Abstract:
An elevator maintenance kit is provided for surfacing an elevator sheave that engages with an elevator tension member. The kit includes a substrate with an adhesive backing, and a substrate applicator that is operable to apply the substrate to the sheave as the sheave is rotated. The adhesive backing is operable to attach the substrate to the sheave during the sheave rotation.

Description:
[0001]    This patent application is a continuation of and claims priority to U.S. patent application Ser. No. 14/395,992 filed Mar. 12, 2015, which claims priority to PCT Application No. PCT/US2012/036580 filed on May 4, 2012, which applications are hereby incorporated herein by reference in their entireties. 
     
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
       [0002]    This disclosure relates generally to elevators and, more particularly, to methods and apparatuses for applying a substrate onto an elevator sheave. 
       2. Background Information 
       [0003]    A typical traction elevator car drive system includes a plurality of tension members that serpentine around a plurality of sheaves (also referred to as “pulleys”), and connect a motor to an elevator car and a counterweight. During operation, the motor moves the tension members about the sheaves to lift or lower the elevator car within an elevator hoistway. 
         [0004]    Under certain conditions, one or more of the tension members may slip against one or more of the sheaves. Buildup of relatively high shear forces between the tension members and the sheaves, for example, may cause one of the tension members to momentarily lose traction with one of the sheaves. The loss and subsequent re-establishment of traction may induce vibrations in the tension members that can produce airborne noise within the hoistway and/or structural borne noise within the drive system. One approach for reducing such noise is to condition the tension members with a conditioning agent such as, for example, wax. Such an approach, however, can be time consuming and typically must be frequently repeated. 
       SUMMARY OF THE DISCLOSURE 
       [0005]    According to an aspect of the invention, an elevator maintenance kit is provided for surfacing an elevator sheave that engages with an elevator tension member. The kit includes a substrate with an adhesive backing, and a substrate applicator that is operable to apply the substrate to the sheave as the sheave is rotated. The adhesive backing is operable to attach the substrate to the sheave during the sheave rotation. 
         [0006]    Alternatively or in addition to this or other aspects of the invention, the substrate also includes a polymer film that is operable to be attached to the sheave with the adhesive backing. In some embodiments, the polymer film comprises ultra high molecular weight polyethylene. 
         [0007]    Alternatively or in addition to this or other aspects of the invention, the substrate applicator comprises a flexible substrate carrier sheet to which the substrate is attached. The carrier sheet is operable to move with the substrate through the sheave-member interface and compress the substrate against the sheave as the sheave is rotated. 
         [0008]    Alternatively or in addition to this or other aspects of the invention, the substrate is removably attached to the carrier sheet with an adhesive. 
         [0009]    Alternatively or in addition to this or other aspects of the invention, the maintenance kit also includes an adhesive that is operable to removably attach the carrier sheet to the tension member. 
         [0010]    Alternatively or in addition to this or other aspects of the invention, the substrate has a substrate width and a substrate length, and the carrier sheet has a sheet width and a sheet length. The sheet width is greater than or equal to the substrate width, and the sheet length is greater than or equal to the substrate length. 
         [0011]    Alternatively or in addition to this or other aspects of the invention, the substrate applicator includes a cylindrical applicator body around which the substrate is wrapped. The applicator body is operable to rotate about an axis thereof and feed the substrate into the sheave-member interface as the sheave rotates. 
         [0012]    Alternatively or in addition to this or other aspects of the invention, the applicator body includes one or more annular alignment grooves. Each of the one or more alignment grooves is operable to mate with a respective annular flange of the sheave. 
         [0013]    Alternatively or in addition to this or other aspects of the invention, the applicator body extends between first and second alignment flanges. The alignment flanges are operable to be arranged within a tension member engagement groove of the sheave. The substrate is arranged between the alignment flanges. 
         [0014]    Alternatively or in addition to this or other aspects of the invention, the maintenance kit also includes an applicator base to which the applicator body is rotatably connected and supported. 
