Method for assembling a balustrade for a people moving device using an adjustable assembly jig

A method for assembling a balustrade for a people moving device is provided comprising the steps of providing a frame, balustrade components, and an adjustable assembly jig, aligning the balustrade components on the assembly jig in a predetermined geometry, assembling the balustrade components into a balustrade assembly on the assembly jig, and attaching the balustrade assembly to the frame.

BACKGROUND OF THE INVENTION 
a. Technical Field 
The present invention relates to balustrades for people moving devices in 
general, and to methods for assembling balustrades for people moving 
devices in particular. 
b. Background Art 
Escalators, moving walkways, and other people moving devices efficiently 
move a large volume of pedestrian traffic from one point to another. 
Passengers step on moving steps (or belts, or pallets) and are transported 
along at a constant rate of speed. For safety reasons passenger handrails 
are provided, traveling in the same direction and speed as the steps. A 
balustrade assembly supports and guides one of the handrails on each side 
of the steps. 
Each balustrade assembly includes balustrade panels (typically glass) which 
extend up from a base to support the handrail. The balustrade panels are 
supported and positioned by panel holders enclosed within the base by 
enclosure panels. Typically, the panel holders are attached to the frame 
of the device by adjustable brackets. 
Proper alignment of the balustrade components is critical during assembly. 
Aesthetically, it is important that each balustrade be aligned with the 
device's other balustrade. In applications where escalators are installed 
side by side, it is also important that the balustrades of one escalator 
be aligned with the balustrades of the adjacent escalator. For safety 
reasons, alignment is critical to prevent injuries to passengers passing 
by misaligned joints. 
It is known in the art that balustrades may be assembled piece by piece on 
the frame trusses of the escalator. Specifically, the assembly begins by 
locating and attaching the panel holders relative to the frame trusses. 
The remaining components are then located and attached to the panel 
holders and to each other as the balustrade assemblies are erected. There 
are several disadvantages to this piecemeal method of assembly. 
First, mounting the balustrade components on the truss one at a time 
accumulates the dimensional tolerances of the components, since each piece 
is positioned relative to the last piece. Accumulated tolerances may not 
be a problem for a particular balustrade, but they are often a problem 
when one balustrade must be aligned with the other balustrade of that 
particular escalator. Moreover, alignment problems are often exacerbated 
when the balustrades of adjacent escalators must be aligned relative to 
one another. 
Second, accumulated dimensional tolerances often require that one or more 
balustrade components be dimensionally altered before the component(s) can 
be installed. A person of skill in the art will recognize that the 
practice of custom fabricating or altering parts during assembly is a 
costly process. Moreover, if these parts require replacement in the 
future, the replacement part must also be customized. 
Third, assembling each balustrade on top of the frame is cumbersome. Often 
scrap and debris generated during the assembly process must be cleaned out 
of the hardware already attached to the frame. 
Fourth, it is impractical to assemble the balustrade piecemeal on the frame 
at the same time the rest of the escalator is being assembled. As a 
result, the time required to assemble the entire escalator is greater and 
therefore increases the leadtime of producing an escalator. A person of 
ordinary skill in the art will recognize that it is a competitive 
advantage to minimize the time required to manufacture an escalator. 
DISCLOSURE OF THE INVENTION 
It is, therefore, an object of the present invention to provide a method 
for assembling a balustrade of a people moving device which facilitates 
the assembly of the balustrade. 
It is a further object of the present invention to provide a method for 
assembling dimensionally consistent balustrades for people moving devices. 
It is a still further object of the present invention to provide a method 
for assembling a balustrade of a people moving device which minimizes the 
effects of dimensional inaccuracies of the balustrade components. 
It is a still further object of the present invention to provide a method 
for assembling a balustrade of a people moving device which minimizes the 
effects of dimensional inaccuracies of the balustrade frame. 
It is a still further object of the present invention to provide a method 
for assembling a balustrade for a people moving device which minimizes the 
time required for manufacturing the entire people moving device. 
It is a still further object of the present invention to provide an 
assembly jig upon which a balustrade can be accurately assembled. 
It is a still further object of the present invention to provide an 
transportation jig upon which an assembled balustrade can be transported. 
According to the present invention a method for assembling a balustrade for 
a people moving device is provided comprising the steps of providing a 
frame, balustrade components, and an adjustable assembly jig, aligning the 
balustrade components on the assembly jig in a predetermined geometry, 
assembling the balustrade components into a balustrade assembly on the 
assembly jig, and attaching the balustrade assembly to the frame. 
According to one aspect of the present invention, an alignment jig is 
provided for aligning the assembled balustrade relative to the roller 
tracks attached to the frame of the people moving device. 
According to another aspect of the present invention, a transportation jig 
is provided for transporting the assembled balustrade. 
