Patent Publication Number: US-2017362061-A1

Title: Transfer station and car disengagement mechanism for a ropeless elevator system

Description:
FIELD OF THE INVENTION 
     The subject matter disclosed herein relates generally to the field of elevators, and more particularly to a multicar, ropeless elevator system. 
     BACKGROUND OF THE INVENTION 
     Ropeless elevator systems, also referred to as self-propelled elevator systems, are useful in certain applications (e.g., high rise buildings) where the mass of the ropes for a roped system is prohibitive and there is a desire for multiple elevator cars to travel in a single lane. There exist ropeless elevator systems in which a first lane is designated for upward traveling elevator cars and a second lane is designated for downward traveling elevator cars with at least two transfer stations in the hoistway used to move cars horizontally between the first lane and second lane. 
     Transfer stations do not typically provide redundancy for transfer station operation. Therefore, the numbers of structures capable of moving elevator cars is equal to or lower than the number of lanes of the hoistway. The assumption is that in a worst case scenario, independent working carriages in the transfer station may work with a reduced number of carriages. Working with a reduced number of carriages decreases overall elevator system efficiency and may cause operation delays, as well as logistical challenges. 
     BRIEF DESCRIPTION OF THE INVENTION 
     According to one aspect of the invention, a transfer station for a ropeless elevator system includes a plurality of lanes configured to accommodate vertical travel of an elevator car therein. Also included is a parking area located adjacent at least one of the plurality of lanes. Further included is a carriage moveable between the plurality of lanes and the parking area, the carriage configured to support and move the elevator car in a horizontal direction. Yet further included is a car disengagement mechanism engageable with the elevator car for disengagement of the elevator car from a primary propulsion mechanism of the car within the plurality of lanes and for movement of the elevator car between at least one of the plurality of lanes and the parking area. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the car disengagement mechanism comprises a car lifting mechanism that is secondary to the primary propulsion mechanism. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that a parking mechanism is located in the parking area and configured to receive the elevator car from the car disengagement mechanism. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the car disengagement mechanism is coupled to the carriage. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the car disengagement mechanism and the carriage are moveable between the parking area and at least one of the plurality of lanes. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the parking mechanism is at least one propelled pallet. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the parking mechanism enters one of the plurality of lanes to receive the elevator car for movement to the parking area, the car disengagement mechanism disposed in one of the parking area and the plurality of lanes. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the car disengagement mechanism is independently moveable relative to the carriage. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the car disengagement mechanism includes an independent propulsion mechanism to control movement of the car disengagement mechanism. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the independent propulsion mechanism comprises at least one of an electric motor, a belt and a chain. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the car disengagement mechanism engages the elevator car one floor away from the transfer station. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the elevator car is movable with the carriage and the car disengagement mechanism on floors of the plurality of lanes that are not the transfer station floor. 
     According to another aspect of the invention, a transfer station for a ropeless elevator system includes a plurality of lanes configured to accommodate vertical travel of an elevator car therein. Also included is a parking area located adjacent at least one of the plurality of lanes. Further included is a carriage moveable between the plurality of lanes, the carriage configured to support and move the elevator car in a horizontal direction. Yet further included is a car disengagement mechanism located within at least one of a terminal of the parking area and the plurality of lanes, the car disengagement mechanism engageable with the elevator car for movement of the elevator car within the parking area. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the carriage is moveable from the plurality of lanes to the parking area to transfer to the elevator car to the car disengagement mechanism. 
     According to another aspect of the invention, a method of moving an elevator car within a transfer station region is provided. The method includes moving the elevator car in a vertical direction within a plurality of lanes of a hoistway. The method also includes supporting the elevator car with a carriage located within the plurality of lanes. The method further includes disengaging a primary propulsion mechanism configured to move the elevator car within the plurality of lanes. The method yet further includes moving the elevator car with the carriage. The method also includes transferring the elevator car from one of the plurality of lanes to a parking area located adjacent the plurality of lanes with a car disengagement mechanism. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include moving the car disengagement mechanism independently relative to the carriage. 
     These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
         FIG. 1  illustrates a multicar ropeless elevator system according to one aspect of the invention; 
         FIG. 2  is a schematic illustration of one car of the multicar ropeless elevator system; 
         FIG. 3  is a perspective view of a transfer station of the multicar ropeless elevator system according to one embodiment; 
         FIG. 4  is a perspective view of the transfer station according to another embodiment; 
         FIG. 5  is a perspective view of a transfer station with an independent forklift for moving cars of the multicar ropeless elevator system; and 
         FIG. 6  is a perspective view of a transfer with a forklift coupled to a carriage of the multicar ropeless elevator system. 
