Patent Publication Number: US-9884744-B2

Title: Ropeless high-rise elevator installation approach

Description:
FIELD OF DISCLOSURE 
     The present disclosure relates generally to elevators and, more particularly, to self-propelled elevator systems. 
     BACKGROUND OF THE DISCLOSURE 
     Self-propelled elevator systems, including ropeless elevator systems, are useful in certain applications, such as, high rise buildings, where the mass of the ropes for a conventional roped elevator system is prohibitive and it is beneficial to have multiple elevator cars in a single shaft. In self-propelled elevator systems, a first hoistway may be designated for upward travel of the elevator cars, and a second hoistway may be designated for downward travel of the elevator cars. In addition, transfer stations may be used to move the elevator cars horizontally between the first and second hoistways. 
     SUMMARY OF THE DISCLOSURE 
     An exemplary embodiment of the present invention is directed to a method for constructing a building with an elevator system. The method may include forming a first hoistway for the elevator system within two adjacent levels of the building, installing a first stationary part of a first linear permanent magnet motor within the first hoistway, placing a first elevator car within the first hoistway, mounting a first moving part of the first linear permanent magnet motor on the first elevator car, and using the first stationary part and the first moving part of the first linear permanent magnet motor to generate a vertical thrust force to move the first elevator car within the first hoistway. The first elevator car may carry at least one of passengers, equipment and materials for construction of upper levels of the elevator system and the building. 
     Another exemplary embodiment of the present invention is directed to a ropeless elevator system. The exemplary ropeless elevator system may comprise a first elevator hoistway, a second elevator hoistway, a plurality of elevator cars configured to travel in at least one of the first and second elevator hoistways, and an elevator propulsion system. The elevator propulsion system may comprise at least one first stationary portion positioned in the first elevator hoistway, at least one second stationary portion positioned in the second elevator hoistway, and a plurality of moving portions. The plurality of moving portions may be selectively operatively connected to the plurality of elevator cars. The plurality of moving portions selectively operatively connected to the plurality of elevator cars may interact with at least one of the first and second stationary portions to provide a motive force to move the plurality of elevator cars within at least one of the first and second elevator hoistways. At least two of the plurality of elevator cars may be operatively connected to each other such that the moving portions selectively operatively connected to the at least two of the plurality of elevator cars are provided a combined motive force by the moving portions selectively operatively connected thereto. 
     Another exemplary embodiment of the present disclosure is directed to a method for operating a ropeless elevator system. The ropeless elevator system may include a first hoistway, a second hoistway, an upper transfer station positioned above the first and second hoistways, and a lower transfer station positioned below the first and second hoistways. The method may comprise circulating a plurality of elevator cars in a loop around the first hoistway, the upper transfer station, the second hoistway, and the lower transfer station; stopping circulation of the plurality of elevator cars in the loop; coupling two elevator cars together; and moving the coupled elevator cars upwards or downwards within the first and second hoistways. 
     Although various features are disclosed in relation to specific exemplary embodiments, it is understood that the various features may be combined with each other, or used alone, with any of the various exemplary embodiments without departing from the scope of the disclosure. For example, the carrying at least one of passengers, equipment and materials for construction of upper levels of the elevator system and the building may be performed prior to completion of the elevator system. The method may further comprise forming a second hoistway for the elevator system next to the first hoistway; installing a second stationary part of a second linear permanent magnet motor within the second hoistway; placing a second elevator car within the second hoistway; mounting a second moving part of the second linear permanent magnet motor on the second elevator car; and coupling the first and second elevator cars together such that they share an interior compartment. 
     In another example, the method may further comprise installing an oversized elevator car in the first and second hoistways, and utilizing the first and second linear permanent magnet motors to provide a thrust force to move the oversized elevator car vertically within the first and second hoistways. An extended moving part of the linear permanent magnet motor may be incorporated to generate a greater thrust force. The method may further comprise utilizing a plurality of elevator cars within the first hoistway. In another example, the method may further comprise installing at least one additional elevator car in the first hoistway, and operatively coupling the at least one additional elevator car to the first elevator car. The method may further comprise utilizing a top or bottom surface of the first elevator car to transport loads within the first hoistway. The method may further comprise mounting an extended platform on top of the first elevator car. 
