Abstract:
A method and an adapter kit for fastening a first elevator component to a second elevator component. The kit comprises a first bracket having two opposing walls interconnected by a web configured for attachment to the first component wherein a slot extending parallel to the web is provided in each of the opposing walls. A second and a third bracket is provided each having two opposing walls interconnected by a web wherein a slot is provided in the web extending between the two opposing walls. The second and third brackets are mountable to the second component by their respective slots. The first bracket is mountable to the second and third brackets by the slots in its opposing walls when the first bracket is positioned such that its opposing walls lie adjacent to the opposing walls of the second and third brackets, respectively.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a method and an adapter for mounting a first elevator component to a second elevator component and the resultant elevator installation derived therefrom. 
       BACKGROUND OF THE INVENTION 
       [0002]    In a conventional elevator installation, the elevator car is supported within a structural frame. Guides in the form of roller guides or guide shoes are mounted by a series of bolts to each corner of the structural frame to engage with opposing guide rails mounted along the hoistway and thereby guide the car smoothly as it travels through the hoistway. Similarly, the counterweight is normally contained within a structural frame having guides mounted at each corner to engage with opposing guide rails. 
         [0003]    During modernization of an existing elevator, it is often necessary for the technician to replace the guides on the car and/or the counterweight frames. However, the existing bolt hole pattern left behind in the structural frame after removal of the existing guide might not match the bolt hole pattern required by the new guide. Hence, before the modernization can commence, the technician needs to visit the installation to determine the existing bolt hole pattern by either identifying the existing guide or by actual measurement. Thereafter, on a case by case basis, an adapter plate is manufactured to interface the new guide with the existing bolt hole pattern. 
       SUMMARY OF THE INVENTION 
       [0004]    There is, therefore, a need for a universal adapter and an associated method to enable a technician to mount a elevator guide to a wide diversity of bolt hole arrangements provided in an elevator frame and, additionally, for an adapter that enables adjustment of the position of the guide relative to the frame in two mutually perpendicular directions before final fixation. 
         [0005]    One aspect of the invention involves a method for mounting an elevator guide to an elevator frame comprising the steps of providing a first bracket having two opposing walls and an interconnecting web wherein each of the opposing walls has a slot aligned in a first direction towards a guide rail, mounting a guide to the web of the first bracket, providing a second bracket having two opposing walls and an interconnecting web with a slot provided therein extending in a second direction perpendicular to the first direction, aligning the second bracket so that its slot overlaps holes in the elevator frame, adjusting the second bracket in the second direction, fastening the second bracket through its slot to the holes in the frame, positioning the first bracket such that its opposing walls lie adjacent to the opposing walls of the second bracket, adjusting the first bracket in the first direction, and fastening the first bracket to the second bracket through the slots in the opposing walls of the first bracket. 
         [0006]    The method may further comprise the steps of providing a third bracket having two opposing walls and an interconnecting web with a slot provided therein extending in the second direction, aligning the second and third brackets so that they are spaced apart in the first direction, and repeating for the third bracket all steps defined in relation to the second bracket. 
         [0007]    Accordingly, the slots in the first bracket permit the adjustment in the first direction of the first bracket relative to the second and third brackets, whereas the slots in the second and third brackets permit adjustment in the second direction relative the frame. 
         [0008]    Advantageously, the second and third brackets are initially only loosely fastened through their slots to the holes in the frame and subsequently the first bracket is position such that its opposing walls lie adjacent to the opposing walls of the second and third brackets, respectively and the first bracket is moved in the second direction to ensure correct alignment of the guide with the associated rail after which the second and third brackets are fastened securely through their slots to the existing holes in the frame. 
         [0009]    One aspect of the invention involves an elevator installation comprising a frame for movement along guide rails, a plurality of guides to engage with the guide rails, and a plurality of adapter kits to mount the guides to the frame. Each adapter kit comprises a first bracket having two opposing walls and an interconnecting web configured for attachment to a guide wherein each of the opposing walls has a slot aligned in a first direction towards a guide rail and a second bracket having two opposing walls and an interconnecting web with a slot provided therein extending in a second direction perpendicular to the first direction. The second bracket is fastened through its slot to holes in the frame. The opposing walls of the first bracket lie adjacent to the opposing walls of the second bracket. The first bracket is fastened through the slots in its opposing walls to the second bracket. 
