Abstract:
An emergency power supply for a traction elevator system utilizes a microprocessor-based control arrangement with pulse-width modulator technology to create an efficient, cost-effective back-up power system for a traction elevator. The microprocessor-based control arrangement is used to sense a power loss, or any type of irregularity in the power supply. Upon sensing some type of power malfunction, the microprocessor-based control arrangement disconnects the elevator system from the main power source and then generates a control signal to initiate the supply of back-up power. Once the elevator electrical system has been recharged and stabilized, the elevator control system will sense that recovery has occurred and will then provide an appropriate speed and direction command to the traction motor drive system.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 14/153,158, filed Jan. 13, 2014, which claims the benefit of U.S. Provisional Application Ser. No. 61/757,943, filed Jan. 29, 2013 and herein incorporated by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to power system controls for traction elevators and, more particularly, to a microprocessor-controlled emergency back-up power system for traction elevators. 
       BACKGROUND OF THE INVENTION 
       [0003]    With the globalization of the elevator industry there has been a trend to standardize elevator systems worldwide. This trend is leaning toward the use of traction systems for smaller elevator applications (i.e., less floors). Previously, hydraulic elevator systems were commonly used in applications with less than seven landings. The trend anticipates that these applications will begin to utilize traction elevator systems. Such systems must be provided with emergency or back-up power systems that supply power not only to the controller, door operator, and valves, but also to the main drive system. 
         [0004]    Recent developments have lead to traction elevator systems replacing older technology (i.e., “soft start” systems) with new Variable Voltage/Variable Frequency Drive (VVVFD) technologies. VVVFD technology has two advantages: first, VVVFD technology allows a traction motor to be connected to the main power system with a low level of inrush current; and second, VVVFD technology allows a traction motor to run at both a very low speed and a very low power. Thus, while a typical traction motor might be a 20 hp three-phase load when running at a normal speed, a VVVFD-based motor may only be a 2 hp load at its slowest speed. The reason for this low load is that a traction elevator system comprises a counter-weighted configuration. That is, the elevator&#39;s typical loading of passengers (i.e., the passenger weight) is exactly matched by the counter weight. This allows for optimal efficiency of the system. However, under most elevator conditions, an exact matching of the counter weight and the passenger load does not occur. Thus, a traction elevator will tend to drift up or down depending on this imbalance. 
         [0005]    By continually monitoring the elevator load, it is possible to keep track of which direction the car would drift. When a power outage occurs, this information is available for use by the emergency back-up power system. Also, to handle the capacitive nature of the VVVFD and its input filtering, a three phase inductor system is placed between an inverter output stage and the VVVFD, so as to compensate for the reactance of the input filter. 
         [0006]    Furthermore, unlike the hydraulic elevator systems, a traction elevator system requires that the back-up power system provide full power to the traction motor (e.g., &gt;20 hp load at full motor speed), even when normal building power is present and properly functioning. This requires that the back-up power system be capable of switching a high power load. This requirement to handle high levels of normal power results in a system where the back-up power is fed in parallel to the normal control power system. As a result, it is critical to control the sequencing of the various power systems so as to assure that both the back-up power and the normal control power sources are not simultaneously connected to the traction elevator system. 
       SUMMARY OF THE INVENTION 
       [0007]    The needs remaining in the prior art are addressed by the present invention, which relates to power system controls for traction elevators and, more particularly, to an emergency back-up power system for traction elevators. 
         [0008]    In accordance with the present invention, an emergency power supply for a traction elevator system has been configured that utilizes a microprocessor-based control arrangement with pulse-width modulator technology to create an efficient, cost-effective back-up power system for a traction elevator. The microprocessor-based control arrangement is configured to sense a power loss, or any type of irregularity in the power supply (i.e., the incoming three-phase power from a utility company). Upon sensing some type of power malfunction, microprocessor-based control arrangement disconnects the elevator system from the main power source, and then generates a control signal to initiate the supply of back-up power. The control arrangement also provides an indicator signal, allowing the elevator controller to know that the elevator system is now using “emergency” power, as well as a low-voltage parallel power feed to the elevator system (i.e., in parallel with the emergency power). Once the elevator electrical system has been recharged and stabilized, the elevator controller will sense that recovery has occurred and will then provide an appropriate speed and direction command to the traction motor drive system. 
         [0009]    One particular aspect of the present invention is the ability to provide a pure three-phase sine wave output for elevator control. By virtue of using microprocessor-based control of the pulse width modulation of the output waveform, it is possible to create and maintain the preferred three-phase sine wave output. By controlling the output pulse width modulation, an accurate sine wave can be generated, while at the same time minimizing the voltage on the high-voltage DC bus. 