     In another example, the moving portions selectively operatively connected to the at least two of the plurality of elevator cars operatively connected to each other may be synchronized with each other in order to move the elevator cars at a same speed and direction. The ropeless elevator system may further comprise an oversized elevator car that is larger than the first elevator car or the second elevator car, and the elevator propulsion system may include moving portions selectively operatively connected to the oversized elevator car. The interaction of the moving portions selectively operatively connected to the oversized elevator car and the stationary portions positioned in the first and second hoistways may generate a thrust force to move the oversized elevator car in a vertical direction within the first and second hoistways may generate a thrust force to move the oversized elevator car in a vertical direction within the first and second hoistways. 
     In another example, the ropeless elevator system may further comprise an upper transfer station positioned at or above a top level of the first and second hoistways, and a lower transfer station positioned at or below a bottom level of the first and second hoistways. The plurality of elevator cars may operate in a loop within the first hoistway, the upper transfer station, the second hoistway, and the lower transfer station when the plurality of elevator cars are not connected to each other. The elevator cars may operate bi-directionally within the first and second hoistways when the at least two of the plurality of elevator cars are operatively connected to each other. 
     In other examples, the method may further comprise synchronizing motors of the coupled elevator cars together such that the coupled elevator cars move at a same speed and direction. The method may further comprise carrying loads on top of or beneath the elevator cars. The method may further comprise hanging a load from a bottom surface of one of the plurality of elevator cars. The method may further comprise inserting a cargo car within the first and second hoistways, the cargo car having a size that is greater than a size of one elevator car, and moving the cargo car upwards or downwards within the first and second hoistways. 
     These and other aspects and features will become more readily apparent upon reading the following detailed description when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts an elevator system according to an exemplary embodiment; 
         FIG. 2  is a top down view of an elevator car in a hoistway in an exemplary embodiment; 
         FIG. 3  is a top down view of a moving portion of a propulsion system in an exemplary embodiment; 
         FIG. 4  is a top down view of a stationary portion and a moving portion of a propulsion system in an exemplary embodiment; 
         FIG. 5  is a perspective view of an elevator car and a propulsion system in an exemplary embodiment; 
         FIG. 6  is a top down view of two elevator cars in two hoistways in an exemplary embodiment; 
         FIG. 7  is a schematic representation of a partially constructed building with two levels of an elevator system installed in an exemplary embodiment; 
         FIG. 8  is a schematic representation of a partially constructed building with three levels of an elevator system installed in an exemplary embodiment; 
         FIG. 9  is a schematic representation of a building with an elevator system after final construction in an exemplary embodiment; 
         FIG. 10  is a schematic representation of an elevator system in which elevator cars circulate in a loop in an exemplary embodiment; 
         FIG. 11  is a schematic representation of an elevator system in which elevator cars move bi-directionally in an exemplary embodiment; 
         FIG. 12  is a top down view of two elevator cars coupled together in two hoistways in an exemplary embodiment; 
         FIG. 13  a top down view of a cargo car in two hoistways in an exemplary embodiment; 
         FIG. 14  is a perspective view of the cargo car of  FIG. 13 ; 
         FIG. 15  is a flowchart illustrating an exemplary process for constructing a building with an elevator system in an exemplary embodiment; and 
         FIG. 16  is a flowchart illustrating an exemplary process for operating a ropeless elevator system in an exemplary embodiment. 
     
    
    
     While the present disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments thereof will be shown and described below in detail. The invention is not limited to the specific embodiments disclosed, but instead includes all modifications, alternative constructions, and equivalents thereof 
     DETAILED DESCRIPTION 
       FIG. 1  depicts an elevator system  20  in an exemplary embodiment. This elevator system  20  is shown for illustrative purposes to assist in disclosing various embodiments of the invention. As is understood by a person skilled in the art,  FIG. 1  does not depict all of the components of an exemplary elevator system, nor are the depicted features necessarily included in all elevator systems. 
