Patent Publication Number: US-2017373552-A1

Title: Mounting assembly for elevator linear propulsion system

Description:
FIELD OF THE INVENTION 
     The subject matter disclosed herein relates generally to the field of elevators, and more particularly to a multicar, self-propelled elevator system having a linear propulsion system. 
     BACKGROUND 
     Self-propelled elevator systems, also referred to as ropeless 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 self-propelled 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. At least one transfer station is provided in the hoistway to move cars horizontally between the first lane and second lane. 
     Existing self-propelled elevators employ linear motors having primary portions (e.g., stator coils) secured to a holding structure and embedded in a resin or plastic mold. Existing holding structures require additional measures to achieve stiffness along longitudinal axis of the primary portions. Existing holding structures may also create difficulties during assembly under restrictions of small tolerance. Existing holding structures may also require an outside support structure, which often increases the airgap between the primary portions and secondary portions of the linear motor. 
     BRIEF DESCRIPTION 
     According to one embodiment, an elevator system includes an elevator car to travel in a hoistway; and a linear propulsion system to impart force to the elevator car; the linear propulsion system including: a secondary portion mounted to the elevator car; and a primary portion mounted in the hoistway; the primary portion including: a mounting assembly including: a mounting panel; a plurality of coils mounted to the mounting panel; and a cover secured to the mounting panel, the cover and mounting panel enclosing the coils. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the mounting assembly is modular assembly, a plurality of mounting assemblies forming the primary portion. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the secondary portion includes two secondary portions, the primary portion being positioned between the two secondary portions. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the secondary portion includes two secondary portions, the primary portion includes two primary portions, the two primary portions being positioned between the two secondary portions. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the mounting panel includes a base and a plurality of flanges extending from the base. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the coils are mounted to the base. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the cover extends over the base and the flanges. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the mounting assembly includes a plurality of coil cores, the coil cores interposed between the mounting panel and the cover. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the coils are supported on the coil cores. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the mounting panel and the cover are made from a non-conductive material. 
     According to another embodiment, a mounting assembly for a linear propulsion system including a primary portion and a secondary portion, the mounting assembly comprising: a mounting panel; a plurality of coils mounted to the mounting panel; and a cover secured to the mounting panel, the cover and mounting panel enclosing the coils. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the mounting assembly is modular assembly, a plurality of mounting assemblies forming the primary portion. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the mounting panel includes a base and a plurality of flanges extending from the base. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the coils are mounted to the base. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the cover extends over the base and the flanges. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the mounting assembly includes a plurality of coil cores, the coil cores interposed between the mounting panel and the cover. 
     In addition to one or more of the features described above or below, or as an alternative, further embodiments could include the coils are supported on the coil cores. 
    
    
     
