Patent Description:
Conveyance systems, such as, for example, elevator systems, escalator systems, and moving walkways may require periodic monitoring to perform diagnostics. <CIT> discloses a hybrid load monitoring system and method which includes one or more direct or physical sensor measurements in addition to a plurality of virtual sensors.

According to an aspect of the present invention, a method of monitoring a conveyance apparatus within a conveyance system as defined by claim <NUM> is provided.

Further embodiments of the method may include that prior to the detecting the vibratory signature at the primary location during the commissioning phase using the primary sensing apparatus located at the primary location, the method further includes: moving the conveyance apparatus for the commissioning phase.

Further embodiments of the method may include that prior to the detecting the vibratory signature at the primary location during the normal operation phase using the primary sensing apparatus located at the primary location, the method further includes: moving the conveyance apparatus for the normal operation phase.

Further embodiments of the method may include: determining an abnormality in response to the vibratory signature at the secondary location during the normal operation phase without the presence of the secondary sensor.

Further embodiments of the method may include that the primary location is located on the conveyance apparatus.

Further embodiments of the method may include that the secondary location is located on the conveyance apparatus.

Further embodiments of the method may include that the secondary sensing apparatus is removed from the conveyance system prior to the detecting a vibratory signature at the primary location during a normal operation phase using the primary sensing apparatus located at the primary location; and converting the vibratory signature at the primary location during the normal operation phase to a vibratory signature at the secondary location during the normal operation phase using the transfer algorithm.

Further embodiments of the method may include: tracking component degradation level in response to the vibratory signature at the secondary location during the normal operation phase without the secondary sensing apparatus.

According to another aspect of the present invention , a sensor system for monitoring a conveyance apparatus of a conveyance system as defined by claim <NUM> is provided.

Further embodiments of the sensor system may include that the operations further include: determining an abnormality in response to the vibratory signature at the secondary location during the normal operation phase.

Further embodiments of the sensor system may include that the primary location is located on the conveyance apparatus.

Further embodiments of the sensor system may include that the secondary location is located on the conveyance apparatus.

Further embodiments of the sensor system may include that the secondary sensing apparatus is removed from the conveyance system prior to the detecting a vibratory signature at the primary location during a normal operation phase using the primary sensing apparatus located at the primary location; and converting the vibratory signature at the primary location during the normal operation phase to a vibratory signature at the secondary location during the normal operation phase using the transfer algorithm.

Further embodiments of the sensor system may include that operations further include: tracking component degradation level in response to the vibratory signature at the secondary location during the normal operation phase without the secondary sensing apparatus.

According to another example, a computer program product tangibly embodied on a computer readable medium is disclosed herein.

Further embodiments of the computer program product may include that prior to the detecting the vibratory signature at the primary location during the commissioning phase using the primary sensing apparatus located at the primary location, the operations further includes: moving the conveyance apparatus for the commissioning phase.

Technical effects of embodiments of the present disclosure include using determining a transfer algorithm between vibratory signatures in a primary location and a secondary location and then using the transfer algorithm to determine vibratory signature at the secondary location using vibratory signature at the primary location.