     As shown in  FIG. 1 , the elevator system  20  includes a first hoistway  22  in which a plurality of elevator cars  24  travel upward and a second hoistway  26  in which the plurality of elevator cars  24  travel downward. Elevator system  20  transports elevator cars  24  from a first floor  28  to a top floor  30  in first hoistway  22 , and transports elevator cars  24  from the top floor  30  to the first floor  28  in second hoistway  26 . Although not shown, elevator cars  24  may also stop at intermediate floors  32  to allow ingress to and egress from an elevator car intermediate the first floor  28  and top floor  30 . 
     Positioned across the first and second hoistways  22 ,  26  above the top floor  30  is an upper transfer station  34 . Upper transfer station  34  imparts horizontal motion to elevator cars  24  to move the elevator cars  24  from the first hoistway  22  to the second hoistway  26 . It is understood that upper transfer station  34  may be located at the top floor  30 , rather than above the top floor  30 . Positioned across the first and second hoistways  22 ,  26  below the first floor  28  is a lower transfer station  36 . Lower transfer station  36  imparts horizontal motion to elevator cars  24  to move the elevator cars  24  from the second hoistway  26  to the first hoistway  22 . It is to be understood that lower transfer station  36  may be located at the first floor  28 , rather than below the first floor  28 . 
     Together, the first hoistway  22 , the upper transfer station  34 , the second hoistway  26 , and the lower transfer station  36  comprise a loop  38  in which the plurality of cars  24  circulate to the plurality of floors  28 ,  30 ,  32  and stop to allow the ingress and egress of passengers to the plurality of floors  28 ,  30 ,  32 . 
     Turning now to  FIGS. 2-5 , with continued reference to  FIG. 1 , elevator system  20  includes a propulsion system  50  disposed on the elevator cars  24 , in the hoistways  22 ,  26 , and in the transfer stations  34 ,  36 ,  42 . The propulsion system  50  imparts vertical motion to elevator cars  24  to propel the elevator cars from one level to the next within the hoistways  22 ,  26  and into and out of the transfer stations  34 ,  36 ,  42 . Different types of motors can be used for the propulsion system  50 , such as, but not limited to, a linear permanent magnet motor, a flux switching motor, an induction motor, a friction motor, or the like. The propulsion system  50  may comprise a moving part  52  mounted on each elevator car  24  and a stationary part  54  mounted to a structural member  56  positioned within the hoistways  22 ,  26  and transfer stations  34 ,  36 ,  42 . The interaction of the moving part  52  and the stationary part  54  generates a thrust force to move the elevator cars  24  in a vertical direction within the hoistways  22 ,  26  and transfer stations  34 ,  36 ,  42 . 
     In an example, the moving part  52  includes permanent magnets  58 , and the stationary part  54  includes windings  60 ,  62  mounted on structural member  56 . Permanent magnets  58  may be attached to a support element  64  of the moving part  52 , with the support element  64  coupled to the elevator car  24 . Structural member  56  may be made of a ferromagnetic material and coupled to a wall of the first and/or second hoistways  22 ,  26  by support brackets  66 . Windings  60 ,  62  may be formed about structural member  56 . Windings  60  provide the stationary part of the propulsion system within the first hoistway  22 , and windings  62  provide the stationary part of the propulsion system within the second hoistway  26 . A support element  64  of the moving part  52  may be positioned about windings  60 ,  62  such that the windings  60 ,  62  and permanent magnets  58  are adjacent. 
     Windings  60  in the first hoistway  22  are energized by a power source (not shown) to propel one or more elevator cars  24  upward in the first hoistway  22  and transfer stations  34 ,  36 ,  42 . When a voltage is applied to windings  60 , the interaction between the windings  60  and permanent magnets  58  impart motion to the elevator car  24 . Windings  62  in the second hoistway  26  operate as a regenerative brake to control descent of the elevator car  24  in the second hoistway  26  and transfer stations  34 ,  36 ,  42 . Windings  62  also provide a current back to the drive unit, for example, to recharge an electrical system. 
