacking a machine room and/or a counterweight.