         [0015]    Alternatively or in addition to this or other aspects of the invention, the maintenance kit also includes a second substrate including a second adhesive backing. The second substrate is wrapped around the applicator body. The applicator is further operable to apply the second substrate to the sheave as the sheave is rotated about the axis thereof The second adhesive backing is operable to attach the second substrate to the sheave as the second substrate moves through a circumferentially extending second sheave-member interface between the sheave and a second elevator tension member during the sheave rotation. 
         [0016]    According to another aspect of the invention, a method is provided for applying a substrate onto an elevator sheave that engages with an elevator tension member. The method includes steps of: (a) positioning a substrate applicator adjacent to the sheave, wherein the substrate is engaged with the applicator and includes an adhesive backing; (b) disposing an end of the substrate between the sheave and the tension member at a first end of the sheave-member interface; and (c) applying the substrate to the sheave by rotating the sheave, and by attaching the substrate to the sheave with the adhesive backing during the rotation of the sheave. 
         [0017]    Alternatively or in addition to this or other aspects of the invention, the sheave has a sheave circumference, the tension member has a member width, and the substrate has a substrate length and a substrate width. The substrate length is greater than or equal to the sheave circumference, and the substrate width is greater than or equal to the member width. 
         [0018]    Alternatively or in addition to this or other aspects of the invention, the applicator comprises a flexible substrate carrier sheet to which the substrate is attached. The step of disposing comprises disposing the carrier sheet and the end of the substrate between the sheave and the tension member, wherein the carrier sheet is arranged between the substrate and the tension member. The step of applying further comprises removing the carrier sheet from a portion of the substrate that extends out of a second end of the sheave-member interface. 
         [0019]    Alternatively or in addition to this or other aspects of the invention, the method also includes steps of: removably attaching the carrier sheet to the tension member proximate to the first end of the sheave-member interface with an adhesive; and removing the carrier sheet from the tension member proximate to the second end of the sheave-member interface. 
         [0020]    Alternatively or in addition to this or other aspects of the invention, the applicator includes a cylindrical applicator body around which the substrate is wrapped. The step of applying includes feeding the substrate from the applicator body into the sheave-member interface by rotating the applicator body about an axis thereof during the sheave rotation. 
         [0021]    Alternatively or in addition to this or other aspects of the invention, the tension member is arranged in a groove of the sheave, and the groove extends between first and second annular sheave flanges. The applicator body includes one or more annular alignment grooves. The step of positioning includes mating each of the one or more alignment grooves with a respective one of the sheave flanges. 
         [0022]    Alternatively or in addition to this or other aspects of the invention, the tension member is arranged in a groove of the sheave, and the groove extends between first and second annular sheave flanges. The applicator body extends axially between a pair of annular alignment flanges. The step of positioning includes positioning the alignment flanges within the groove between the sheave flanges. 
         [0023]    Alternatively or in addition to this or other aspects of the invention, a second substrate is engaged with the applicator and includes a second adhesive backing. The step of disposing includes disposing an end of the second substrate between the sheave and a second tension member at a first end of a circumferentially extending second sheave-member interface between the sheave and the second tension member. The step of applying includes: applying the second substrate to the sheave by rotating the sheave about the axis thereof; and attaching the second substrate to the sheave with the second adhesive backing as the second substrate moves through the second sheave-member interface during the rotation of the sheave. 
         [0024]    The foregoing features and the operation of the invention will become more apparent in light of the following description and the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]      FIG. 1  is a diagrammatic illustration of an elevator system arranged in a building hoistway. 
           [0026]      FIG. 2  is a diagrammatic cross-sectional illustration of a substrate for reducing and/or preventing noise between an elevator sheave and an elevator tension member. 
           [0027]      FIG. 3  is a diagrammatic side-sectional illustration of a substrate applicator for applying a substrate onto an elevator sheave engaged with an elevator tension member. 
           [0028]      FIG. 4  is a diagrammatic front view illustration of the substrate applicator of  FIG. 3 . 