     Other configurations and locations for the propulsion system  50  may be used. For example, as shown in  FIG. 6 , the elevator system  20  has four stationary parts  54 , two for each of the first and second hoistways  22 ,  26 . The stationary parts  54  are positioned in each hoistway at two opposite sidewalls of each hoistway  22 ,  26 . Elevator cars  24  include at least one moving part of the propulsion system for each stationary part of the propulsion system, as described above. Other configurations and locations for the propulsions system may be used. 
     In another exemplary embodiment, the elevator system  20  can be used during construction at an early stage of installation.  FIG. 7  depicts a partially constructed building  80  having two levels  82 ,  84  of an elevator system  86  installed. With at least two adjacent levels  82 ,  84  of the elevator system  86  installed, construction workers can start using the elevator system  86  to build upper levels of both the elevator system  86  and the building  80 . Once the stationary part of the propulsion system is installed in the hoistway, and the moving part of the propulsion system is mounted to the elevator car, the elevator system  84  is functional and ready to be used. For example, workers, equipment, and materials for construction of the upper levels of the elevator system  86  and building  80  may be carried from the first level  82  to the second level  84  within the elevator cars  88  using the partially installed elevator system  86 . 
     As shown best in  FIG. 8 , after the construction equipment and materials are loaded on the second level  84 , workers can use them to build a third level  90  of the elevator system  86 , as well as other parts of the building  80 . After the third level  90  of the elevator system  86  is built, more materials, equipment, and workers for construction of the upper levels of the elevator system  86  and building  80  may be carried from the first level  82  or second level  84  to the third level  90  within the elevator cars  88  using the partially installed elevator system  86 . After each successive level of the elevator system  86  is built, it can be immediately used to construct the next level of the elevator system and/or building. The partially completed elevator system  86  can be used for installation of all the upper levels of the elevator system and building. 
     In addition, as shown best in  FIG. 9 , when construction of the entire elevator system  20  and building  92  is finished, minimal labor is needed to convert the elevator system  20  from construction utilization to the expected passenger utilization. For example, the elevator cars  88  may be cleaned and refurbished, or replaced with new, polished ones, and the structure and stationary part within the hoistways of the elevator system  20  remain the same as that used during construction. The moving part may also be re-used, either staying on the elevator cars  88  that remain in the elevator system  20 , or taken off the elevator cars  88  and mounted on new elevator cars for use in the elevator system  20 . Thus, the moving part, stationary part and hoistway are part of a final construction of the elevator system  20  of the building  92 , with the elevator system used during construction being permanent, not temporary. The term “final construction of the elevator system,” as used herein, is defined as the complete, fully-installed elevator system in the building. 
     In order to build an elevator system  20  where the elevator cars  24  circulate in a loop  38  to the plurality of floors, as described above and shown schematically in  FIG. 10 , at least two hoistways  22 ,  26  are installed in the building. As shown schematically in  FIG. 11 , during construction with partial installation of the elevator system  86 , the elevator cars  24  can operate bi-directionally, represented by arrows  94 . For example, a control system or control units of the elevator cars  24  may be programmed to move the elevator cars  24  in both the upward and downward directions within each of the hoistways  96 ,  98 . More than one elevator car  24  may be used within each hoistway  96 ,  98  to allow construction workers to work on different levels of the partially constructed building, having multiple elevator cars at their convenience. After final construction of the elevator, the control system can then be programmed to operate the elevator cars  24  in a loop within the hoistways  96 ,  98 . 
     In order to increase a size of the load carried by the elevator cars, two or more elevator cars can be coupled together within one or more hoistways. For example, referring now to  FIG. 12 , with continued reference to  FIGS. 1-11 , therein is illustrated an elevator system  100  in another exemplary embodiment. The elevator system  100  includes a first elevator car  102  positioned within the first hoistway  22  and a second elevator car  104  positioned within the second hoistway  26 . The elevator system  100  further includes moving parts  52  of the propulsion system  50  mounted on the elevator cars  102 ,  104  and stationary parts  54  of the propulsion system disposed in the hoistways  22 ,  26 . The first elevator car  102  includes a first interior compartment  106 , and the second elevator car includes a second interior compartment  108 . 