     
    
    
     The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1 , a multicar, ropeless elevator system  10  is illustrated according to one embodiment. Elevator system  10  includes a hoistway  11  having a plurality of lanes  13 ,  15  and  17 . While three lanes are shown in  FIG. 1 , it is understood that embodiments may be used with multicar, ropeless elevator systems that have any number of lanes. In each lane  13 ,  15 ,  17 , cars  14  travel in one direction, i.e., up or down. For example, in  FIG. 1  cars  14  in lanes  13  and  17  travel up and cars  14  in lane  15  travel down. One or more cars  14  may travel in a single lane  13 ,  15 , and  17 . 
     Above the top floor is an upper transfer station  30  to impart horizontal motion to elevator cars  14  to move elevator cars  14  between lanes  13 ,  15  and  17 . It is understood that upper transfer station  30  may be located at the top floor, rather than above the top floor. Below the first floor is a lower transfer station  32  to impart horizontal motion to elevator cars  14  to move elevator cars  14  between lanes  13 ,  15  and  17 . It is understood that lower transfer station  32  may be located at the first floor, rather than below the first floor. Although not shown in  FIG. 1 , one or more intermediate transfer stations may be used between the lower and the upper transfer station floors. Intermediate transfer stations are similar to the upper transfer station  30  and lower transfer station  32 . Additionally, both the upper transfer station  30  and the lower transfer station  32  may be at system terminals, or at any floor above or below. Therefore, it is to be understood that an upper transfer station is meant to be the highest placed transfer station in the loop and a bottom transfer station is the lowest transfer station in the loop. Transfer stations at various locations advantageously impact the functional capability of the system by increasing loop options. For example, the lanes may include cars traveling in a unidirectional or bidirectional manner. Furthermore, parking of the cars may be performed in transfer stations depending on the particular location and configuration 
     Cars  14  are self-propelled using, for example, a linear motor system having a fixed portion  16  and a moving portion  18 . One or more fixed portions  16  are mounted in lanes  13 ,  15  and  17 . Fixed portion  16  may include coils that are energized by one or more drives to produce magnetic flux. Moving portion  18  may include permanent magnets that co-act with the coils  26  to impart force on car  14 . One or more moving portions  18  are mounted on cars  14 . One of the motor portions is supplied with drive signals to control movement of cars  14  in their respective lanes. 
     Referring to  FIG. 2 , illustrated is another view of the elevator system  10  including an elevator car  14  that travels in hoistway  11 . Elevator car  14  is guided by one or more guide structure  24  extending along the length of hoistway  11 , where the guide structure  24  may be affixed to hoistway wall, propulsion device, carriage structural member  19 , or stacked over each other. For ease of illustration, the view of  FIG. 2  only depicts a single side guide structure  24 ; however, there may be two or more guide structure  24  positioned, for example, on opposite sides of the elevator car  14 . Elevator system  10  employs a vertical propulsion system  20 , where same placement variations apply to vertical propulsion stationary portion  16  placed in the hoistway. Vertical propulsion stationary portion  16  includes multiple segments  22 . Segments  22  may be affixed to hoistway wall, guide structure, carriage structural member  19 , or stacked over each other. Propulsion moving portion  18  may be affixed to a car frame or be a structural member of a car frame. A number of propulsion moving portions  18  may be placed on a car. 
     Referring now to  FIGS. 3-6 , with continued reference to  FIGS. 1 and 2 , a transfer station  40  is illustrated. The illustrated transfer station  40  may be positioned at any vertical location within the hoistway  11 . For example, the transfer station  40  may be the upper transfer station  30 , the lower transfer station  32 , or an intermediate transfer station located between two of them. The transfer station  40  is a location where the elevator cars  14  may be moved (horizontally and/or vertically) to transfer the cars  14  between the lanes  13 ,  15 ,  17  and between a parking and/or storage area  42 . 
     Transport of the cars  14  is made with a frame-like structure referred to as a carriage  46 . The carriages  46  may be used to park or store elevator cars  14  in a manner that allows disengagement of the cars from the guiding structures within the hoistway. The carriages  46  may or may not be moved out of the lanes  13 ,  15 ,  17  and move horizontally and/or vertically. The carriages may be configured to allow the elevator cars  14  to pass through the frame-like structures, such that the carriages may be positioned in the middle lanes during normal operation of the elevator system  10 . This alleviates the need to maintain the carriages out of the lanes until they are needed. The number of carriages  46  at each transfer station may vary, such that the number of carriages may be equal to or less than the number of lanes. 