         [0010]    The elevator installation may further comprise a third bracket having two opposing walls and an interconnecting web with a slot provided therein extending in the second direction wherein the second and third brackets are spaced apart in the first direction. 
         [0011]    Furthermore, the elevator installation may further comprise projections extending from the web of the first brackets defining a channel therebetween to at least partially accommodate the associated guide rail. Thereby, the adapter kits seismically retain the frame on the guide rails even in the event of an earthquake. 
         [0012]    One aspect of the invention provides an adapter kit for fastening a first component to a second component, comprising a first bracket having two opposing walls interconnected by a web configured for attachment to the first component wherein a slot extending parallel to the web is provided in each of the opposing walls and a second bracket having two opposing walls interconnected by a web wherein a slot is provided in the web extending between the two opposing walls. The second bracket is mountable to the second component by means of its slot, and the first bracket is mountable to the second bracket by means of the slots in its opposing walls when the first bracket is positioned such that its opposing walls lie adjacent to the opposing walls of the second bracket. 
         [0013]    The adapter kit may further comprise a third bracket having two opposing walls interconnected by a web wherein a slot is provided in the web extending between the two opposing walls, wherein the third bracket is mountable to the second component by means of its respective slot and the first bracket is mountable to the second and third brackets by means of the slots in its opposing walls when the first bracket is positioned such that its opposing walls lie adjacent to the opposing walls of the second and third brackets, respectively. 
         [0014]    Accordingly, the slots in the first bracket permit the lateral adjustment of the first bracket relative to the second and third brackets, whereas the slots in the second and third brackets permit transverse adjustment relative the second component. 
         [0015]    Preferably, each slot in the second and third brackets is offset from the center of its respective web. This permits a greater adjustment range. Similarly, each hole in the opposing walls of the second and third bracket may be offset from the center of the respective opposing wall. 
         [0016]    Preferably, the first bracket is designed so that its opposing walls can lie adjacent but external to the opposing walls of the second and third brackets. Alternatively, the first bracket may be designed so that its opposing walls can lie adjacent but internal to the opposing walls of the second and third brackets. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0017]    The novel features of the invention are set out in the claims below. The invention itself, however, as well as other features and advantages thereof, are best understood by reference to the detailed description, which follows, when read in conjunction with the accompanying drawings, wherein: 
           [0018]      FIG. 1  is a perspective view of one embodiment of an adapter kit; 
           [0019]      FIG. 2  is a perspective view illustrating the interaction between the adapter kit of  FIG. 1  and a structural frame of a car of an elevator installation; 
           [0020]      FIG. 3  is a perspective view illustrating the interaction between a roller guide in an elevator installation and the adapter kit of  FIG. 1 ; 
           [0021]      FIG. 4  is a plan view illustrating the adapter kit of  FIG. 1  adjusted to accommodate a maximum bolt hole range; 
           [0022]      FIG. 5  is a plan view similar to  FIG. 4  illustrating the adapter kit of  FIG. 1  adjusted to accommodate a minimum bolt hole range; 
           [0023]      FIG. 6  is a perspective view of one embodiment of an adapter kit according to the present invention; and 
           [0024]      FIG. 7  is a perspective view of one embodiment of an adapter kit according to the present invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0025]      FIG. 1  schematically illustrates a perspective view of one embodiment of an adapter kit  1  configured to interface a new roller guide with an existing bolt hole pattern in an upper cross beam of an car frame of an elevator installation. The adapter kit  1  comprises an n-shaped upper bracket  10  and two u-shaped lower brackets  30 . 
         [0026]    The n-shaped upper bracket  10  is formed by two opposing walls  12  interconnected by a web  14 . Two projections  16  extend from the web  14  defining a channel  18  therebetween. As explained in further detail with respect to  FIG. 2 , in use, the channel  18  accommodates a guide rail. A plurality of bolt holes  20  is provided in the web  14  for attachment to the new roller guide. Furthermore, two elongate slots  22  in direct alignment are provided in each of the opposing walls  12  of the n-shaped bracket  10  so as to extend parallel to the web  14 . 
         [0027]    As with the upper bracket  10 , each of the u-shaped lower brackets  30  is formed by two opposing walls  32  interconnected by a web  34 . Two directly aligned elongate slots  36  extending between the opposing walls  32  are provided in the web  34  of each of the lower brackets  30  to enable attachment of the lower brackets  30  to the upper cross beam of the elevator car frame. A bolt hole  38  is provided in each of the opposing walls  32  of each of the lower brackets  30 . Preferably, the elongate slots  36  are offset from the center of the web  34 . Similarly, the bolt holes  38  are preferably offset from the center of the opposing walls  32 . 