           [0029]      FIG. 5  is another diagrammatic side-sectional illustration of the substrate applicator of  FIG. 3 . 
           [0030]      FIG. 6  is another diagrammatic front view illustration of the substrate applicator of  FIG. 3 . 
           [0031]      FIG. 7  is still another diagrammatic side-sectional illustration of the substrate applicator of  FIG. 3 . 
           [0032]      FIG. 8  is still another diagrammatic front view illustration of the substrate applicator of  FIG. 3 . 
           [0033]      FIG. 9  is a flow diagram of a method for applying a substrate onto a contact surface of a sheave utilizing the substrate applicator of  FIG. 3 . 
           [0034]      FIG. 10  is a diagrammatic side-sectional illustration of another substrate applicator for applying a substrate onto an elevator sheave engaged with an elevator tension member. 
           [0035]      FIG. 11  is a partial diagrammatic front view illustration of the substrate applicator of  FIG. 10 . 
           [0036]      FIG. 12  is another diagrammatic side-sectional illustration of the substrate applicator of  FIG. 10 . 
           [0037]      FIG. 13  is still another diagrammatic side-sectional illustration of the substrate applicator of  FIG. 10 . 
           [0038]      FIG. 14  is a flow diagram of a method for applying a substrate onto a contact surface of a sheave utilizing the substrate applicator of  FIG. 10 . 
           [0039]      FIG. 15  is a diagrammatic side-sectional illustration of still another substrate applicator for applying a substrate onto an elevator sheave engaged with an elevator tension member. 
           [0040]      FIG. 16  is a diagrammatic front view illustration of still another substrate applicator for applying a substrate onto an elevator sheave engaged with an elevator tension member. 
           [0041]      FIG. 17  is a diagrammatic front view illustration of a substrate applicator for applying a plurality of substrates onto an elevator sheave engaged with a plurality of elevator tension members. 
           [0042]      FIG. 18  is a diagrammatic front view illustration of still another substrate applicator for applying a substrate onto an elevator sheave engaged with an elevator tension member. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0043]      FIG. 1  illustrates an (e.g., traction) elevator system  20  arranged in a building hoistway  26 . The elevator system  20  includes an elevator car drive system  22  that moves an elevator car  24  vertically within the hoistway  26  between, for example, a plurality of elevator landings  28 . 
         [0044]    The drive system  22  includes a motor  30 . The elevator system  20  also includes a counterweight  32 , a plurality of elevator sheaves  34 ,  36 ,  38  and  40 , and one or more (e.g., anchored) elevator tension members  42  (e.g., ropes, belts, etc.). The elevator system  20  includes one or more sheaves. A first of the sheaves  34  (e.g., a drive sheave) is rotatably connected to the motor  30 . The elevator system  20  could include one or more sheaves  38  (e.g., an idler sheave) rotatably connected to the counterweight  32 . The elevator system  20  could include one or more sheaves  36  and  40  (e.g., idler and/or diverter sheaves) rotatably connected to the elevator car  24 . The tension members  42  are engaged with (e.g., serpentined around) the elevator sheaves, and connect the motor  30  to the elevator car  24  and the counterweight  32 . The present invention, however, is not limited to any particular drive system components and/or configurations. 
         [0045]    During elevator system operation, the motor  30  selectively rotates the first sheave  34  to move the tension members  42  about the sheaves  36 ,  38  and  40 . The movement of the tension members  42 , in turn, causes the elevator car  24  and the counterweight  32  to respectively move (e.g., lift or lower) vertically within the hoistway  26 . 
         [0046]    Under certain conditions, one or more of the tension members  42  may momentarily or periodically slip against one or more of the sheaves (e.g., the sheaves  36 ,  38  and  40 ) during tension member movement. Buildup of relatively high shear forces between the tension members and the sheaves, for example, may cause a respective one of the tension members to momentarily lose traction with a respective one of the sheaves. The loss and subsequent re-establishment of traction may induce vibrations in the tension members that can produce airborne noise within the hoistway  26  and/or structural borne noise within the drive system  22 . 
