Patent Publication Number: US-2018029832-A1

Title: Vehicle and method for elevator system installation

Description:
BACKGROUND 
     The subject matter disclosed herein relates generally to the field of elevators, and more particularly to a multicar, ropeless elevator system. 
     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. A transfer station at each end of the hoistway is used to move cars horizontally between the first lane and second lane. 
     Additionally, present elevator system installation methods require either scaffolding, hoists installed at a top of the hoistway and/or a jump lift method, in which a machine room is repeatedly relocated up the hoistway as upward construction of the building progresses. These methods require significant labor for the scaffolding installation and/or repeated jump lift re-positioning, and in most cases elevator installation occurs only after the building is at full height. Further, each of these installation methods has limitations. 
     BRIEF SUMMARY 
     In one embodiment, an elevator car for an elevator system includes a first deck including one or more linear drive elements operably connected to a linear drive system at a hoistway and a second deck abutting the first deck, and separated from the first deck by a floor. The second deck is at least partially open at one side to allow access to the hoistway for installation of elevator system components in the hoistway. 
     Alternatively or additionally, in this or other embodiments the second deck is an upper deck and the first deck is a lower deck. 
     Alternatively or additionally, in this or other embodiments a pass through opening is located between the first deck and the second deck to move elevator system components between the first deck and the second deck. 
     Alternatively or additionally, in this or other embodiments a floor opening is disposed at a first deck floor to allow passage of elevator system components between the hoistway and the first deck. 
     Alternatively or additionally, in this or other embodiments the linear drive elements are secondary portions of a linear motor system interactive with a plurality of primary portions secured in the hoistway to urge motion of the elevator car along the hoistway. 
     Alternatively or additionally, in this or other embodiments a hoist is located at the second deck to move and position elevator system components for installation. 
     Alternatively or additionally, in this or other embodiments the elevator system is a multi-car ropeless elevator system. 
     Alternatively or additionally, in this or other embodiments one of the first deck and/or the second deck is collapsible to allow the elevator car to pass through a transfer station at a hoistway end. 
     Alternatively or additionally, in this or other embodiments the elevator car includes brakes and/or safeties to stop and hold the elevator car at a selected position in the hoistway. 
     In another embodiment, a method of installing an elevator system in a hoistway includes loading an elevator car with elevator system components for installation. The elevator car includes a first deck including one or more linear drive elements operably connected to a linear drive system at the hoistway and a second deck abutting the first deck, and separated from the first deck by a floor. The second deck is at least partially open at one side to allow access to the hoistway for installation of elevator system components in the hoistway. The elevator car is urged along the hoistway to an installation zone and the elevator system components are installed to the hoistway from the at least partially open second deck. 
     Alternatively or additionally, in this or other embodiments installing the elevator system components further includes affixing rail segments to the hoistway and affixing linear drive system components to the hoistway. The linear drive system components are made operational so the elevator car may be driven along the newly installed rail segments. 
     Alternatively or additionally, in this or other embodiments the linear drive system components include primary portions of a linear drive system interactive with secondary portions affixed to the elevator car. 
     Alternatively or additionally, in this or other embodiments the rail segments are aligned with previously installed rail segments prior to affixing the rail segments to the hoistway. 
     Alternatively or additionally, in this or other embodiments the linear drive system components are connected to a temporary electrical power line to provide electrical power to the linear drive system components. 
     Alternatively or additionally, in this or other embodiments the elevator car is driven along the hoistway to a second installation zone via the linear drive system components powered by the temporary electrical power line. 
     Alternatively or additionally, in this or other embodiments the linear drive system components are sequentially disconnected from the temporary electrical power line and connected to a permanent electrical power line fixed in the hoistway. 
     Alternatively or additionally, in this or other embodiments the elevator car is loaded with additional elevator system components for installation prior to proceeding to the second installation zone. 
     Alternatively or additionally, in this or other embodiments the second deck is an upper deck and the first deck is a lower deck. 
     Alternatively or additionally, in this or other embodiments additional elevator cars are operated in the hoistway outside of the installation zone during installation. 
     Alternatively or additionally, in this or other embodiments additional elevator cars are operated below the installation zone during installation. 
