Elevator car frame assembly

An elevator car of an elevator system includes a car body and a car frame supportive of the car body. The car frame includes two opposing side frames, each side frame formed from a plurality of side frame segments, including two upright members and one or more upright braces connecting the two upright members, adjacent side frame segments secured to each other via a joint. A method of installation of an elevator car of an elevator system includes positioning a first side frame segment of a plurality of side frame segments adjacent to second side frame segment of the plurality of side frame segments, and securing the first side frame segment to the second side frame segment via a splice joint thereby constructing a car frame of the elevator car. One or more car bodies are installed into the car frame.

BACKGROUND

Exemplary embodiments pertain to the art of elevator systems, and more particularly to configurations of car frames for elevator cars of elevator systems.

Elevator systems are useful for carrying passengers, cargo, or both, between various levels in a building. This typical occurs via an elevator car moved along a hoistway by an elevator drive system. In high-rise elevator systems, such as those configured to convey passengers along hoistways of, for example, 100 meters or more in height, it may be advantageous to utilize multi-deck elevator cars to increase the volume of passengers that may be conveyed along the hoistway at any given time. A multi-deck elevator car includes two or more car bodies, or passenger compartments, arranged vertically, one atop another. Installation of such elevator cars into the hoistway, however, is often cumbersome and costly, with in many cases the hoistway constructed around the elevator car after placement of the multi-deck elevator car.

BRIEF DESCRIPTION

In one embodiment, an elevator car of an elevator system includes a car body and a car frame supportive of the car body. The car frame includes two opposing side frames, each side frame formed from a plurality of side frame segments, including two upright members and one or more upright braces connecting the two upright members, adjacent side frame segments secured to each other via a joint.

Additionally or alternatively, in this or other embodiments the joint is a splice joint and one or more tubular support members are located in a hollow cross-section of an upright member of the two upright members. The one or more tubular support members are configured to receive a fastener of the splice joint and prevent damage to the upright member due to securing of the splice joint.

Additionally or alternatively, in this or other embodiments the splice joint is configured to prevent shear loading of the fastener.

Additionally or alternatively, in this or other embodiments a first upright member of the two upright members has a first wall thickness and a second upright member of the two upright members has a second wall thickness different from the first wall thickness.

Additionally or alternatively, in this or other embodiments the splice joint further includes a splice plate extending from an uptight member of a first side frame segment to an upright member of a second frame segment, the fastener extending through the splice plate.

Additionally or alternatively, in this or other embodiments the tubular support member is secured in the upright member via welding.

Additionally or alternatively, in this or other embodiments an alignment feature is located at a side frame segment to align the guide frame segment with an adjacent side frame segment and a guide rail of the elevator system.

Additionally or alternatively, in this or other embodiments the alignment feature includes two alignment brackets defining a bracket gap therebetween, the bracket gap receptive of a rail blade of the guide rail.

Additionally or alternatively, in this or other embodiments the alignment feature includes one or more adjustment elements to adjust a position of the side frame segment relative to the guide rail.

Additionally or alternatively, in this or other embodiments the alignment feature is secured to the upright brace.

In another embodiment, an elevator system includes a hoistway, a guide rail secured in the hoistway, and an elevator car. The elevator car includes a car body, and a car frame supportive of the car body. The car frame includes two opposing side frames, each side frame formed from a plurality of side frame segments, including two upright members and one or more upright braces connecting the two upright members, adjacent side frame segments secured to each other via a splice joint.

Additionally or alternatively, in this or other embodiments one or more tubular support members are located in a hollow cross-section of an upright member of the two upright members. The one or more tubular support members are configured to receive a fastener of the splice joint and prevent damage to the upright member due to securing of the splice joint.

Additionally or alternatively, in this or other embodiments the splice joint further includes a splice plate extending from an uptight member of a first side frame segment to an upright member of a second frame segment, the fastener extending through the splice plate.

Additionally or alternatively, in this or other embodiments an alignment feature is located at a side frame segment to align the guide frame segment with an adjacent side frame segment and the guide rail.