An advantage of the present invention is that the problem of dimensional 
tolerance build up within the balustrade component parts is minimized or 
eliminated. 
A further advantage of the present invention is that the problem of 
dimensional inaccuracies within the frame is minimized or eliminated. 
A still further advantage of the present invention is that balustrade 
assemblies can be assembled to uniform dimensions. Uniformly dimensioned 
balustrade assemblies facilitate alignment of balustrades within a 
particular machine, as well as between adjacent machines. Uniformly 
dimensioned balustrades also facilitate component repair or replacement 
after installation. 
A still further advantage of the present invention is that debris resulting 
from the assembly of the balustrade does not damage or interfere with the 
rest of the people moving device. 
A still further advantage of the present invention is that the balustrade 
may be assembled coincidentally with the rest of the people moving device, 
thereby minimizing the time required to manufacture the people moving 
device. 
These and other objects, features and advantages of the present invention 
will become more apparent in light of the detailed description of the best 
mode embodiment, thereof, as illustrated in the accompanying drawings.

BEST MODE FOR CARRYING OUT THE INVENTION 
I. Elements 
Referring to FIG. 1, an escalator 10 is shown having a frame 12, a step 
chain 14, a plurality of moving steps 15, and a pair of balustrade 
assemblies 16. The frame 12 includes two trusses 18 aligned side by side, 
connected to each other by structural members 20 running therebetween. The 
frame 12 may be described as having an upper landing 22 and a lower 
landing 24 connected to one another by an inclined midsection 26. Matching 
pairs of roller tracks 28 are attached on the inside of each truss 18, 
i.e. the side of the truss 18 facing the other truss. The upper landing 22 
usually houses an escalator drive 30 between the trusses 18. The step 
chain 14 travels a closed loop, running from one elevation to the other 
elevation, and back. 
Referring to FIG. 2, each balustrade assembly 16 includes a plurality of 
balustrade panels 34, a base 36, a handrail 38, and handrail guides 41. 
The base 36 includes a panel holder(s) 40 for supporting the balustrade 
panels 34, a plurality of enclosure panels 42, adjustable panel holder 
brackets 44, and wedge-shaped clamps 46 for attaching the balustrade 
panels 34 to the panel holders 40. The panel holder 40 is an extruded, or 
otherwise formed member having a cross-sectional profile and a length. The 
cross-sectional profile includes a channel 48 and a pair of C-shaped slots 
50, all of which extend the length of the panel holder 40. Each adjustable 
panel holder bracket 44 includes a first half 52 and a second half 54, 
which together may be adjusted in two axis of direction. The first half 52 
of each bracket 44 includes a vertical 55 and a horizontal 57 locating 
surface for contact with the panel holder 40. 
The enclosure panels 42 include an outer cladding 56, an outer decking 58, 
an inner profile 60, and a skirt panel 62. The outer decking 58 and outer 
cladding 56 enclose the mechanics on the side of the balustrade panel 34 
opposite the moving steps 15. The inner profile 60 and skirt panel 62 
enclose the mechanics adjacent the moving steps 15. 
Referring to FIGS. 1 and 2, the handrails 38 form endless loops which 
travel from one end of the device to the other along the top of the 
balustrade panels 34 and then return through the base 36 of the balustrade 
assembly 16. At each end of the balustrade assemblies 16, the balustrade 
panels 34 have curved sections 64, or "newels", which enable the handrails 
38 to curve down and into the base 36 of the balustrade 16. 
Referring to FIGS. 3A and 3B, an assembly jig 66, mounted on the floor 68 
of the factory, includes a left hand 70 and a right hand 72 side (FIG. 
3B), each having a midsection 74, a lower landing section 76, and an upper 
landing section 78. The upper landing sections 78 extend into a pit 80 in 
the floor 68, thereby enabling the midsections 74 to be positioned level 
to the floor 68. Left side balustrades (i.e. those on the left when facing 
the escalator at the bottom landing) are assembled on the right hand side 
of the assembly jig 66. Right side balustrades are assembled on the left 
hand side 70 of the assembly jig. Assembling the balustrades 16 in this 
"back to back" manner facilitates the relative alignment of the enclosure 
panels 42 of each balustrade 16. 
The midsections 74 of the assembly jig 66 may be adjusted lengthwise to 
accommodate different length balustrade assemblies 16. Specifically, the 
lower landing sections 76 may be driven along the midsections 74 by 
electromechanical drives (not shown), toward the upper landing sections 78 
to specific positions for particular length (or "rise") escalators. A 
series of columns 84 (FIG. 3A), fixed to the floor 68, support the 
assembly jig 66. 
The assembly jig further includes a plurality of stanchions 86 and panel 
holder mounts 88. The panel holder mounts 88 are fixed to, and spaced 
along, the midsections 74 and both landing sections 76,78. 