     Alternatively or additionally, in this or other embodiments elevator system components are passed through a pass through opening between the first deck and the second deck prior to installation from the second deck. 
     Alternatively or additionally, in this or other embodiments a hoist affixed to the second deck is utilized to lift and position the elevator system components for installation. 
     Alternatively or additionally, in this or other embodiments the elevator system is a multi-car ropeless elevator system. 
     Alternatively or additionally, in this or other embodiments elevator system components are conveyed to the installation car via a supply car travelling along the hoistway, and are transferred from the supply car to the installation car. 
     In yet another embodiment, a method of constructing a structure includes loading an elevator car with elevator system components for installation. The elevator car includes a first deck including one or more linear drive elements operably connected to a linear drive system at the hoistway and a second deck abutting the first deck, and separated from the first deck by a floor, the second deck at least partially open at one side to allow access to the hoistway for installation of elevator system components in the hoistway. The elevator car is urged along the hoistway to an installation zone via the linear drive system. The elevator system components are installed to the hoistway from the at least partially open second deck. Building materials for the structure are conveyed along the hoistway via the installation car. The building materials are installed at a construction zone of the structure. 
     Alternatively or additionally, in this or other embodiments the structure is constructed incrementally along with the elevator system component installation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts a multicar elevator system in an exemplary embodiment; 
         FIG. 2  depicts an embodiment of an installation car for an elevator system; 
         FIG. 3  depicts another embodiment of an installation car for an elevator system; 
         FIG. 4  depicts a method for installation of hoistway components for an elevator system; and 
         FIG. 5  depicts another embodiment of a multicar elevator system. 
       The detailed description explains the invention, together with advantages and features, by way of examples with reference to the drawings. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  depicts a multicar, ropeless elevator system  10  in an exemplary 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 have any number of lanes. In each lane  13 ,  15 ,  17 , multiple elevator cars  14  can travel in one direction, i.e., up or down, or multiple cars within a single lane may be configured to move in opposite directions. 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 first floor and the top floor. Intermediate transfer stations are similar to the upper transfer station  30  and lower transfer station  32  are configured to impart horizontal motion to the elevator cars  14  at the respective transfer station, thus enabling transfer from one lane to another lane at an intermediary point within the elevator shaft  11 . Further, although not shown in  FIG. 1 , the elevator cars  14  are configured to stop at a plurality of floors to allow ingress to and egress from the elevator cars  14 . 
     Elevator cars  14  are propelled within lanes  13 ,  15 ,  17  using a propulsion system such as a linear, permanent magnet motor system having a primary, fixed portion, or first part  16 , and a secondary, moving portion, or second part  18 . The first part  16  is a fixed part because it is mounted to a portion of the lane, and the second part  18  is a moving part because it is mounted on the elevator car  14  that is movable within the lane. 
     The first part  16  includes windings or coils mounted on a structural member, and may be mounted at one or both sides of the lanes  13 ,  15 , and  17 , relative to the elevator cars  14 . Specifically, first parts  16  will be located within the lanes  13 ,  15 ,  17 , on walls or sides that do not include elevator doors. 
     The second part  18  includes permanent magnets mounted to one or both sides of cars  14 , i.e., on the same sides as the first part  16 . The second part  18  engages with the first part  16  to support and drive the elevators cars  14  within the lanes  13 ,  15 ,  17 . First part  16  is supplied with drive signals from one or more drive units to control movement of elevator cars  14  in their respective lanes through the linear, permanent magnet motor system. The second part  18  operatively connects with and electromagnetically operates with the first part  16  to be driven by the signals and electrical power. The driven second part  18  enables the elevator cars  14  to move along the first part  16  and thus move within a lane  13 ,  15 , and  17 . 
     Those of skill in the art will appreciate that the first part  16  and second part  18  are not limited to this example. In alternative embodiments, the first part  16  may be configured as permanent magnets, and the second part  18  may be configured as windings or coils. Further, those of skill in the art will appreciate that other types of propulsion may be used without departing from the scope of the invention. Further, the components of the first part  16  and second part  18  may be reversed, such that fixed, first part includes permanent magnets and the moving, second part includes windings or coils. 
