Method for expanding a rise of an elevator hoistway

Disclosed is a method of expanding an elevator system in a hoistway, involving: connecting an elevator car at a first level to an overhead winch that is connected to a hoist-beam at a second level, the elevator car being supported by a rail system, the rail system defining, at a first level, first and second rails with first and second rail terminal ends; connecting a machine system mounted to the first rail terminal end to a machine hoist mounted at the second level; removing a dead-end hitch from the second rail terminal end; hoisting the machine system to the second level; extending the rail system to the second level to define third and fourth rail terminal ends; hoisting the elevator car and the dead-end hitch to the second level; and installing the machine system and the dead-end hitch at the second level, to the third and fourth rail terminal ends.

BACKGROUND

The embodiments relate to an or elevator system and more specifically to a method for expanding a rise of an elevator hoistway.

Modular building construction design restricts the use of a traditional outside material hoist. This drives the need for a temporary use elevator in the permanent hoistway of the building. As floors are added, the elevator should be relatively quickly able to service the new landings without disrupting the construction of the modular building.

BRIEF SUMMARY

Disclosed is a method of expanding an elevator system in a hoistway, including: connecting an elevator car at a first hoistway level to an overhead winch that is connected to a hoist-beam at a second hoistway level, wherein the elevator car is supported by a rail system disposed in the hoistway, wherein the rail system defines, at the first hoistway level, first and second rails that respectively define first and second rail terminal ends; connecting a machine system mounted to the first rail terminal end to a machine hoist mounted at the second hoistway level; removing a dead-end hitch from the second rail terminal end; hoisting the machine system, via the machine hoist, to the second hoistway level; extending the rail system to the second hoistway level to define third and fourth rail terminal ends; hoisting the elevator car and the dead-end hitch, via the overhead winch, to the second hoistway level; and installing the machine system and the dead-end hitch at the second hoistway level, to respective ones of the third and fourth rail terminal ends.

In addition to one or more of the above disclosed aspects, or as an alternate, prior to connecting the elevator car to the overhead winch, the method includes: raising an overhead deck and the hoist-beam from the first hoistway level to the second hoistway level, to thereby increase a rise of the hoistway.

In addition to one or more of the above disclosed aspects, or as an alternate, prior to hoisting the elevator car, the method includes: disconnecting a suspension implement between the machine system and the elevator car; disconnecting a hoistway mounted brake implement from the elevator car; and extending the hoistway mounted brake implement to define an extended hoistway mounted brake implement, and connecting the extended hoistway mounted brake implement to the elevator car; and after hoisting the elevator car, the method includes: extending the suspension implement to define extended suspension implement, and connecting the extended suspension implement between the machine system and the elevator car.

In addition to one or more of the above disclosed aspects, or as an alternate, between raising the overhead deck and connecting the machine system to the machine hoist, the method includes: mounting the machine hoist at the second hoistway level; and after installing the dead-end hitch at the second hoistway level, the method includes: removing the machine hoist.

In addition to one or more of the above disclosed aspects, or as an alternate, between raising the overhead deck and connecting the elevator car to the overhead winch, the method includes: connecting the overhead winch to the hoist-beam; and after installing the dead-end hitch at the second hoistway level, the method includes: removing the overhead winch.

In addition to one or more of the above disclosed aspects, or as an alternate, the method includes supporting the dead-end hitch against the elevator car prior to hoisting the elevator car to the second hoistway level.

In addition to one or more of the above disclosed aspects, or as an alternate, prior to hoisting the elevator car to the second hoistway level, the method includes: disconnecting system electronics from the elevator car; and after hoisting the elevator car to the second hoistway level, the method includes: reconnecting the system electronics to the elevator car.

In addition to one or more of the above disclosed aspects, or as an alternate, after removing the machine hoist and the overhead winch, the method includes: testing the elevator system; and returning the elevator system to service.

In addition to one or more of the above disclosed aspects, or as an alternate, extending the rail system to the second hoistway level includes: installing rail system extension members to the first and second rails, to define first and second extended rail members, wherein the first and second extended rail members define the third and fourth rail terminal ends at the second hoistway level.

In addition to one or more of the above disclosed aspects, or as an alternate, the hoistway mounted brake implement includes governor and a governor cable.

In addition to one or more of the above disclosed aspects, or as an alternate, extending the hoistway mounted brake implement includes: (i) relocating the governor to the second hoistway level; (ii) extending the governor cable to define an extended governor cable; and (iii) connecting the extended governor cable to the governor.