Referring to FIG. 6A, each panel holder mount 88 includes a locating member 
89 and an adjustable support member 93. The locating member 89 is pivotly 
attached to a stanchion 86. Each locating member 89 comprises a clamping 
wedge 87 for clamping the panel holder 40 to the locating member 89. Each 
support member 93 includes a clamping means 85 for fixing the panel holder 
to the support member 93. 
The stanchions 86 are attached to the assembly jig 66 between the two sides 
70,72 (see also FIGS.3A and 3B) and include arms 90 having suction cups 91 
for supporting the balustrade panels 34 during assembly. The stanchions 86 
may be pivoted down and out of the way to avoid interference with the 
lower landing sections 76 (see FIGS. 3A and 3B) for different length 
balustrades. FIGS. 3A and 3B show stanchions 86 pivoted out of the way in 
phantom. 
Referring to FIGS. 3A and 3B, the upper 78 and lower 76 landing sections of 
the assembly jig 66 may be adjusted for length by either adding rail 
extensions (not shown) on, or by replacing the existing landing rail 
assemblies 76,78 with longer ones. The upper and lower landing sections 
78,76 are supported by fluid cylinders 92 mounted on the left and right 
hand sides 70,72 of the midsection 74. The fluid cylinders 92 can be used 
to pivot, and thereby change the angle of, the landings 76,78 relative to 
the midsection 74 for different escalator inclinations. Alternatively, the 
angle of the landings 76,78 relative to the midsection 74 can be changed 
by different toolings, adjustable brackets, etc. 
Referring to FIG. 4, the alignment jig 94 comprises a rigid structural 
frame 96 fixed to the floor 68 of the factory. On one end, the jig 94 
includes a fixed post structure 95 for locating the roller tracks 28 in 
the lower landing 24 area of the frame 12. On the other end, the alignment 
jig 94 includes a movable post structure 97 which may be moved to 
accommodate different geometry escalators. 
The alignment jig 94 locates the roller tracks 28 on the frame 12, correct 
relative to one another. The alignment jig 94 further comprises means 120 
for locating the panel holders 40 of the balustrade assembly 16 (FIG. 2) 
relative to the roller tracks 28. In the preferred embodiment, the 
locating means 120 comprises a plurality of physical gauges 122 which 
locate panel holder brackets 44 relative to the roller tracks 28 at 
specific positions along the length of the roller tracks 28. The gauges 
122 locate the panel holder brackets 44 both horizontally and vertically. 
Different gauges 122 may be used for differently configured balustrade 
assemblies. A person of ordinary skill in the art will recognize that the 
gauges 122 may comprise numerous embodiments; i.e. as simple as a machined 
spacer (shown), or as complex as an adjustable automated component which 
is sized and positioned automatically by robotics (not shown). 
Referring to FIGS. 5A and 5B, the transportation jig 101 comprises a frame 
102, left 106 and right 108 support arms, horizontal 116 and vertical 
indicators 118, and horizontal 117 and vertical 119 drive assemblies. The 
frame 102 includes a pressure vessel 104 fabricated from a length of 
tubular steel with a cap welded on both ends. The left 106 and right 108 
support arms, attached to the left and right sides of the pressure vessel 
104, each support a plurality of suction cups 114. The suction cups 114 
are attached to the pressure vessel 104 by conventional plumbing 115. The 
horizontal 116 and vertical 118 indicators indicate angular deviation of 
the jig 101 from horizontal and vertical reference planes. The horizontal 
117 and vertical 119 drive assemblies include conventional apparatus for 
imparting horizontal and vertical motion to the transportation jig 101, 
respectively. To be specific, the drive assemblies 117,119 are used to 
move the lifting point of the transportation jig 101 (i.e. the force 
vector provided by the overhead crane), thereby enabling the lifting point 
to be adjusted relative to the center of gravity of the jig 101. A person 
of ordinary skill in the art will recognize that the aforementioned 
conventional apparatus may be electromechanical, hydraulic, pneumatic, or 
otherwise. 
II. Assembly 
An escalator is assembled along an assembly line (not shown). At a 
particular station, the alignment jig 94 (see FIG. 4) is used to position 
and attach the roller tracks to the frame, as well as a pair of panel 
holder brackets in each landing of each side. At the same time, at a 
separate station, the balustrades of the escalator are being assembled on 
the assembly jig (see FIGS. 3A, 3B, and 6). 
Referring to FIG. 6A, in the assembly of each balustrade, lengths of 
extruded panel holder 40, either straight or shaped, are attached to the 
panel holder mounts 88 of the assembly jig 66. Specifically, the locating 
members 89 are positioned in the horizontal position (as shown in FIG. 6A) 
and the panel holders 40 are attached. The clamping wedge 87 located at 
the end of each locating member 89 both attaches and locates the panel 
holder lengths 40. 