     Referring now to  FIGS. 2 and 3 , in an exemplary embodiment, an installation car  20  is utilized for installation of elevator system  10  components, including rails  12  and primary portions  16 , in the lanes  13 ,  15 ,  17 . The installation car includes an upper deck  22  and a lower deck  24 . The lower deck  24  is configured as a regular car  14 , and may be used as such when not utilized for installation of elevator system components. During construction or installation operations, the lower deck  24  may be utilized for parts and equipment storage, for example, storage of rail  12  segments, primary portions  16 , wiring harnesses and connectors (not shown) and the like. The upper deck  22  has an open configuration on at least one side to allow access to the hoistway, and is configured to support an overhead crane  26  or other hoist or handling equipment used for lifting and moving components to be installed in the hoistway  11 . In other embodiments, the components may be lifted into the installation car  20  from below using, for example, a jacking mechanism. In some embodiments, the lower deck  24  is open or partially open to allow access to the hoistway  11  from the lower deck  24 . The upper deck  22  may be also used for component storage as well as be equipped with needed tools. There may be one or more pass through openings  28  between the upper deck  22  and the lower deck  24  to allow passage of components and/or personnel between the lower deck  24  and the upper deck  22 . In some embodiments, the pass through  28  opening is closable when not in use. In some embodiments, a closable floor opening  34  is provided in a floor  36  of the lower deck  24  to allow loading of components into the lower deck  24  from below. In some embodiments, the upper deck  22  is retractable to allow the installation car  20  to make use of the transfer station  32 . 
     The installation car  20  is equipped with linear motor elements to drive the installation car  20  along the rails  12 . The linear motor drive for the installation car  20  may be, for example, secondary portion  18 /primary portion  16  pair or other linear drive system such as a magnetic screw drive. In some embodiments, secondary portions  18  are secured to the installation car  20  are interactive with primary portions  16  installed in the hoistway  11  to drive the installation car along rails  12 . In some embodiments, the secondary portions  18  are secured at a lower deck  24  of the installation car  20 , so that the upper deck  22  is positionable at a hoistway portion where rail segments, primaries and other components have yet to be installed. Further, the installation car  20  may include other basic elevator car  14  components such as brakes, safeties, control panel and doors. However, they may be modified from elevator car  14  to support the purpose of the installation car  20 . For example, parts may be modified to support heavier loads, and the installation car  20  may have an increased number of secondary portions  18  or increased secondary portion  18  length, compared to elevator car  14 , in order to increase the lifting capacity to more than the rated duty of the elevator car  14  to be installed later. Further, the brakes and/or safeties may be modified to stop and hold a heavily loaded installation car  20 , which may have a weight greater than a service weight of the regular car  14 . 
     The installation car  20  is utilized to install the elevator system  10  components in segments as a building is raised, rather than waiting for installation of the elevator system  10  when the building has achieved its completed height. An exemplary installation method is outlined in  FIG. 4 . Initially, referring to block  100 , the installation car  20  is loaded with components including primary portions  16 , rail  12  segments, electrical cables and/or connectors and other components as needed. In some embodiments, the installation car  20  is loaded with components sufficient to install one floor of rise to the elevator system  10 . In addition to utilizing the installation car  20  for installation and construction of the elevator system  10 , the installation car  20  may similarly be utilized for construction of the building. Building components and materials may be loaded into the installation car  20  and shuttled or transported via the installation car  20  to a construction floor or area where the materials may be unloaded from the installation car  20  and utilized at the construction area. In other embodiments, components for elevator system installation and/or building construction are supplied to the installation car  20  via a second installation car  20  or a supply car travelling along the hoistway  11 . Components are then transferred from the supply car to the installation car  20  for installation. 
     In block  102 , the installation car  20  is moved upward in the hoistway  11  via secondary portion  18  interaction with primary portions  16  previously installed, and is stopped at an installation point such that the installation point is accessible from the upper deck  22 . In block  104 , the rail  12  segments are moved into position and secured to the hoistway  11 , in some embodiments with the use of the overhead crane  26 . Further, in some embodiments, the rail  12  segments may be aligned to previously installed rail  12  segments with the aide of an optical alignment device, or other alignment mechanism. In block  106 , the primary portions  16  are installed to hoistway  11 , in some embodiments with the aid of an optical alignment device, and electrical connections are made to previously installed primary portions  16 , so that the elevator system  10  is then operational to the newly installed floor level. 