         [0047]      FIG. 2  illustrates a substrate  44  (e.g., tape) that is configured to reduce and/or prevent the noise induced by slippage between one or more of the tension members  42  and one or more of the sheaves (e.g., the sheaves  36 ,  38  and  40 ). The substrate  44 , for example, may enable localized surface slippage (e.g., reduce friction) between one of the tension members and a respective one of the sheaves. Enabling localized surface slippage reduces a magnitude of shear forces that can buildup between the tension member and the sheave, which may reduce noise generating vibrations. 
         [0048]    The substrate  44  extends between an exterior substrate surface  46  and an interior substrate surface  48 . The substrate  44  can include a noise reduction, low friction polymer film  50  and an adhesive backing  52 . The polymer film  50  extends from the exterior substrate surface  46  to the adhesive backing  52 . The adhesive backing  52  extends from the polymer film  50  to the interior substrate surface  48 . 
         [0049]    The polymer film  50  may be constructed from, for example, a polyethylene (PE) polymer such as ultra high molecular weight (UHMW) polyethylene. In another example, the polymer film  50  may be constructed from a fluoropolymer such as polytetrafluoroethylene (PTFE). It is worth noting, however, that UHMW polyethylene may have improved wear characteristics as compared to other polymers such as PTFE; e.g., UHMW polyethylene exhibits a relatively low material transfer rate. Utilizing UHMW polyethylene therefore can reduce film material transfer onto the tension members, which thereby can reduce the potential for material transfer induced slippage between the tension members and the first sheave  34  (e.g., the drive sheave). The present invention, however, is not limited to any particular film materials. 
         [0050]    The adhesive backing  52  may be constructed from, for example, an acrylic adhesive that is resistant to severe environmental conditions (e.g., fluctuations between high and low temperatures) as well as aging. The present invention, however, is not limited to any particular adhesive materials. 
         [0051]    An example of a substrate tape with an UHMW polyethylene film and an acrylic adhesive backing is Squeak Reduction Tape 5430, which is manufactured by 3M™ Corporation of St. Paul, Minn. Another example of a substrate tape is a PTFE tape with a plurality of indentations and/or projections arranged thereon. The indentations and/or projections can be adapted to further reduce shear force buildup between the tension member(s) and the sheave(s). Examples of indentation/projection shapes include, but are not limited to, circles, ovals, triangles, rectangles, hexagons, trapezoids, straight lines and/or wavy lines. Such indentations and/or projections can also be included on substrates constructed from various other types of materials such as, for example, UHMW polyethylene, etc. 
         [0052]      FIGS. 3-8  illustrate an embodiment of a substrate applicator  54  for applying the substrate  44  onto a sheave  56  (e.g., the sheave  36  in  FIG. 1 ) and, in particular, onto a tension member contact surface  58 . Briefly, referring to  FIGS. 3 and 4 , the contact surface  58  is engaged with a tension member  60  (e.g., the tension member  42  in  FIG. 1 ) along a circumferentially extending sheave-member interface  62 . The contact surface  58  is configured within an annular tension member groove  64 . The contact surface  58  has a surface width  66  that extends axially between an annular first flange  68  and an annular second flange  70 . The contact surface  58  also has a surface circumference that extends circumferentially around the sheave  56 , which is equal to or less than a length  72  of the substrate  44 . 
         [0053]    In the embodiment in  FIGS. 3 and 4 , the substrate applicator  54  is configured as a flexible substrate carrier sheet  74  to which the exterior substrate surface  46  may be removably attached. The carrier sheet  74  has a sheet length  76  that extends longitudinally between a first sheet end  78  and a second sheet end  80 , which length  76  is equal to or greater than the substrate length  72 . The carrier sheet  74  has a sheet width  82  that extends laterally (e.g., axially) between a first sheet side  84  and a second sheet side  86 . The sheet width  82  is equal to or less than the surface width  66 , and equal to or greater than a width  88  of the substrate  44 . The substrate width  88  is equal to or greater than a width  90  of the tension member  60 . The carrier sheet  74  also has a sheet thickness that extends between an interior sheet surface  92  and an exterior sheet surface  94 . 