     Each of the first and second elevator cars  102 ,  104  also includes intervening walls  110 , which are adjustable. As used herein, the term “intervening walls” is defined as the walls that lie between the first elevator car  102  and the second elevator car  104 . The intervening walls  110  can be adjusted or removed in order to allow a coupling of the first and second elevator cars  102 ,  104  together and a joining of the first and second interior compartment  106 ,  108 . This results in a larger interior compartment  109 , which may be used to lift and carry greater loads, such as, larger equipment (e.g., forklifts and cement mixers), larger materials (e.g., dry wall, transformers, and air conditioning units), and an increased number of construction workers. 
     When coupled together, the first and second elevator cars  102 ,  104  have a joined interior compartment  109  that is greater than (e.g. double) the size of each of the first and second interior compartments  106 ,  108 . This may be beneficial when using the elevator system during construction, and also, after final construction of the elevator system, to carry greater loads, such as, large-sized objects that do not fit inside each of the first and second interior compartments  106 ,  108 . The moving parts  52  and stationary parts  54  on the first and second elevator cars  102 ,  104  are synchronized with each other in order to move the first and second elevator cars  102 ,  104  at a same speed and direction within the hoistways  22 ,  26 . The control system and control units may then operate the coupled elevator cars  102 ,  104  bi-directionally (upwards and downwards) within the first and second hoistways  22 ,  26 . It is to be understood that the elevator cars may be coupled in other configurations than that shown and described in  FIG. 12 . For example, two elevator cars in the first hoistway  22  may be coupled with two elevator cars in the second hoistway  26 , three elevator cars in one hoistway may be coupled together, three elevator cars in three separate hoistways may be coupled together, etc. 
     As shown in  FIGS. 13 and 14 , elevator system  100  may have a cargo car  120  positioned within the first and second hoistways  22 ,  26 . The cargo car  120  may be oversized, or larger than each of the first and second elevator cars  102 ,  104 , spanning across both the first and second hoistways  22 ,  26 . For example, the cargo car  120  may be double the size of each of the first and second elevator cars  102 ,  104  and may have an interior compartment  122  which is double the size of each of the first and second interior compartments  106 ,  108 . Additionally, the cargo car  120  or elevator car  24  may be designed to carry a greater load, such as, by having a lighter construction or decreasing a weight of the cargo car  120  or elevator car  24 . 
     Moving parts  52 , mounted on the cargo car  120 , interact with the stationary parts  54  disposed in the first and second hoistways  22 ,  26  to generate a thrust force to move the cargo car  120  in a vertical direction within the hoistways  22 ,  26 . The control system and control unit may operate the cargo car  120  such that it moves bi-directionally (upwards and downwards) within the first and second hoistways  22 ,  26 . In order to use the cargo car  120 , other elevator cars may have to be removed from the first and second hoistways  22 ,  26 . The cargo car may carry people and large-sized objects, which do not fit inside each of the first and second interior compartments  106 ,  108  during construction and after final construction. 
     According to another embodiment, loads may be carried through the hoistways to different floors of the building on top of, beneath, or outside the elevator cars  24  or cargo car  120 , such as on a top or bottom surface of the elevator cars  24  or cargo car  120 . Loading cargo, materials, equipment, and other large-sized objects on top of or beneath the elevator cars may be beneficial if it does not fit inside the elevator cars. For example, an extended platform may be mounted on top of an elevator car  24 , coupled elevator cars  102 ,  104 , or cargo car  120 , or a roof of the elevator may be extended, in order to place large-sized objects on top of the elevator car. In another example, objects may hang below the elevator cars  24 ,  102 ,  104 ,  120 , such as, via a hook, ropes, or harnesses attached to a bottom surface of the elevator cars. 