     Further, in block  107 , electrical components for operation of the primary portions  16  are installed, such as electrical wiring and controllers or drives for the primary portions. In an exemplary embodiment, a permanent electrical buss segment  50  is installed in the hoistway  11  and secured to previously installed permanent buss segments  50 . In some embodiments, the permanent buss segments  50  are configured to provide power, in some cases, direct current or alternating current. The permanent buss segments  50  are not operational during installation to reduce safety hazards during the installation. To power the primary portions  16  during installation, one or more temporary, light gauge, installation wires  52  are utilized. These installation wires  52  are connected to a power source (not shown), and further connected to installed primary portions  16  via drives  54  to transmit alternating current to the primary portions  16 , in some embodiments. Connection of the installation wires  52  to the primary portions  16  makes the installed primary portions  16  operational. 
     In block  108 , the installation car  20  is moved upward to the next installation point, or alternatively returned downward to a component storage location to be loaded with more components for installation. In block  110 , the installation car  20  is moved upward to the next installation point, and installation of the components is repeated as above. In this way, the installation of the elevator progresses from bottom to top of the hoistway  11 . Once the finished height is reached, the installation car  20  works its way down the hoistway  11 , incrementally disconnecting the installation wires  52  from the primary portions  16  and connecting the permanent buss segments to the primary portions  16 . When the final permanent buss segment  50  is connected to the primary portions  16 , the permanent buss segments  50  are energized. 
     Further, in some embodiments, the installation car  20  allows the hoistway  11  and building to be constructed incrementally. Initially, a first portion of the hoistway  11  and building may be constructed. Then, the installation car  20  is used to convey both elevator system components and hoistway and building materials to a construction zone. A second portion of the building and hoistway  11  are erected and elevator system components are installed therein and activated as described above. Once work at the second portion is accomplished, the installation car  20  may be driven to a third portion where the construction and installation sequence is again performed. This process may then continue until completion of the building. 
     Referring now to  FIG. 5 , as height increases, components may be shuttled to an intermediate staging floor  38 , so that the installation car  20  does not need to travel to a bottom of the hoistway each time more installation materials are to be loaded onto the installation car  20 . This also allows for additional cars  14  to be operated below the staging floor  38  in a normal operating mode, conveying passengers along the elevator system  10 . Physical barriers in the hoistway  11  and/or lockout in controls are utilized to isolate installation car  20  travel from normal car  14  travel. Further, while in the embodiments herein the installation car  20  is described as having two decks, it is to be appreciated that three or more decks may be utilized in other embodiments. Additionally, to prevent water ingress to the hoistway  14  during building construction, a movable cover  40  may be placed above the installation point, and may be movable as installation of the elevator system  10  progresses upward. 
     One of the benefits coming from this solution is safety of personnel working in hoistway  14 . When the installation car  20  reaches the construction zone and is secured (on brakes), the installation car  20  creates a working platform that can be safely accessed from a floor below the construction zone. The upper deck  22  may be surrounded with proper height fence/balustrade for personnel safety. With proper height of this kind of protection, risk of work at height would be significantly reduced for personnel working on upper deck  22  (above the partially finished hoistway). 
     Another benefit of this solution is possibility of creating small fully separated construction zones. When the installation car  20  is placed in the construction zone, working position in the hoistway  14  below and above as well as neighboring hoistways  14  may be protected with nets or barriers. This would prevent injuries caused by falling objects to personnel working on the installation car  20  as well as other to users of the hoistway  14 . This solution allows for safe use of the hoistway  14  below in regular system operation mode while not impacting traffic as the installation car  20  can be self-efficient with its part storage. 
     The installation car  20  eliminates the need for temporary work, such as scaffolding, which will be removed later. The process enables loading of the hoistway  14  material at a lower landing, with no need for cranes or separate service elevators to raise the materials. In addition, the installation car  20  can be used for general construction purposes of moving people or materials, to nearly the highest structurally complete floor of the building, while the building is under construction. Since power wires are brought up the building with the other equipment, the system can be operational well before building power is available at the highest floor for the hoistway  14 . This can improve the installation schedule by several months. 
     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.