<FIG> is a view of a sensor system <NUM> including a primary sensing apparatus <NUM> located at a primary location and one or more secondary sensing apparatus <NUM> each located at secondary locations, according to an embodiment of the present disclosure. The primary sensing apparatus <NUM> is configured to determine sensor data <NUM> and transmit the sensor data <NUM> to a monitoring system <NUM>. The sensor data <NUM> includes primary sensor data 202a and secondary sensor data 202b. The primary sensing apparatus <NUM> is configured to detect primary sensor data 202a of the elevator car <NUM> and determine secondary sensor data 202b, discussed further below. Primary sensor data 202a and secondary sensing data 202b may include but is not limited to vibratory signatures <NUM> (i.e., vibrations over a period of time) or accelerations and derivatives or integrals of accelerations of the elevator car <NUM>, such as, for example, distance, velocity, jerk, jounce, snap. etc. The primary sensing data 202a may also include light, pressure, sound, humidity, and temperature, or any other desired data parameter. In an embodiment, the primary sensing apparatus <NUM> is configured to transmit sensor data <NUM> that is raw and unprocessed to the monitoring system <NUM> for processing. In an embodiment, the primary sensing apparatus <NUM> is configured to process the sensor data <NUM> prior to transmitting the sensor data <NUM> to the monitoring system <NUM>. The processing of the sensor data <NUM> may reveal data, such as, for example, a number of elevator door openings/closings, elevator door time, vibrations, vibratory signatures, a number of elevator rides, elevator ride performance, elevator flight time, relative and absolute car position (e.g. elevation, floor number), releveling events, rollbacks, elevator car <NUM> x, y acceleration at a position: (i.e., rail topology), elevator car <NUM> x, y vibratory signatures at a position: (i.e., rail topology), door performance at a landing number, nudging event, vandalism events, emergency stops, etc. Although illustrated as separate devices, the monitoring system <NUM> and the primary sensing apparatus <NUM> may be a single device in a non-limiting embodiment. The monitoring system <NUM> may be a computing device, such as, for example, a desktop or cloud computer. The monitoring system <NUM> may also be a mobile computing device that is typically carried by a person, such as, for example a smartphone, PDA, smartwatch, tablet, laptop, etc. The monitoring system <NUM> may also be two separate devices that are synced together, such as, for example, a cellular phone and a desktop computer synced over an internet connection. The monitoring system <NUM> may also be a cloud computing network.

The monitoring system <NUM> may be local relative to the primary sensing apparatus <NUM> or remote relative to the primary sensing apparatus <NUM>. The primary sensing apparatus <NUM> is configured to transmit the sensor data <NUM> to the monitoring system <NUM> via short-range wireless protocols <NUM> and/or long-range wireless protocols <NUM>. Short-range wireless protocols <NUM> may include but are not limited to Bluetooth, Wi-Fi, HaLow (<NUM>. 11ah), zWave, Zigbee, or Wireless M-Bus. In one embodiment, using short-range wireless protocols <NUM>, the primary sensing apparatus <NUM> is configured to transmit the sensor data <NUM> to a local gateway device <NUM> and the local gateway device <NUM> is configured to transmit the sensor data <NUM> to a monitoring system <NUM> through a network <NUM>. The network <NUM> may be a computing network, such as, for example, a cloud computing network, cellular network, or any other computing network known to one of skill in the art. Using long-range wireless protocols <NUM>, the primary sensing apparatus <NUM> is configured to transmit the sensor data <NUM> to a monitoring system <NUM> through a network <NUM>. Long-range wireless protocols <NUM> may include but are not limited to cellular, satellite, LTE (NB-IoT, CAT M1), LoRa, Satellite, Ingenu, or SigFox.

<FIG> also shows a possible primary locations (i.e., installation locations) of the primary sensing apparatus <NUM> within the elevator system <NUM>. The primary sensing apparatus <NUM> may be hard and/or wirelessly connect to the controller <NUM> of the elevator system <NUM>. In an embodiment, the primary sensing apparatus <NUM> may be attached to a door header 104e of a door <NUM> of the elevator car <NUM>. Advantageously, by attaching the primary sensing apparatus <NUM> to the door header 104e of the elevator car <NUM> the primary sensing apparatus <NUM> may detect accelerations of the elevator car <NUM> and while being relatively isolated from vibrations from the doors <NUM> of the elevator car <NUM> when the doors <NUM> are not opening or closing. For example, when located on the door <NUM>, the primary sensing apparatus <NUM> may detect when the elevator car <NUM> is in motion, when the elevator car <NUM> is slowing, when the elevator car <NUM> is stopping, and when the doors <NUM> open to allow passengers to exit and enter the elevator car <NUM> because when the doors <NUM> open and close the vibrations will be transferred to the header 104e. It is understood that the primary sensing apparatus <NUM> may also be installed in other locations other than the header 104e of the elevator system <NUM>. In another embodiment, the primary sensing apparatus <NUM> is installed on a door <NUM> structure of the elevator car <NUM>. In another embodiment, the primary sensing apparatus <NUM> is installed elsewhere on the elevator car <NUM>. In one embodiment, separate door state sensors may be used. These door state sensors may be mounted on the landing door or car door. In one embodiment, the door state sensor may be an accelerometer, magnetic switch, read switch, proximity sensors, trigger switch, or any other desired known sensing device.