In addition to one or more of the above disclosed aspects, or as an alternate, the rail system includes guide rails.

In addition to one or more of the above disclosed aspects, or as an alternate, the machine system includes a traction machine and its bedplate.

In addition to one or more of the above disclosed aspects, or as an alternate, the suspension implement includes a coated steel belt.

In addition to one or more of the above disclosed aspects, or as an alternate, the system electronics include an electronic elevator controller.

DETAILED DESCRIPTION

FIG. 1is a perspective view of an elevator system101including an elevator car103, a counterweight105, a tension member107, a guide rail (or rail system)109, a machine (or machine system)111, a position reference system113, and an electronic elevator controller (controller)115. The elevator car103and counterweight105are connected to each other by the tension member107. The tension member107may include or be configured as, for example, ropes, steel cables, and/or coated-steel belts. The counterweight105is configured to balance a load of the elevator car103and is configured to facilitate movement of the elevator car103concurrently and in an opposite direction with respect to the counterweight105within an elevator shaft (or hoistway)117and along the guide rail109.

The tension member107engages the machine111, which is part of an overhead structure of the elevator system101. The machine111is configured to control movement between the elevator car103and the counterweight105. The position reference system113may be mounted on a fixed part at the top of the elevator shaft117, such as on a support or guide rail, and may be configured to provide position signals related to a position of the elevator car103within the elevator shaft117. In other embodiments, the position reference system113may be directly mounted to a moving component of the machine111, or may be located in other positions and/or configurations as known in the art. The position reference system113can be any device or mechanism for monitoring a position of an elevator car and/or counterweight, as known in the art. For example, without limitation, the position reference system113can be an encoder, sensor, or other system and can include velocity sensing, absolute position sensing, etc., as will be appreciated by those of skill in the art.

The controller115is located, as shown, in a controller room121of the elevator shaft117and is configured to control the operation of the elevator system101, and particularly the elevator car103. For example, the controller115may provide drive signals to the machine111to control the acceleration, deceleration, leveling, stopping, etc. of the elevator car103. The controller115may also be configured to receive position signals from the position reference system113or any other desired position reference device. When moving up or down within the elevator shaft117along guide rail109, the elevator car103may stop at one or more landings125as controlled by the controller115. Although shown in a controller room121, those of skill in the art will appreciate that the controller115can be located and/or configured in other locations or positions within the elevator system101. In one embodiment, the controller may be located remotely or in the cloud.

The machine111may include a motor or similar driving mechanism. In accordance with embodiments of the disclosure, the machine111is configured to include an electrically driven motor. The power supply for the motor may be any power source, including a power grid, which, in combination with other components, is supplied to the motor. The machine111may include a traction sheave that imparts force to tension member107to move the elevator car103within elevator shaft117.

Although shown and described with a roping system including tension member107, elevator systems that employ other methods and mechanisms of moving an elevator car within an elevator shaft may employ embodiments of the present disclosure. For example, embodiments may be employed in ropeless elevator systems using a linear motor to impart motion to an elevator car. Embodiments may also be employed in ropeless elevator systems using a hydraulic lift to impart motion to an elevator car. Embodiments may also be employed in ropeless elevator systems using self-propelled elevator cars (e.g., elevator cars equipped with friction wheels, pinch wheels, or traction wheels).FIG. 1is merely a non-limiting example presented for illustrative and explanatory purposes.

As indicated, modular building construction design restricts the use of a traditional outside material hoist, which drives the need for a temporary use elevator in the permanent hoistway of the building. As floors are added, the elevator should be relatively quickly able to service the new landings without disrupting the construction of the modular building.

In view of the above concerns, the disclosed embodiments provide an installation method for expanding a rise of an elevator system101in a hoistway117, which may be referred to as a jump process. Turning toFIG. 2, the figure shows a building200prior to expanding the rise of the elevator system101in the hoistway117. A first building level195of the building200includes a first level entryway125afor accessing the elevator car103at a first hoistway level (or first level)210of a hoistway117. Within the first hoistway level210, an elevator car103is supported by a rail system109that includes first and second rails220,230, which may be guide rails. The first and second rails220,230respectively define first and second rail terminal ends234,236. A machine system111, including a traction machine240and its bedplate250, and a dead-end hitch (DEH)260, are respectively atop the first and second rail terminal ends234,235. A suspension implement270, which includes a coated steel belt (CSB)280connected to a counterweight105, supports the elevator car103. A hoistway mounted brake implement290, which may include a governor300having a governor cable310, are also mounted within the hoistway117. In addition, system electronics with related wiring (collectively the system electronics320), which may include the controller115, may also be mounted within the hoistway117. An overhead deck330, that includes a hoist-beam340, is mounted to first level mounts350at the first hoistway level210.