         [0028]    In use, the upper bracket  10  is lowered over the lower brackets  30  so that the opposing walls  12  of the upper bracket  10  lie adjacent but external to the opposing walls  32  of the lower brackets  30 , respectively. Carriage bolts  40  are then introduced through the four bolt holes  38  in the opposing walls  32  of the lower brackets  30  and subsequently through the elongate slots  22  in the opposing walls  12  of the upper bracket  10 . Accordingly, transverse relative movement (along the y-direction in the drawing) between the upper and lower brackets is prevented since the opposing walls  32  of the lower brackets  30  are enclosed by the opposing walls  12  of the upper bracket  10 . However, the engagement of the carriage bolts  40  with the bolt holes  38  and the elongate slots  22  enables the upper bracket  10  to slide laterally (along the x-direction in the drawing) relative to the lower brackets  30 . Once the upper bracket  10  is in the required lateral position, a washer  42 , a lock washer  44  and a hex nut  46  are introduced to each of the carriage bolts  40  to fasten and secure the upper bracket  10  to the lower brackets  30 . 
         [0029]    Use of the adaptor kit  1  to interface a new roller guide  200  with an existing bolt hole pattern  104  in an upper cross beam  102  of an car frame  100  of an existing elevator installation  400  will be explained in detail in association with  FIGS. 2 and 3 . 
         [0030]    As shown in  FIG. 2 , the lower brackets  30  are transversely aligned and laterally spaced so that each of the elongate slots  36  coincides with an existing bolt hole  104  in the cross beam  102  of the car frame  100  within the elevator installation  400 . Hex-head screws  106  are introduced through the slots  36  and into the existing bolt holes  104 . At this stage the screws  106  are not secured tightly so as to allow transverse movement of the lower brackets  30  relative to the cross beam  102 . 
         [0031]    As illustrated in  FIG. 3 , carriage bolts  40  are introduced through the bolt holes  20  in the upper bracket and through corresponding holes  202  in the base of the roller guide  200 . A washer  42 , a lock washer  44  and a hex nut  46  are introduced to each of the carriage bolts  40  to fasten and secure the roller guide  200  to the upper bracket  10  of the adapter kit  1 . 
         [0032]    The upper bracket  10  is then lowered over the lower brackets  30  as described previously with respect to  FIG. 1  and the ensemble of the roller guide  200  and the adapter kit  1  can be moved transversely via the engagement of the untightened screws  106  in the elongate slots  36  of the lower brackets  30 . When the roller guide  200  is in the correct transverse alignment with the guide rail  300 , the upper bracket  10  and attached roller guide  200  are lifted from the lower brackets  30 . The hex-head screws  106  are then tightened to fasten and secure the lower brackets  30  to the cross beam  102  of the car frame  100  thereby fixing the transverse position of the adapter kit  1  and roller guide  200 . 
         [0033]    Next, the upper bracket  10  and attached roller guide  200  are again lowered over the lower brackets  30  and the carriage bolts  40  are introduced through the bolt holes  38  of the lower brackets  30  and the elongate slots  22  of the upper bracket  10  as described previously with respect to  FIG. 1 . The roller guide  200  is moved towards the guide rail  300  until it is in the correct lateral position so that the guide rail  300  extends at least partly into the channel  18  provided between the two projections  16  extending from the web  14  of the upper bracket  10 . Then the washers  42 , lock washers  44  and hex nuts  46  are introduced to each of the carriage bolts  40  to fasten and secure the upper bracket  10  to the lower brackets  30 , thereby fixing the lateral position of the adapter kit  1  and roller guide  200 . 
         [0034]    The procedure outlined above is repeated in respect of the three additional corners of the car frame  100 . It should be noted that not only do the adapter kits  1  enable lateral and transverse adjustment of the position of the new roller guides  200  before they are finally fixed in position, but since each of the opposing guide rails  300  is at least partially accommodated in the channel  18  provided between the projections  16  of an associated upper bracket  10 , the adapter kits  1  act to seismically retain the frame on the guide rails  300  even in the event of an earthquake. 