         [0010]    An exemplary embodiment of the present invention takes the form of a back-up power system for a traction elevator comprising a microprocessor-based control arrangement configured to recognize a loss of an input power supply, as well as irregularities in the power supply (including phase irregularities), where the microprocessor-based control arrangement includes a control module for generating a control signal to remove the input power supply from the traction elevator and a pulse-width modulated indicator signal. 
         [0011]    The back-up power system includes an inverter timing system operatively connected to the microprocessor-based control arrangement, wherein the inverter timing system receives the indicator signal from the microprocessor-based control arrangement. A back-up power generating means is included that communicates with the inverter timing system, wherein the back-up power generating means generates an output to provide back-up power. The inverter timing system includes a job cycle lockout timer, which limits an amount of time that the back-up power generating means supplies output power and ensures operation of a full elevator cycle prior to returning to normal control power. A main power lockout timer is also included, which prevents simultaneous operation of the back-up power system and normal control power. 
         [0012]    Other and further aspects and features of the present invention will become apparent during the course of the following discussion and by reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    Referring now to the drawings, where like numerals represent like parts in several views, 
           [0014]      FIG. 1  is block diagram of an overall power system for a traction elevator; 
           [0015]      FIG. 2  is a detailed circuit diagram of various aspects of a back-up power system formed in accordance with the present invention; 
           [0016]      FIG. 3  is a circuit diagram of the main power control of the present invention; 
           [0017]      FIG. 4  is a circuit diagram of the battery power system of the present invention; 
           [0018]      FIG. 5  is a circuit diagram of the dc/dc inverter converter of the present invention; and 
           [0019]      FIG. 6  is a circuit diagram of the three-phase generator of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]      FIG. 1  is block diagram of an overall power system for a traction elevator and  FIG. 2  is a more detailed circuit diagram of the relevant aspects of a back-up power system  10 . The back-up power system  10  consists of three major areas: 1) normal power control; 2) microprocessor-based control arrangement for power sensing and inverter timing systems; and 3) a backup power generation system. 
         [0021]    Referring to  FIGS. 2 and 3 , normal power control is done via the main contactor  20  and supporting systems. The normal power input source is connected on the line side  22  of the main contactor  20 . The elevator system load (i.e., the traction motor itself) is connected on the load side  24  of the main contactor  20 . Under normal power conditions, the power on the line side of the main contactor  20  is connected through a normally-closed contact  26  (and perhaps an optional step-down transformer  28 ) to the line side output of contactor  20 . Normally-closed contact  26  is shown as one element of a job cycle lock-out timer  42 . The operation of job cycle lockout timer  42  will be described in more detail below. Transformer  28  allows for a common contactor design approach for a wide range of system voltages. This design may use normal input power to power coil  29  within contactor  20 . This approach reduces the power requirement on the inverter battery system and allows for normal system operation when the system is turned off. 
         [0022]    Still referring to  FIGS. 2 and 3 , the three-phase input power is monitored within power loss sensing arrangement  30 . Various configurations may be used for a microprocessor-based version of arrangement  30 , including a memory  31  component that stores various power levels suitable for acceptable operation in different implementations. Threshold circuitry  32  may be included in the microprocessor-based power loss sensing arrangement to determine when the input power level has dropped below a predetermined value. Other components may be used to sense any type of power irregularity. Upon sensing a power loss or irregularity, a control module  33  within the microprocessor-based power loss sensing arrangement generates a control signal to “open” contactor  20  and remove the main power supply from the elevator control system. As shown in  FIG. 2 , control module  33  performs this function by sending a control signal to (normally-closed) contact  26 , activating contact  26  to move into its “open” position. Opening contact  26  thus disconnects the elevator system from the main power system. Additionally, control module  33  of the microprocessor-based power loss sensing arrangement will transmit an indicator signal to inverter timing system  40 , indicating that the elevator system requires emergency power. 
         [0023]    Referring now to  FIGS. 1-3 , the inverter timing system  40  consists of job cycle lock-out timer  42  (mentioned above) and a main power lockout timer  44 . Typically, emergency power units permit the elevator system to operate until either normal control power is restored or a low battery voltage condition is present. These conditions are not desirable for high power applications. The job cycle lock-out timer  42 , therefore, sets a maximum amount of time that back-up power is permitted to supply power to the elevator system. This approach also optimizes the back-up power battery system design. In addition, the job cycle lock-out timer  42  assures that a full cycle has been completed before the elevator system is returned to normal control power. This allows for the operation of a full elevator cycle thereby allowing any person on the elevator to be transported to a rescue destination (e.g., the nearest floor in the overhauling direction) prior to the elevator system switching back to normal control power. Prior systems would transfer power back and forth between normal control power and emergency power, if periodic brown-outs were to occur (e.g., every 30 seconds). 