       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  depicts a multicar elevator system in an exemplary embodiment; 
         FIG. 2  depicts components of a drive system in an exemplary embodiment; 
         FIG. 3  is a top down view of a car and portions of a linear propulsion system in an exemplary embodiment; 
         FIG. 4  is a front view of portions of a linear propulsion system in an exemplary embodiment; 
         FIG. 5  is a partially exploded view of a mounting assembly for a stationary portion of a linear propulsion system in an exemplary embodiment; and 
         FIG. 6  is a perspective view of a mounting assembly for a stationary portion of a linear propulsion system in an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  depicts a multicar, self-propelled 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, self-propelled elevator systems 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  15  travel up and cars  14  in lane  17  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 . 
     Cars  14  are propelled using a linear propulsion system having a fixed, primary portion  16  and a moving, secondary portion  18 . The primary portion  16  includes windings or coils mounted at one or both sides of the lanes  13 ,  15  and  17 . Secondary portion  18  includes permanent magnets mounted to one or both sides of cars  14 . Primary portion  16  is supplied with drive signals to control movement of cars  14  in their respective lanes. 
       FIG. 2  depicts components of a drive system in an exemplary embodiment. It is understood that other components (e.g., safeties, brakes, etc.) are not shown in  FIG. 2  for ease of illustration. As shown in  FIG. 2 , one or more power sources  40  are coupled to one or more drives  42  via one or more buses  44 . In the example in  FIG. 2 , the power sources are DC power sources, but embodiments are not limited to using DC power. DC power sources  40  may be implemented using storage devices (e.g., batteries, capacitors). DC power sources  40  may be active devices that condition power from another source (e.g., rectifiers). Drives  42  receive DC power from the DC buses  44  and provide drive signals to primary portions  16  of the linear propulsion system. Each drive  42  may be a converter that converts DC power from DC bus  44  to a multiphase (e.g., 3 phase) drive signal provided to a respective section of the primary portions  16 . The primary portion  16  is divided into a plurality of sections, with each section associated with a respective drive  42 . 
     A controller  46  provides control signals to each of the drives  42  to control generation of the drive signals. Controller  46  may use pulse width modulation (PWM) control signals to control generation of the drive signals by drives  42 . Controller  46  may be implemented using a processor-based device programmed to generate the control signals. Controller  46  may also be part of an elevator control system or elevator management system. Elements of  FIG. 2  may be implemented in a single, integrated module, or be distributed along the hoistway. 
       FIG. 3  is a top down view of a car  14  and portions of the linear propulsion system in an exemplary embodiment. A primary portion  16  of the linear propulsion system is mounted in the hoistway  11 , on one or both sides of a lane. Car  14  mounts the secondary portion  18  of the linear propulsion system, on one or both sides of car  14 . The primary portion  16  is positioned near a single secondary portion  18  or near more than one secondary portion  18  as shown in  FIG. 3 , where primary portion  16  is positioned between two secondary portions  18 . In an exemplary embodiment, primary portion  16  includes a plurality of coils or windings. Secondary portion  18  may include permanent magnets. Drive signals applied to the primary portions  16  generate magnetic flux that imparts force on secondary portions  18  to move or hold car  14 . 
       FIG. 4  is a front view of portions of a linear propulsion system in an exemplary embodiment. As shown in  FIG. 4 , secondary portions  18  (e.g., permanent magnets) are positioned on the outside of the primary portions  16  (e.g., coils). The primary portion  16  includes a plurality of modular mounting assemblies  50  ( FIG. 5 ). As described in further detail herein, the primary portion  16  includes coils  51  secured in a mounting assembly  50  ( FIG. 5 ). Two mounting assemblies  50  are arranged so that the coils  51  are adjacent to each other and positioned between two secondary portions  18 . 
       FIG. 5  is a partially exploded view of a mounting assembly  50  for the primary portion  16  of the linear propulsion system in an exemplary embodiment. The mounting assembly  50  includes a mounting panel  52  that supports coils  51 . Mounting panel  52  may be made from a non-conductive material, such as fiberglass or plastic. Mounting panel  52  includes a generally rectangular base  54  having a plurality of mounting holes  56  formed therein. Coil cores  58  are secured at the mounting holes  56  via fasteners. Coil cores  58  may be made from a non-conductive material, such as fiberglass or plastic. Coils  51  are supported on the coil cores  58 . 
     Extending from base  54  are one or more optional flanges  60 . Flanges  60  lie in the same plane as base  54 . Flanges  60  include mounting holes  56  and spacers  59  may be secured at outer edges of the flanges  60  using fasteners. Flanges  60  provide a conduit to accommodate wiring to coils  51 . Flanges  60  also improve rigidity of the mounting assembly  50 . 
       FIG. 6  is a perspective view of an assembled mounting assembly  50  in an exemplary embodiment. A cover  70  is placed over the coils  51  and secured to coil cores  58  and spacers  59  with fasteners. Cover  70  may be made from a non-conductive material, such as fiberglass or plastic. Cover  70  extends over the base  54  and flanges  60 . The mounting assembly  50  rigidly encloses the coils  51  in an enclosure including the base  54 , cover  70 , coil cores  58  and spacers  59 . 
     As shown in  FIG. 5 , the mounting assembly  50  is a modular unit including a subset of the total number of coils  51  used in the primary portion  16  of the linear propulsion system. The coils  51  of each mounting assembly  50  may be driven by a single, respective drive  42 . In other embodiments, a drive  42  may provide drive signals to coils  51  in multiple mounting assemblies  50 . The modular nature of the mounting assembly  50  facilitates installation of the primary portions  16  along the length of the hoistway  11 . Installers need only to handle the modular mounting assemblies  50 , which are less cumbersome than existing designs. 
     Placing the coils  51  between base  54  and cover  70  is a compact design, and reduces the physical size of the primary portion  16  compared to existing designs. Therefore, the distance between coils  51  may be decreased, the electromagnetic airgap between surfaces of primary portions  16  and secondary portions  18  may be increased and/or the linear propulsion system dimensions may be reduced while the airgap remains constant. The improved stiffness of the mounting assembly  50  allows for easier maintaining of the airgap. Assembly costs may also be reduced, as the mounting assembly may be formed with lower precision machines. Base  54 , cover  70 , coil cores  58  and spacers  59  may be molded or cast in high quantity using a lower amount of materials. The modular nature of the mounting assembly  50  provides repeatable, structural features. 
     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.