The primary sensing apparatus <NUM> may be configured to detect primary sensor data 202a including acceleration in any number of directions. In an embodiment, the primary sensing apparatus <NUM> may detect primary sensor data 202a including accelerations along any number or combination of three axis, an X axis, a Y axis, and a Z axis, as show in in <FIG>. The X axis may be perpendicular to the doors <NUM> of the elevator car <NUM>, as shown in <FIG>. The Y axis may be parallel to the doors <NUM> of the elevator car <NUM>, as shown in <FIG>. The Z axis may be aligned vertically parallel with the elevator shaft <NUM> and pull of gravity, as shown in <FIG>. Vibratory signatures may be generated along the X-axis and the Y-axis as the elevator car <NUM> moves along the Z-axis.

The primary sensing apparatus <NUM> may be installed on the elevator system <NUM> during a commissioning phase and normal operation of the elevator system <NUM> in a primary location that is known, whereas the one or more secondary sensing apparatus <NUM> may only be installed on the elevator system <NUM> during the commissioning phase of the elevator system <NUM> in one or more secondary locations that are known. The secondary sensing apparatus <NUM> are low cost physical sensors in comparison to the primary sensing apparatus. The Secondary sensing apparatus <NUM> may sense different modalities of data as well (e.g., not just three-axis accelerometer signals but also light, sound, etc.). In embodiment, the second sensing apparatus <NUM> may be a three-axis accelerometer configured. In an embodiment, the secondary sensing apparatus <NUM> may detect secondary sensor data 202b include vibratory signatures <NUM> along one or more axis. The one or more axis may include three axis, such as, for example, the X axis, the Y axis, and the Z axis, as show in in <FIG>. The secondary sensing apparatus <NUM> may then transmit the secondary sensor data 202b to the primary sensing apparatus <NUM>. The primary sensing apparatus <NUM> may translate the secondary sensor data 202b into the primary sensor data 202a or the primary sensing apparatus <NUM> may transmit the secondary sensor data 202b to the monitoring system <NUM> and then the monitoring system <NUM> may translate the secondary sensor data 202b into the primary sensor data 202a. The secondary sensing apparatus <NUM> may utilize short range wireless signals <NUM> to communicate with the primary sensing apparatus <NUM> including but not limited to a magnetic field, RFID, Bluetooth, Wi-Fi, HaLow (<NUM>. 11ah), zWave, Zigbee, or Wireless M-Bus.

<FIG> is an enlarged view of multiple possible primary locations of the primary sensing apparatus <NUM> along the door header 104e. As shown in <FIG>, the primary sensing apparatus <NUM> may be located on a door header 104e proximate a top portion 104f of the elevator car <NUM>. The doors <NUM> are operably connected to the door header 104e through a door hanger 104a located proximate a top portion 104b of the door <NUM>. The door hanger 104a includes guide wheels 104c that allow the door <NUM> to slide open and close along a guide rail 104d on the door header 104e.

Advantageously, the door header 104e is an easy to access area to attach the primary sensing apparatus <NUM> because the door header 104e is accessible when the elevator car <NUM> is at landing <NUM> and the elevator door <NUM> is open. Thus, installation of the primary sensing apparatus <NUM> is possible without taking special measures to take control over the elevator car <NUM>. For example, the additional safety of an emergency door stop to hold the elevator door <NUM> open is not necessary as door <NUM> opening at landing <NUM> is a normal operation mode. The door header 104e also provides ample clearance for the primary sensing apparatus <NUM> during operation of the elevator car <NUM>, such as, for example, door <NUM> opening and closing.