         [0035]      FIG. 4  and  FIG. 5  illustrate the broad range of existing bolt hole patterns  104  that a given adapter kit  1  can accommodate. Since the lower brackets  30  are independent there is no theoretical limit to the extent of lateral displacement x therebetween. However, in practice, the majority of existing guides use a square bolt hole pattern or formation (as shown) with the four holes  104  arranged at the corners of a square. With this in mind,  FIG. 4  shows the maximum hole pattern spread for the lower brackets  30 . The holes  104  in the cross beam  102  of the frame  100  are aligned with the outer extremities of the corresponding slots  36  in the lower brackets  30 . It is envisaged that the adapter kit  1  should accommodate a maximum hole pattern area of 190.5 mm×190.5 mm (7½ ″×7½ ″). As illustrated in  FIG. 5 , for the minimum hole pattern is provided for when the holes  104  in the cross beam  102  of the frame  100  are aligned with the inner extremities of the corresponding slots  36  in the lower brackets  30 . It is envisaged that the adapter kit  1  should accommodate a minimum hole pattern area of 89 mm×89 mm (3½ ″×3½ ″). 
         [0036]      FIG. 6  shows an alternative adapter kit  1 ′ configured to interface a new roller guide with an existing bolt hole pattern in a cross beam of an elevator counterweight frame. Since the arrangement of the counterweight frame for guidance along its associated guide rails is essentially the same as that of the car frame for guidance along its associated guide rails, reference is made to  FIGS. 2 and 3  and associated description, where citations to car and car frame can be interchanged for counterweight and counterweight frame, for understanding the procedure for mounting the guide to the counterweight frame using the adapter kit  1 ′ of the present embodiment. 
         [0037]    The adapter kit  1 ′ for the counterweight frame is essentially a smaller version to the car adapter kit  1 . However, there are some notable differences. When the upper bracket  10  is lowered over the lower brackets  30 , the opposing walls  12  of the upper bracket  10  lie adjacent but internal to the opposing walls  32  of the lower brackets, respectively. Accordingly, the carriage bolts  40  are inserted from outside and into the adapter kit  1 ′ whereas in the preceding embodiment the carriage bolts  40  were inserted in the opposite direction from inside and out from the adapter kit  1 . Furthermore, rather than having two elongate slots  22  in each wall of the upper bracket and two elongate slots  36  in each of the lower brackets, a single slot  22 ′ is provided in each wall  12  of the upper bracket  10  and a single slot  36 ′ is provided in the web  34  of each lower bracket  30 . Preferably, the counterweight adapter kit  1 ′ is designed to accommodate hole pattern areas of between 51 mm×51 mm (2″×2″) and 108 mm×108 mm (4¼″×4¼″). 
         [0038]      FIG. 7  illustrates a further adapter kit  1 ″ configured to interface a new roller guide with an existing bolt hole pattern in an cross beam of an elevator counterweight frame. The upper bracket  10  is identical to that already shown and described with reference to  FIG. 6 . The principle difference between the present embodiment and that of  FIG. 6  is that a single lower bracket  30 ′ is implemented. The single lower bracket  30 ′ is formed by two opposing walls  32  interconnected by a web  34 . A single elongate slot  36 ′ extending between the opposing walls  32  is provided in the web  34  to enable attachment of the lower bracket  30  to the upper cross beam of the elevator counterweight frame. Whereas the lower brackets  30  of the previously embodiments were fastened by screws  106  to four bolt holes  104  in the cross beam of the frame, in the present embodiment, screws  106  may be inserted through the single slot  36 ′ to secure the lower bracket  30 ′ to two transversely aligned bolt holes  104  in the counterweight frame  100 . Furthermore, two bolt holes  38  are provided in each of the opposing walls  32  of the lower brackets  30 ′ so, as in the previous examples, the upper bracket  10  is secured via its slots  22 ′ to the lower bracket  36 ′ by four carriage bolts  40 . Additionally, a semi-circular cut-out  37  is formed in the lower bracket  36 ′ to accommodate any tie-rod or other obstruction that may be present in the area that would otherwise be required to mount the lower bracket  30 ′ to the frame. 
         [0039]    Although the invention has been described as having particular benefit in the modernization of an existing elevator to mount new roller guides to existing bolt holes in the car and counterweight frames, it will be appreciated that the adapter kits are suitable for mounting any first component to a second component. 
         [0040]    In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.