         [0024]    In accordance with the attributes of the present invention, the particular time intervals as used by inverter timing system  40  may be programmed within the microprocessor-based power loss sensing arrangement and, therefore, modified as necessary by personnel in charge of maintaining the elevator&#39;s functionality. 
         [0025]    The main power lock-out timer  44  performs two functions. First, it disconnects the load from normal control power when a power irregularity is detected. Second, it will not reconnect the elevator system to normal control power until after the inverter timing system  40  is shutdown and disconnected. Therefore, the inverter timing system  40  prevents simultaneous operation of the back-up power system and normal control power. Once again, the control and indicator signals as generated by control module  33  within the microprocessor-based power loss sensing arrangement ensure that the back-up power system has been disconnected before bringing the normal power supply back on line. 
         [0026]    Referring to  FIGS. 4-6 , the back-up power generation system consists of three areas: 1) a dc battery power system  50 ; 2) a dc/dc converter  70 ; and 3) a three phase generator  90 . 
         [0027]    Referring to  FIGS. 2, 4, and 5 , the battery power system  50  includes battery cells  52 , a maintenance safety circuit  54 , a low battery detection circuit  56 , a battery charger system  58 , a battery over-current circuit  60 , and a main power overcurrent device  62 . A 48V system is an optimal design because the system current levels are still at a level where wiring can be used instead of bus bars. Furthermore, even though a higher rated voltage system would reduce the current level of the system, such a design would require more batteries and would thus be a more expensive configuration. 
         [0028]    The maintenance safety circuit  54 , which further includes a battery disconnect switch  55 , prevents the operation of the back-up power system during maintenance operations. The disconnect switch  55  prevents inadvertent operation of the back-up power system while the elevator is locked-out for maintenance. As shown in  FIG. 4 , when the disconnect switch  55  is opened, no power is available to the control logic of the dc to dc converter, thus preventing the inverter  70  ( FIG. 5 ) from being started, or the inverter output relay from being closed. The low battery detection circuit  56 , as shown in FIG.  5 , protects the lifetime capacity of the batteries  52  by stopping the job cycle lock-out timer  42  if the voltage of the batteries  52  falls too low. The life of a battery is a function of the charge/discharge cycles it sees and how deep (i.e. level of discharge) the cycles are. By controlling the depth of the discharge cycle, the lifetime capacity of the batteries  52  can be maintained. 
         [0029]    The battery charging system  58  is provided to permit long term operation of the battery power system  50 . This battery charging system  58  is powered from the input line power source and under normal control power provides a current limiting and a voltage limiting charge to the batteries  52 . After a job cycle has occurred and normal control power is restored, the battery charging system  58  will initially operate in a current limiting mode with the charging voltage determined by the battery system. As the batteries  52  charge, the battery voltage will rise until the charger&#39;s voltage limit is reached and then the charging system  58  operates in a voltage limiting mode until the next job cycle is required. 
         [0030]    The battery over-current protection circuit  60  (i.e., overload protection circuit) provides protection to the backup batteries  52  and prevents the back-up control power system from overheating. The over-current circuit  60  consists of a high frequency current sensor that performs cycle by cycle current level sensing. If the current level exceeds the safe level for the battery power system  50 , the over-current circuit  60  will shutdown the converter  70 . However, the battery over-current circuit  60  will only operate if an inverter primary FET control circuit  72  is operational. Therefore, if either the FET  78  or the inverter primary FET control circuit  72  fail, the battery over-current protection  60  system may not function correctly. Therefore, a main battery overcurrent device  62  (shown in  FIG. 4 ) is provided to protect the battery system against a failure of FET  78 . Operation of the primary FET control circuit  72  will be subsequently described. 
         [0031]    Referring to  FIG. 5 , the configuration of the dc/dc converter  70  was selected to optimize the simplicity of the design. The converter  70  consists of a primary FET resonant mode H-bridge configuration control circuit  72  and a high ripple current compatible capacitor system  76 . The FET circuit  72  comprises field effect transistors (FET&#39;s)  78  and, perhaps, optional RC snubber circuits  80 . The FET circuit  72  is utilized to drive a main transformer  82  and utilize its leakage inductance to provide a resonant mode power source for a secondary  84  of the main transformer  82 . The secondary  84  is connected via a tuning capacitor to a high speed full bridge rectifier  86  combined with a low resistance capacitor bank  88 . Alternatively, the tuning capacitor may be placed in series with the primary winding. The pulse width of the main transformer  82  and primary FET circuit  72  are controlled via a voltage feedback control system  83  that controls the DC bus voltage. To allow safe maintenance operations on the unit, the high voltage dc bus is automatically discharged whenever normal control power is restored or when the unit is switched off. In addition, the converter  70  will pre-charge the dc bus capacitors of the capacitor bank  88  before the converter  70  is connected to the elevator system. This allows for a soft start of the converter  70  and for the feedback control system  83  to stabilize. An over-temperature circuit  89  is provided to protect the power FET&#39;s  78  from experiencing too high a temperature. To prevent this from occurring, the temperature of the heat sink is monitored. If the temperature of the heat sink exceeds its temperature limit, the job cycle lock-out timer  42  is stopped and the converter  70  is shutdown. Advantageously, various elements of the system control functionality utilized to monitor and operate the battery back-up properties are incorporated within the microprocessor-based power loss sensing arrangement, allowing the features, details, limits and the like to be evaluated and modified, as necessary. 