If the primary location of the primary sensing apparatus <NUM> is on the door header 104e, primary sensing apparatus <NUM> may be able to detect door <NUM> open and close motions (i.e., acceleration) but not as clearly as a primary sensing apparatus <NUM> located on the door <NUM>. However, advantageously, mounting the primary sensing apparatus <NUM> on the header 104e allows for clearer recording of a ride quality of the elevator car <NUM>, which is equally important and would not be possible if the primary sensing apparatus <NUM> was mounted on the door <NUM> due to additional vibration of the door <NUM> during the elevator car <NUM> motion. Thus, by mounting the primary sensing apparatus <NUM> on the header 104e the primary sensing apparatus <NUM> is able to get clearer acceleration detections along the X axis, the Y axis, and the Z axis from which vibratory signatures could be compiles in the X axis along the Z axis and the Y axis along the Z axis. It is understood that while two primary sensing apparatuses <NUM> are illustrated in <FIG>, only one primary sensing apparatus <NUM> is required and two are illustrated to show two possible primary locations for the primary sensing apparatus <NUM>.

<FIG> illustrates a block diagram of the primary sensing apparatus <NUM> of the sensing system of <FIG>. It should be appreciated that, although particular systems are separately defined in the schematic block diagram of <FIG>, each or any of the systems may be otherwise combined or separated via hardware and/or software. As shown in <FIG>, the primary sensing apparatus <NUM> may include a controller <NUM>, a plurality of sensors <NUM> in communication with the controller <NUM>, a communication module <NUM> in communication with the controller <NUM>, and a power source <NUM> electrically connected to the controller <NUM>.

The plurality of sensors <NUM> may include an inertial measurement unit (IMU) sensor <NUM> configured to detect primary sensor data 202a of the primary sensing apparatus <NUM> and the elevator car <NUM> when the primary sensing apparatus <NUM> is attached to the elevator car <NUM>. The IMU sensor <NUM> may be a sensor, such as, for example, an accelerometer, a gyroscope, or a similar sensor known to one of skill in the art. The primary sensor data 202a detected by the IMU sensor <NUM> may include vibratory signatures (i.e., accelerations) as well as derivatives or integrals of accelerations, such as, for example, velocity, jerk, jounce, snap. etc. The IMU sensor <NUM> is in communication with the controller <NUM> of the primary sensing apparatus <NUM>.

The plurality of sensors <NUM> may also include additional sensors including but not limited to a light sensor <NUM>, a pressure sensor <NUM>, a microphone <NUM>, a humidity sensor <NUM>, and a temperature sensor <NUM>. The light sensor <NUM> is configured to detect primary sensor data 202a including light exposure. The light sensor <NUM> is in communication with the controller <NUM>. The pressure sensor <NUM> is configured to detect primary sensor data 202a including pressure levels. The pressure sensor <NUM> is in communication with the controller <NUM>. The microphone <NUM> is configured to detect primary sensor data 202a including audible sound and sound levels. The microphone <NUM> is in communication with the controller <NUM>. The humidity sensor <NUM> is configured to detect primary sensor data 202a including humidity levels. The humidity sensor <NUM> is in communication with the controller <NUM>. The temperature sensor <NUM> is configured to detect primary sensor data 202a including temperature levels. The temperature sensor <NUM> is in communication with the controller <NUM>.

The controller <NUM> of the primary sensing apparatus <NUM> includes a processor <NUM> and an associated memory <NUM> comprising computer-executable instructions that, when executed by the processor <NUM>, cause the processor <NUM> to perform various operations, such as, for example, processing the primary sensor data 202a collected by the IMU sensor <NUM>, the light sensor <NUM>, the pressure sensor <NUM>, the microphone <NUM>, the humidity sensor <NUM>, and the temperature sensor <NUM>. The processor <NUM> may be but is not limited to a single-processor or multi-processor system of any of a wide array of possible architectures, including field programmable gate array (FPGA), central processing unit (CPU), application specific integrated circuits (ASIC), digital signal processor (DSP) or graphics processing unit (GPU) hardware arranged homogenously or heterogeneously. The memory <NUM> may be a storage device, such as, for example, a random access memory (RAM), read only memory (ROM), or other electronic, optical, magnetic or any other computer readable medium.