Additionally or alternatively, in this or other embodiments the alignment feature includes two alignment brackets defining a bracket gap therebetween, the bracket gap receptive of a rail blade of the guide rail.

Additionally or alternatively, in this or other embodiments the alignment feature includes one or more adjustment elements to adjust a position of the side frame segment relative to the guide rail.

In yet another embodiment, a method of installation of an elevator car of an elevator system includes positioning a first side frame segment of a plurality of side frame segments adjacent to second side frame segment of the plurality of side frame segments, and securing the first side frame segment to the second side frame segment via a splice joint thereby constructing a car frame of the elevator car. One or more car bodies are installed into the car frame.

Additionally or alternatively, in this or other embodiments the first side frame segment is aligned to a guide rail of the elevator system and to the second side frame segment via an alignment feature of the first side frame segment.

Additionally or alternatively, in this or other embodiments aligning the first frame segment to the guide rail further includes receiving a rail blade of the guide rail in a bracket gap of the alignment feature.

Additionally or alternatively, in this or other embodiments a position of the first side frame segment relative to the guide rail is adjusted via one or more adjustment elements of the alignment feature.

DETAILED DESCRIPTION

Shown inFIG. 1is a schematic view of an exemplary traction elevator system10. The elevator system10includes an elevator car14operatively suspended or supported in a hoistway12with one or more load bearing members, such as a rope or a belt16. The belt16interacts with sheaves18and52to be routed around various components of the elevator system10. Sheave18is configured as a diverter, deflector or idler sheave and sheave52is configured as a traction sheave, driven by a machine50. Movement of the traction sheave52by the machine50drives, moves and/or propels (through traction) the belt16that is routed around the traction sheave52. Diverter, deflector or idler sheaves18are not driven by a machine50, but help guide the belt16around the various components of the elevator system10. The belt16could also be connected to a counterweight22, which is used to help balance the elevator system10and reduce the difference in belt tension on both sides of the traction sheave52during operation. The sheaves18and52each have a diameter, which may be the same or different from each other.

In some embodiments, the elevator system10could use two or more belts16for suspending and/or driving the elevator car14In addition, the elevator system10could have various configurations such that either both sides of the one or more belts16engage the sheaves18,52or only one side of the one or more belts16engages the sheaves18,52. The embodiment ofFIG. 1shows a1:1roping arrangement in which the one or more belts16terminate at the elevator car14and counterweight22, while other embodiments may utilize other roping arrangements.

Referring toFIG. 2, the elevator car14travels in the hoistway12along a path of one or more guide rails24arranged in the hoistway12. In the embodiment ofFIG. 2, two guide rails24located at opposing sides of the elevator car14are utilized, but it is to be appreciated that in other embodiments other numbers of guide rails24may be utilized, such as one or four guide rails24. The elevator car14includes a car body26affixed to a car frame28. In some embodiments, such as illustrated inFIG. 2, the elevator car14is a double deck configuration, with two car bodies26affixed to a common car frame28. While the embodiments disclosed herein include two car bodies26affixed to the car frame28, it is to be appreciated that the present disclosure may be utilized with other elevator car14configurations, such as those with one car body26or three or more car bodies26affixed to a common car frame28.

Car guides30mounted at the elevator car14interact with the guide rails24, thereby guiding the elevator car14along the path of the guide rails24. In some embodiments, such as shown inFIG. 2, the elevator car14includes four car guides30, with two car guides30located to be interactive with each of the guide rails24.

Referring now toFIG. 3, the car frame28is illustrated in more detail. The car frame28includes a side frame36at each lateral side of the car frame28, with a upper cross member38and a lower cross member40extending between the side frames36and defining an upper extent and a lower extent, respectively, of the car frame28. Intermediate cross members42support the car bodies26in the car frame28. The side frame36includes upright members44and upright braces46connecting the upright members44to provide support to the upright members44. In some embodiments, the upright members44are tubular, having, for example, a rectangular cross-section. In some embodiments, such as shown inFIG. 3, the upright braces46are X-shaped, and may be formed by, for example, laser cutting or other fabrication process. The upright braces46are, for example, welded to the upright members44to form the side frames36.