A second building level350, which may be a modular level, is installed above first building level195. The second building level350may include, preinstalled, a second level entryway125bfor accessing the elevator car103at a second hoistway level (or second level)360of the hoistway117. The second hoistway level360may be defined by hoistway panels370that are preinstalled or installed on site. The hoistway panels370may include second level mounts380.

A belt spool390containing an extension belt segment400of the coated steel belt280, required for extending the coated steel belt280, may be stored in the hoistway pit (or pit)410. A cable spool420containing an extension cable segment430, required for extending the governor cable310, may also be stored in the pit410.

Tuning toFIG. 3, the overhead deck330and hoist-beam340are raised from the first hoistway level210to the second hoistway level360. Turning toFIG. 4, the overhead deck330and hoist-beam340are secured to the second hoistway level360via the second level mounts380. Turning toFIG. 4, the overhead deck330and hoist-beam340are installed at the second hoistway level360via the second level mounts380. This increases the rise of the hoistway117.

Turning toFIG. 5, the elevator car103, if it is not already at the top of the first hoistway level210, is moved to the top of the first hoistway level210. An overhead winch440is installed via the hoist-beam340. The overhead winch440is connected to the elevator car103. This allows the elevator car103to travel to the second hoistway level360, i.e., the new rise.

Turning toFIG. 6, a machine hoist450, which is removable, is mounted to the hoist-beam340. The machine hoist450is also mounted to the machine system111. This enables lifting the machine system111to the second hoistway level360. Turning toFIG. 7, the dead-end hitch260is dismounted from the first hoistway level210and prepared for being moved to the second hoistway level360by being attached to the elevator car103. In addition, the system electronics320are disconnected. As shown inFIG. 8, the hoistway mounted brake implement290(FIG. 2) is extended to define an extended hoistway mounted brake implement295. In one embodiment, the suspension implement270is extended with a utilization of the extension cable segment430located in the pit410(FIG. 2). In addition, the machine system111is hoisted via the machine hoist450to the second hoistway level360.

As shown inFIG. 9, first and second rail extension members460,470are respectively installed over the first and second rail terminal ends234,236of the first and second rails220,230along with support brackets480, to define first and second extended rails490,500. The first and second extended rails490,500respectively include third and fourth rail terminal end510,520. As shown inFIG. 10, the elevator car103is hoisted via the overhead winch440to the second hoistway level360. In addition, the suspension implement270(FIG. 2) is extended to define an extended suspension implement275. In one embodiment, the suspension implement270is extended with a utilization of the extension belt segment400located in the pit410(FIG. 2). This implement is then reconnected.

As shown inFIG. 11, the machine system111and the dead-end hitch260are respectively set atop of the third and fourth rail terminal ends510,520.

As shown inFIG. 12, the machine hoist450is removed from the machine system111. As shown inFIG. 13, the overhead winch440is removed from the elevator car103and the hoist-beam340. The system electronics320are reconnected to the elevator car103. The elevator system101is tested and the elevator car103is returned to service.

FIGS. 14-16show a flowchart of a method of expanding of the elevator system101showing additional features of the disclosed embodiments. As shown in block510, the method includes raising the overhead deck330and the hoist-beam340from the first hoistway level210to the second hoistway level360defined by the hoistway117. This increases the rise of the hoistway.

As shown in block520, the method includes connecting the overhead winch440between the hoist-beam340and the elevator car103of the elevator system101. As indicated, the elevator car103is supported by the rail system109disposed in the hoistway117, where the rail system109defines the first and second rails220,230, respectively having the first and second rail terminal ends234,236. In one embodiment, the rails are guide rails.

As shown in block530, the method includes connecting the machine hoist450between the hoist-beam340and the machine system111mounted to the first rail terminal end234. As indicated, in one embodiment, the machine system includes a traction machine240and its bedplate250.