Once the panel holders 40 are in the correct position, the support members 
93 are clamped to the panel holders 40 by the clamping means 85. 
Subsequently, the locating members 89 are released and pivoted out of the 
way as is shown in phantom in FIG. 6B. The panel holders 40 are now 
supported by the support members 93. 
Referring to FIG. 6B, once the panel holders 40 are secured to the assembly 
jig 66, the balustrade panels 34 are placed within the channels 48 of the 
panel holders 40. The arms 90 and suction cups 91 attached to the 
stanchions 86 are used to support the balustrade panels 34 while the 
panels 34 are being secured within the panel holders 40. The balustrade 
panels 34 are fixed in place by the wedge clamps 46 of the base 36. 
Once the panel holders 40, balustrade panels 34, and wedge clamps 46 have 
been assembled as described heretofore, the handrail guides 41 and 
handrails 38 are attached to the assembly. Next, the enclosure panels 42 
are attached to the panel holders 40. The assembled balustrade 16 is now a 
rigid assembly and maybe transported as a single assembly. 
To facilitate mounting the assembled balustrade 16 on the frame 10 of the 
escalator 10 (see FIG. 1), the return handrail guide 43 is temporarily 
placed on top of the outer decking 58. A temporary bracket 59 attached to 
the support hardware of the balustrade 16 keeps the return handrail guide 
43 on top of the outer decking 58. After the balustrade 16 is attached to 
the frame 12 (see FIG. 1), the bracket 59 is removed and the return 
handrail guide 43 is properly positioned. 
In the case where both balustrades 16 of an escalator 10 (FIG. 1) are being 
assembled on the assembly jig 66 at the same time, the left and right 
balustrade assemblies are assembled on the right 72 and left 70 sides of 
the assembly jig 66, respectively. Assembling the balustrades 16 in this 
"back-to-back" manner allows the assemblers to adjust for any dimensional 
discrepancies between the two balustrades 16. 
At this point in the assembly of the escalator, the roller tracks 28 and a 
few panel holder brackets 44 have been positioned and fixed to the frame 
12, the latter by using the gauges 122 of the alignment jig 94. 
Referring to FIGS. 5A and 5B, overhead cranes (not shown) bring the 
transportation jig 101 into position adjacent the assembly jig 66 (shown 
in phantom in FIG. 6B). In this position, the transportation jig 101 is on 
the inside of either balustrade assembly 16; i.e. the side of the 
balustrade that will be adjacent the moving steps 15 of the escalator 10. 
The suction cups 114 on the side of the transportation jig 101 adjacent 
the balustrade assembly 16 are subsequently brought into contact with the 
balustrade panels 34. The suction cups 114 are then attached to the 
balustrade panels 34 by evacuating the air within the suction cups 114. 
The balustrade assembly 16 is subsequently released from the assembly jig 
66 and may be moved to the frame for attachment. 
Referring to FIG. 5B, the suction cups 114 on the opposite side of the 
transportation jig 101 permit the jig 101 to be attached to the inside 
surface of either hand balustrades by lifting the jig 101 over the 
assembly jig 66, rather than having to rotate the transportation jig 101. 
A person of ordinary skill in the art will recognize that the process of 
moving the assembled balustrades 16 may be automated in varying degrees. 
For example, the process could involve manual positioning of the 
transportation jig 101 relative to the assembled balustrade 16, and 
subsequently attaching the jig 101 to the assembly. On the other hand, 
given certain characteristics of the balustrade assembly 16 to be moved, 
the position of the transportation jig 101 relative to the balustrade 16 
necessary to compensate for the center of gravity of the balustrade 16 
could be calculated. Fine tuning of the vertical and horizontal balustrade 
position could then be automatically adjusted via the vertical 119 and 
horizontal drives 117, given feedback from the vertical 118 and horizontal 
116 gauges. In either case, the final position of the balustrade 16 being 
transported would be proper relative to the panel holder brackets 44 
attached to the frame 12 traveling down the assembly line from the 
alignment jig 94. 
The assembled balustrade 16 is attached to the panel holder brackets 44 
which are already fixed to the frame of the escalator 10. Since these 
brackets 44 have been positioned relative to the roller tracks 28 in the 
alignment jig 94, there is no need to adjust the position of the assembled 
balustrade 16. More panel holder brackets 44 are attached along the frame 
12 as necessary. 
Although the invention has been shown and described with respect to a best 
mode embodiment thereof, it should be understood by those of ordinary 
skill in the art that the foregoing and various other changes, omissions 
and additions in the form and detail thereof may be make herein without 
departing from the spirit and scope hereof.