As stated above, installation of a typical multi-deck elevator car into a hoistway may be difficult and costly. As such, the side frames36are segmented, comprising a plurality of frame segments48and the segments coupled as shown inFIG. 4. While five frame segments48are shown inFIG. 4to form each side frame36, it is to be appreciated that other quantities of frame segments48, for example, three, four or six or more frame segments48, may be utilized. A first upright member44aof a first frame segment48ais connected to a second upright member44bof a second frame segment48bvia a splice joint54, shown best inFIG. 5. The splice joint54utilizes two splice plates56located at opposing sides of the upright members44. The splice plates56span a first member end58aof the first upright member44aand a second member end58bof the second upright member44b, defining the joint. Bolts60are other retaining members extend through the upright members44and the splice plates56to secure the splice joint54.

Referring toFIG. 6, a cross-sectional view of the splice joint54is illustrated. As stated above, the upright member44is a hollow, tubular element. In this embodiment, the upright member44has a member wall62defining a rectangular interior64of the upright member44. A tubing sleeve66is installed in the interior64at each bolt60location. In some embodiments, the tubing sleeve66is secured in the interior by, for example, welding the tubing sleeve66to the member wall62. At installation, the bolts60are inserted through plate openings68in the splice plates56, member openings70in the upright members44, and through the tubing sleeve66, and tightened to secure the splice joint54. Use of the tubing sleeve66strengthens the upright member44, to prevent buckling or collapse of the upright member44, thus allowing thinner upright members44to be utilized, saving weight in the elevator system10. Use of the tubing sleeve66also reduces direct shear loading of the bolts60, thus strengthening the joint and effectively increasing the shear strength and fatigue resistance of the bolts. Further, this structure allows for easier segmented assembly of the car frame28in the hoistway12.

In some embodiments, the upright members44have a wall thickness in the range of about ⅛″ to ⅜″. Further, referring again toFIG. 5, in some embodiments the first upright member44aand the second upright member44bhas equal wall thicknesses. In other embodiments, however, the first upright member44ahas a first wall thickness and the second upright member44bhas a second wall thickness different from the first wall thickness. The second wall thickness may be either greater than or less than the first wall thickness.

To facilitate such assembly of the car frame28in the hoistway, the frame segments48include alignment features72, such as shown inFIG. 7. The alignment features72utilize the previously installed guide rail24as a datum reference, and then are adjusted to align the frame segment48with previously installed frame segments48, and more particularly to align the upright members44with upright members44of previously installed frame segments48for assembly of the splice joint54. This ensures that the frame segment48is aligned to both the guide rail24and the other frame segments48of the car frame28.

In one embodiment, as shown inFIG. 7, the alignment feature72includes two alignment brackets74installed at an upright brace46of the frame segment48. To ensure proper alignment, two or more such alignment features72may be utilized per frame segment48. The two alignment brackets74are arranged with a bracket gap76therebetween, to accommodate placement of a rail bade78of the guide rail24in the bracket gap76. Further, each alignment bracket74has a jack screw80installed through a threaded opening82in the alignment bracket74. The jack screw80is tightened into contact with the guide rail24, and may be tightened further to move the upright members44into alignment with upright members44of a previously installed frame segment48. Once the upright members44are aligned, the splice joint54is assembled and secured as shown inFIGS. 5 and 6.

Such an assembly process continues until all of the frame segments48are installed, completing the car frame28. The car bodies26are assembled and installed, in some embodiments, in situ in the hoistway12, thus completing assembly of the elevator car14.

The present disclosure allows for segmented assembly of multi-deck elevator car14of the elevator system10to be efficiently completed in the hoistway12. The use of the splice joint54and the tubular sleeves66enables the use of relatively thin-walled components, such as upright members44, to save considerable weight of the elevator system10. Further, the features disclosed herein ensure alignment of the assembled elevator car14to the guide rail24of the elevator system, and also facilitates alignment of frame segments48with one another during installation and assembly. Also, the present disclosure allows for assembly of upright members44having different wall thicknesses via the splice joint54.