     Parking of the cars  14  may be done for varied amounts of time. Increasing or decreasing the number of cars  14  actively circulating within the lanes is desirable based on the varying levels of use of the hoistway during certain times of the day. For example, during non-peak usage hours, it is desirable to reduce the number of cars circulating by moving some of the cars to the parking area  42 . Conversely, during peak usage hours, it is desirable to increase the number of cars circulating by moving some of the cars from the parking area  42  to the lanes  13 ,  15 ,  17 . 
     Additionally, movement of the cars to the parking area  42  facilitates maintenance of the cars  14 , if needed. It is to be understood that although a single parking area is discussed and illustrated, multiple parking areas may be included at each transfer station  40 . For example, a parking area may be located adjacent more than one of the lanes  13 ,  15 ,  17 . In the illustrated embodiment of  FIG. 3 , a “L-shaped” transfer station is shown based on the combined layout of the parking area  42  and the lanes. By way of another non-limiting example,  FIG. 4  illustrates a “rectangular” or “square-shaped” transfer station based on the combined layout of the parking area  42  and the lanes. These are merely examples and it is to be appreciated that numerous other layouts are contemplated. It is further contemplated that the elevator cars are moveable in a horizontal or vertical manner with the carriage and/or car disengagement mechanism on floors that are not a transfer station floor. 
     As described herein, a car disengagement mechanism is provided to move and/or support the elevator cars  14 . Disengagement is meant to be understood as separation of stationary and moving parts of motor as well as guiding structure from rails. In one embodiment, the car disengagement mechanism is a forklift  50 , but it is to be appreciated that any mechanism may be employed to disengage the elevator car  14  from the primary propulsion system to remove the elevator car from the lane(s) and into a parking area. The forklift  50  of the illustrated embodiment of  FIGS. 3-5  is independently moveable relative to the carriage  46 . In this way, the forklift  50  may retrieve the elevator car  14  as a transition from the carriage  46  or may engage the elevator car  14  without the need for the carriage  46 . The forklift  50  may become a redundancy to the carriage  46  and may pick cars from any lane, as well as the floor above, to transport the elevator car  14  to the parking are where it may pass the elevator car to a storage mechanism or place the car in the storage itself. As shown, the forklift  50  may be moveable in a vertical and/or horizontal manner to engage the elevator car  14  and to facilitate transfer to the parking area  42 . Once disengagement of the elevator car from the primary propulsion system is made, the car may be moved as desired. In one embodiment, the forklift  50  is always disposed within one of the lanes. In such an embodiment, a parking mechanism  60  in the form of a pallet or the like moves into the lane to receive the elevator car from the forklift  50 . All or a portion of the parking mechanism  60  may be moved into the lane during such a maneuver. Upon engagement of the elevator car  14  and the parking mechanism  60 , the elevator car is moved out of the lane to the parking area  42  and may be moved to a desired location within the parking area  42 . 
     In another embodiment, the forklift  50  moves the elevator car  14  out of the lane to the parking area  42 . Upon removal from the lane, the forklift  50  maneuvers the elevator car  14  onto the parking mechanism  60 . 
     In yet another embodiment of an independently moveable forklift  50 , the forklift  50  may be positioned outside of the lane, such that the forklift  50  is not aligned in a vertical direction with any of the lanes. In such an embodiment, the forklift  50  reaches into the lane with engagement members to retrieve the elevator car  14  and to move it to the parking area  42 . 
     In each of the embodiments of an independently moveable forklift  50 , an independent propulsion mechanism is employed to control movement of the forklift  50 . The propulsion mechanism may be an electric motor, a belt, a chain or the like, as is the case with the carriage  46 . 
     In the embodiment illustrated in  FIG. 6 , the forklift  50  is coupled to the carriage  46 . A fixed coupling between the forklift  50  and the carriage  46  allows movement of the forklift  50  and the carriage  46  as a single unit for movement of the elevator cars  14 . In such an embodiment, the carriage  46  and the forklift  50  may both be moved to the parking area  42  for movement of the elevator car  14 . Alternatively, the parking mechanism  60  may enter the lanes to engage the elevator car  14  for movement into the parking area  42  while the carriage  46  and the forklift  50  remain in the lanes. 
     In all of the above-described embodiments, the forklift  50  facilitates removal of elevator cars during normal operation of the overall system. In particular, in combination with the carriage  46 , which allows rapid disengagement of the elevator cars from the main guiding and propulsion components, a car is rapidly removed in an efficient manner. This is highly advantageous to perform maintenance on the elevator cars and to modify the number of cars circulating throughout the lanes during time periods with different operational needs (i.e., peak vs. non-peak hours). 
     While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.