         [0054]    The carrier sheet  74  is constructed from a flexible material that has a material stiffness greater than that of the substrate  44 . Examples of such a flexible material include, but are not limited to, sheet plastic, sheet metal, etc. Generally, the sheet thickness is greater than that of the substrate  44  to further increase its relative stiffness. 
         [0055]      FIG. 9  is a flow diagram of a method for applying the substrate  44  onto the contact surface  58  utilizing the carrier sheet  74 . Referring to  FIGS. 3, 4 and 9 , in step  900 , the exterior substrate surface  46  is removably attached to the interior sheet surface  92  with a light adhesive. The exterior substrate surface  46  can be removably attached to the interior sheet surface  92  with, for example, double sided tape (or folded tape) having a relatively low tackiness. In step  902 , the carrier sheet  74  is positioned adjacent to the sheave  56 . The exterior sheet surface  94 , for example, is removably attached to the tension member  60  with a light adhesive adjacent to the sheave  56 . 
         [0056]    In step  904 , the first sheet end  78  and a respective end  96  of the substrate  44  are disposed between the sheave  56  and the tension member  60  at a first end  98  of the sheave-member interface  62 . This step can be performed, for example, by positioning the carrier sheet  74  and the substrate  44  in the aforesaid location during step  902 . Alternatively, this step can be performed by moving the tension member  60  and rotating the sheave  56  about its axis in, for example, a counter-clockwise direction. 
         [0057]    Referring to  FIGS. 5-9 , in step  906 , the substrate  44  is applied to the contact surface  58  by moving the tension member  60  and rotating the sheave  56  in, for example, the counter-clockwise direction. The adhesive backing  52 , for example, attaches the polymer film  50  to the contact surface  58  as the substrate  44  moves through and is compressed by the carrier sheet  74  in the sheave-member interface  62 . The sheave  56  may be rotated one or more rotations, depending on the substrate length, to fully apply the substrate  44  to the sheave  56 . 
         [0058]    Referring to  FIGS. 7 and 9 , in step  908 , the carrier sheet  74  is removed (e.g., peeled away) from the tension member  60  or the substrate  44  proximate a second end  98  of the sheave-member interface  62 . The carrier sheet  74 , for example, can be peeled away from the tension member  60  where the carrier sheet  74  remains attached to the tension member  60  after the substrate  44  is applied to the contact surface  58 . Alternatively, the carrier sheet  74  can be peeled away from the substrate  44  where the carrier sheet  74  remains attached to the substrate  44  after the substrate  44  application to the contact surface  58  (not shown). 
         [0059]      FIGS. 10-13  illustrate another embodiment of the substrate applicator  54  for applying the substrate  44  onto a sheave  56  (e.g., the sheave  40  in  FIG. 1 ). In the embodiment in  FIGS. 10 and 11 , the substrate applicator  54  includes a cylindrical (e.g., tubular) applicator body  100  around which the substrate  44  may be wrapped. 
         [0060]    The applicator body  100  extends axially between a first body end  102  and a second body end  104 . The applicator body  100  includes a base segment  106 , one or more bridge segments  108  and  110 , and one or more annular alignment flanges  112  and  114 . The base segment  106  has an outer radial substrate contact surface  116  that extends axially between a first base end  118  and a second base end  120 . A first of the bridge segments  108  extends axially between the first base end  118  and a first of the alignment flanges  112 , thereby forming an outer radial annular first alignment groove  122  therebetween. A second of, the bridge segments  110  extends axially between the second base end  120  and a second of the alignment flanges  114 , thereby forming an outer radial annular second alignment groove  124  therebetween. The first alignment flange  112  is arranged adjacent to the first body end  102 . The second alignment flange  114  is arranged adjacent to the second body end  104 . 