     In order to generate a greater thrust force to support an increased weight load within elevator cars  24 , coupled elevator cars  102 ,  104 , or cargo car  120 , the propulsion system  50  of the elevator system  20  may be extended. The moving part  52 , which may include permanent magnets or windings, may be increased. For example, a moving part with an extended length, depth, and/or thickness may be mounted on the elevator cars  24 ,  102 ,  104 ,  120 . In another embodiment, two or more elevator cars may be connected (with or without joining interior compartments) to combine motor power and generate a greater thrust force. For example, a first elevator car may be connected above or below a second elevator car with a heavy load, to help pull or push the second elevator car through the hoistway. The two elevator cars may be connected via a mechanical connection, electromagnetic connection, or the like. The capacity to carry increased weight loads within the hoistways  22 ,  26  is beneficial during construction of the elevator system and building, as well as after final construction. 
     The flowchart of  FIG. 15  illustrates an exemplary process  160  for constructing a building  92  with an elevator system  20 . At block  162 , a hoistway  22 ,  26  for the elevator system  20  is installed within two adjacent levels  82 ,  84  of the building  92 . A stationary part  54  of a linear permanent magnet motor is installed within the hoistway  22 ,  26  at block  164 . An elevator car  24  is placed within the hoistway  22 ,  26  at block  166 . At block  168 , a moving part  52  of the linear permanent magnet motor is mounted on the elevator car  24 . At block  170 , the stationary and moving parts  52 ,  54  of the linear permanent magnet motor are used to generate a vertical thrust force to move the elevator car  24  within the hoistway  22 ,  26 , with the elevator car  24  carrying passengers, equipment, and/or materials for construction of upper levels of the elevator system  20  and building  92 . 
     The flowchart of  FIG. 16  illustrates another exemplary process  180  for operating a ropeless elevator system  100 , the ropeless elevator system  100  including a first hoistway  22 , a second hoistway  26 , an upper transfer station  34  positioned above the first and second hoistways  22 ,  26 , and a lower transfer station  36  positioned below the first and second hoistways  22 ,  26 . At block  182 , a plurality of elevator cars are circulated in a loop around the first hoistway  22 , the upper transfer station  34 , the second hoistway  26 , and the lower transfer station  36 . The circulation of the elevator cars in the loop is stopped at block  184 . Two elevator cars  102 ,  104  are coupled together at block  186 . At block  188 , the coupled elevator cars are moved upwards or downwards within the first and second hoistways  22 ,  26 . 
     It is to be understood that the blocks in the flowcharts illustrated in  FIGS. 15 and 16  may be performed in a different order than that shown. For example, in reference to the exemplary process  160  of  FIG. 15 , the order of block  166  and block  168  may be switched. A moving part  52  of the propulsion system  50  may be mounted on the elevator car  24  before the elevator car  24  is placed within the hoistway  22 ,  26 . 
     By using the elevator systems and methods disclosed herein, immense time and cost savings are achieved when constructing an elevator system and a building containing the elevator system. The disclosed elevator system can be used upon installation of two levels within a partially constructed building to carry passengers and cargo. An elevator motor does not need to be installed at a top of the building. As a result, construction workers do not have to wait until the entire elevator system is finally constructed in order to use the elevator system. The disclosed elevator system facilitates the quick construction of its own system as well as the building, carrying equipment and materials to upper levels without requiring the use of a crane. The coupled elevator cars, cargo car, and extended propulsion systems of the disclosed elevator system create a larger capacity elevator for lifting larger and heavier loads. Furthermore, the moving part, stationary part, and hoistways installed for construction use in the building may be the permanent structures of a final construction of the elevator system. 
     While the foregoing detailed description has been given and provided with respect to certain specific embodiments, it is to be understood that the scope of the disclosure should not be limited to such embodiments, but that the same are provided simply for enablement and best mode purposes. The breadth and spirit of the present disclosure is broader than the embodiments specifically disclosed and encompassed within the claims appended hereto. 
     While some features are described in conjunction with certain specific embodiments of the invention, these features are not limited to use with only the embodiment with which they are described, but instead may be used together with or separate from, other features disclosed in conjunction with alternate embodiments of the invention.