As shown in block540, the method includes disconnecting a suspension implement270between the machine system111and the elevator car103. In one embodiment, the suspension implement270includes a coated steel belt280. As shown in block550, the method includes disconnecting the hoistway mounted brake implement290from the elevator car103. In one embodiment, the hoistway mounted brake implement290include the governor300and the governor cable310. As shown in block560, the method includes disconnecting the system electronics320, which may be hoistway mounted, from the elevator car103. In one embodiment, the system electronics320include the controller115(FIG. 1).

As shown in block570, the method includes removing the dead-end hitch260from the second rail terminal end236. As shown in block580, the method includes supporting the dead-end hitch260against the elevator car103.

As shown in block590, the method includes extending the hoistway mounted brake implement290to define an extended hoistway mounted brake implement295and connecting the extended hoistway mounted brake implement295to the elevator car103. In one embodiment, this includes: (i) relocating the governor to the second hoistway level; (ii) extending the governor cable to define an extended governor cable; and (iii) connecting the extended governor cable to the governor. In one embodiment, the suspension implement270is extended with a utilization of the extension cable segment430located in the pit410.

As shown in block600, the method includes hoisting the machine system111to the second hoistway level360.

As shown in block610, the method includes extending the rail system109to the second hoistway level360. In one embodiment, this includes installing rail system extension members460,470to the first and second rails220,230. This extends the rail system109to third and fourth rail terminal ends510,520of respective ones of first and second extended rails490,500.

As shown in block620, the method includes hoisting the elevator car103, via the overhead winch440, to the second hoistway level360. As shown in block630, the method includes installing the machine system111and dead-end hitch260to respective ones of the third and fourth rail terminal ends510,520of the first and second extended rails490,500.

As shown in block640, the method includes extending the suspension implement270to define an extended suspension implement275, and connecting the extended suspension implement270between the machine system111and the elevator car103. In one embodiment, the suspension implement270is extended with a utilization of the extension belt segment400located in the pit410.

As shown in block650, the method includes removing the machine hoist450. As shown in block660, the method includes removing the overhead winch440. As shown in block670, the method includes reconnecting the system electronics320to the elevator car103. As shown in block680, the method includes testing the elevator system101. As shown in block690, the method includes returning the elevator system101to service.

Turning toFIG. 17, another embodiment of the method of expanding an elevator system101in a hoistway117is shown. This embodiment includes a subset of the steps inFIGS. 14-16, with all other identified steps in those figures being optional. For example, as shown in block700(corresponding to block520, above), the method includes connecting the elevator car103at the first hoistway level210to the overhead winch440that is connected to the hoist-beam340at the second hoistway level360. As indicated, the elevator car103is supported by the rail system109disposed in the hoistway117, and the rail system109defines, at the first hoistway level210, first and second rails220,230that respectively define first and second rail terminal ends234,236.

As shown in block710(corresponding to block530, above), the method further includes connecting the machine system111mounted to the first rail terminal end234to the machine hoist450mounted at the second hoistway level360. As shown in block720(corresponding to block570, above), the method further includes removing the dead-end hitch260from the second rail terminal end236. As shown in block730(corresponding to block600, above), the method further includes hoisting the machine system111, via the machine hoist450, to the second hoistway level360. As shown in block740(corresponding to block610, above), the method further includes extending the rail system109to the second hoistway level360to define the third and fourth rail terminal ends234,236. As shown in block750(corresponding to block620, above), the method further includes hoisting the elevator car103and the dead-end hitch260, via the overhead winch440, to the second hoistway level360. As shown in block760(corresponding to block630, above), the method includes installing the machine system111and the dead-end hitch260at the second hoistway level360, to respective ones of the third and fourth rail terminal ends234,236.

The above disclosed embodiments provide an installation method for expanding a rise of an elevator in a hoistway. The embodiments utilize temporary guide rails, hoisting of the machine, bedplate and the dead-end hitch, the installation of more guide rails, and lengthening of the associated wiring. Hoistway Material are relocated to the new location, as indicated.

In some embodiments, temporary wiring may be used during the method. In some embodiments, elevator landing entrances may be preinstalled in the modular floor, e.g., prior to delivery of the modular floor to a construction site. In some embodiments, rail brackets may also be preinstalled in hoistway panels that form the hoistway, e.g., prior to delivery of the hoistway panels to a construction site. In some embodiments, rather than extending the steel belts, the steel belts are entirely replaced with longer steel belts. This would remove the need for belt monitoring instrumentation.