         [0032]    In choosing an FET  78 , several properties must be met. First, the FET  78  must have a sufficiently low R ds-on  so as to not generate a large amount of heat while conducting the large primary battery currents. Second, the FET  78  must be packaged such that heat can be efficiently dissipated. Third, the FET  78  must have a voltage rating that sufficiently exceeds the battery system voltage so as to minimize the occurrences of avalanching the protection diode. Fourth, the FET  78  must switch quickly to allow for operation of the main transformer  82  at a frequency that will reduce its size via reducing the volt-seconds applied to the main transformer  82 . Finally, the FET  78  must have a current rating compatible with the anticipated battery current levels. 
         [0033]    During operation, while the battery power system  50  provides the overall back-up power for the elevator system, a high frequency power source and storage source are required. The converter  70  needs to quickly ramp up the current (as well as quickly ramp down the current in the opposite state). A capacitor system  76  supports this by allowing the majority of the ac current required by the converter  70  to be sourced from the capacitors of the capacitor system  76 . Therefore, the capacitor system  76  also further optimizes life of the battery system. 
         [0034]    In addition, the capacitor system  76  supports optimization of the FET&#39;s  78  and (optional) RC snubbers  80 . When power flow into the main transformer  82  is stopped during a dead time, a high flyback voltage may occur. This voltage can be high enough to avalanche the power FET  78  integral protection diodes. While the devices chosen for this design are compatible with this type of operation, the avalanching causes a large instantaneous power dissipation as well as increasing the power loss for the system. The use of a resonant mode H-bridge configuration  72  minimizes this flyback voltage by switching the FETs off when they are in a low current condition. In addition, the (optional) RC snubber circuits  80  will slow down the flyback voltage. 
         [0035]    Referring to  FIG. 6 , the back-up power generation system includes a three phase generator  90  that takes the dc bus voltage and sequentially switches it through cascaded FETs such that it generates three sine wave outputs. This waveform requires a DC bus voltage of approximately 680 VDC to generate a 400-480 VAC rms sine wave output. 
         [0036]    The three phase generator  90  comprises an FET-based circuit  90  configured as three half-bridge cascaded field effect transistors (FETs)  94  (it is to be noted that the cascaded arrangements may be replaced by a single FET or a high frequency insulated gate bipolar transistor (IGBT)—for each phase—in an alternative embodiment). FETs  94  provide a correct 120 degree phasing between any two phases. The generator  90  further includes surge limiting by using NTC thermistors  96 . The thermistors  96  limit the initial load surge current required to charge the capacitors and transformers in the elevator system. However, after a short period of time, the thermistors  96  reduce their current limiting and support normal operation of the system with minimal losses. An output over-current protection  98  (i.e., fault) is provided at the sine wave output of the three phase generator  90  and provides two levels of protection. First, because the FETs  94  have a maximum current rating that should not be exceeded, the over-current protection  98  will shutdown the output stage of the generator  90  if the maximum short duration output current limit is exceeded for a short period (i.e., micro-seconds). Second, to prevent an overload condition on the output of the generator  90 , the over-current protection  98  will shutdown the generator  90  if the output current level exceeds an adjustable limit for a predetermined period of time (i.e., within milliseconds). Finally, the generator  90  may further contain output fuses as a back-up to the output over-current protection  98  in the event that the over-current protection  98  does not function correctly. 
         [0037]    The simplicity of this device, its simple interface with the rest of the elevator system, and its single box, microprocessor-based self-contained design make it unique. Other devices require a much higher degree of interconnecting wires and system integration to work correctly. This back-up power system  10  requires installing only seven power cables (i.e., three power wires into the unit, cabinet ground, three power wires out), the two safety circuit wires to the main disconnect, and the two wires for signaling the elevator controller to initiate a rescue operation. 
         [0038]    While the invention has been described with reference to specific embodiments, various changes may be made and equivalents may be substituted for elements thereof by those skilled in the art without departing from the scope of the invention. In addition, other modifications may be made to adapt a particular situation or method to the teachings of the invention without departing from the essential scope thereof.