         [0061]      FIG. 14  is a flow diagram of a method for applying the substrate  44  onto the contact surface  58  utilizing the applicator body  100 . Referring to  FIGS. 10, 11 and 14 , in step  1400 , the substrate  44  is wrapped around the base segment  106  such that, for example, the interior substrate surface  48  is facing the substrate contact surface  116 . 
         [0062]    In step  1402 , the applicator body  100  is positioned adjacent to the sheave  56 . The applicator body  100 , for example, can be disposed between opposing portions of the tension member  60 , and each of the alignment grooves  122  and  124  is mated with a respective one of the sheave flanges  68  and  70 . 
         [0063]    In step  1404 , an end  96  of the substrate  44  is disposed between the sheave  56  and the tension member  60  at the first end  98  of the sheave-member interface  62 . A portion of the substrate  44 , for example, can be unwrapped from the applicator body  100  and placed into position. 
         [0064]    Referring to  FIGS. 12-14 , in step  1406 , the substrate  44  is applied to the contact surface  58  by moving the tension member  60  and rotating the sheave  56  in, for example, the counter-clockwise direction. The adhesive backing  52 , for example, attaches the polymer film  50  to the contact surface  58  as the substrate  44  moves through and is compressed by the tension member  60  in the sheave-member interface  62 . The applicator body  100  rotates concurrently with the sheave  56 , thereby feeding the substrate  44  into the sheave-member interface  62  for attachment onto the sheave  56 . The sheave  56  may be rotated one or more rotations, depending on the substrate length, to fully apply the substrate  44  to the sheave  56 . In some embodiments, a portion of the substrate  44  extending between the applicator body  100  and the sheave  56  may be cut where, for example, the substrate  44  has not already been pre-apportioned into fixed lengths. 
         [0065]    In an alternative embodiment, for example as illustrated in  FIG. 15 , the substrate  44  can be wrapped around the base segment  106  such that, for example, the exterior substrate surface  46  is facing the substrate contact surface  116 . In such an embodiment, the substrate  44  may cross between the applicator body  100  and the sheave  56 . 
         [0066]    In some embodiments, for example as illustrated in  FIG. 16 , the applicator body  100  can be rotatably connected to and support by an applicator base  126 . The applicator base  126  can be configured to be held by a technician during the application process, or alternatively mounted to a component  128  (e.g., the elevator car  24 , the counterweight  32 , etc.) of the elevator system. 
         [0067]      FIG. 17  illustrates an alternate embodiment of a cylindrical applicator body  130 . In contrast to the applicator body  100  in  FIG. 11 , the applicator body  130  includes one or more additional base segments  132 . The additional base segments  132  can be utilized during operation, in a fashion as described above, to concurrently apply a plurality of the substrates  44  to respective tension member contact surfaces  58 . In some embodiments, the applicator body  130  can be configured as a single body as shown in  FIG. 17 . In alternative embodiments, the applicator body  130  can be configured as a plurality of modular sections. 
         [0068]      FIG. 18  illustrates another alternate embodiment of a cylindrical applicator body  134 . In contrast to the applicator body  100  in  FIG. 11 , the applicator body  134  is configured without the alignment grooves  122  and  124  (see  FIG. 11 ). In addition, the applicator body  134  is sized such that the alignment flanges  112  and  114  may be positioned within the tension member groove  64  between the sheave flanges  68  and  70 . 
         [0069]    In some embodiments, for example as illustrated in  FIG. 18 , one or more ends  96  of the substrate  44  may be tapered to prevent formation of abrupt ridges on the sheave  56  after the substrate  44  is applied to the contact face  58 . 
         [0070]    While various embodiments of the present invention have been disclosed, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. For example, the present invention as described herein includes several aspects and embodiments that include particular features. Although these features may be described individually, it is within the scope of the present invention that some or all of these features may be combined within any one of the aspects and remain within the scope of the invention. Accordingly, the present invention is not to be restricted except in light of the attached claims and their equivalents.