The power source <NUM> of the primary sensing apparatus <NUM> is configured to store and supply electrical power to the primary sensing apparatus <NUM>. The power source <NUM> may include an energy storage system, such as, for example, a battery system, capacitor, or other energy storage system known to one of skill in the art. The power source <NUM> may also generate electrical power for the primary sensing apparatus <NUM>. The power source <NUM> may also include an energy generation or electricity harvesting system, such as, for example synchronous generator, induction generator, or other type of electrical generator known to one of skill in the art.

The primary sensing apparatus <NUM> includes a communication module <NUM> configured to allow the controller <NUM> of the primary sensing apparatus <NUM> to communicate with the monitoring system <NUM> through at least one of short-range wireless protocols <NUM> and long-range wireless protocols <NUM>. The communication module <NUM> may be configured to communicate with the monitoring system <NUM> using short-range wireless protocols <NUM>, such as, for example, Bluetooth, Wi-Fi, HaLow (<NUM>. 11ah), Wireless M-Bus, zWave, Zigbee, or other short-range wireless protocol known to one of skill in the art. Using short-range wireless protocols <NUM>, the communication module <NUM> is configured to transmit the sensor data <NUM> to a local gateway device <NUM> and the local gateway device <NUM> is configured to transmit the sensor data to a monitoring system <NUM> through a network <NUM>, as described above. The communication module <NUM> may be configured to communicate with the monitoring system <NUM> using long-range wireless protocols <NUM>, such as for example, cellular, LTE (NB-IoT, CAT M1), LoRa, Ingenu, SigFox, Satellite, or other long-range wireless protocol known to one of skill in the art. Using long-range wireless protocols <NUM>, the communication module <NUM> is configured to transmit the sensor data <NUM> to a monitoring system <NUM> through a network <NUM>. In an embodiment, the short-range wireless protocol <NUM> is sub GHz Wireless M-Bus. In another embodiment, the long-range wireless protocol is Sigfox. In another embodiment, the long-range wireless protocol is LTE NB-IoT or CAT M1 with <NUM> fallback.

The primary sensing apparatus <NUM> also includes a data conversion module <NUM> stored within the memory of the primary sensing apparatus <NUM>. The data conversion module <NUM> is configured to determine a transfer algorithm <NUM> in response to the secondary sensor data 202b and the primary sensor data 202a. The transfer algorithm <NUM> may be stored within the memory <NUM> of the controller <NUM>. Multiple commissioning runs by the elevator car <NUM> up and down the elevator shaft <NUM> may be performed to further refine the transfer algorithm <NUM> during a commissioning phase. The transfer algorithm <NUM> converts secondary sensor data 202b into primary sensor data 202a and may also convert primary sensor data 202a into secondary sensor data 202b. Thus, once the commissioning phase is completed and the secondary sensing apparatus <NUM> removed from the elevator system <NUM>, vibratory signatures <NUM> of the primary sensor data 202a detected by the primary sensing apparatus <NUM> during a normal operation operating phase may be converted to vibratory signatures <NUM> of the secondary sensor data 202b at each secondary location where a secondary sensing apparatus <NUM> previously existed. The vibratory signatures <NUM> may be the acceleration detected along one or more of the X axis, the Y axis, and the Z axis over a period of time or distance. The axis may include three axis such as the X axis, a Y axis, and a Z axis, as shown in <FIG>. In one example, vibratory signatures <NUM> within the primary sensor data <NUM> at the primary location may be converted to vibratory signature <NUM> of the secondary sensor data 210a at the secondary location. Advantageously, the data conversion module <NUM> and associated transfer algorithm <NUM> allows the primary sensing apparatus <NUM> to determine vibratory signatures <NUM> at each of the secondary location during normal operation when the secondary sensing apparatus <NUM> are no longer attached to the elevator system <NUM>.

Advantageously, the transfer algorithm <NUM> eliminates the need to have the secondary sensing apparatus <NUM> installed permanently on the elevator system <NUM>. Advantageously, not all elevator systems have to ability to install the secondary sensing apparatus <NUM>, thus the transfer algorithm <NUM> from one elevator system may be applied to other elevator systems, which provides richer data for predictive machine learning.

Referring now to <FIG>, while referencing components of <FIG>. <FIG> shows a flow chart of a method <NUM> of monitoring a conveyance apparatus within a conveyance system, in accordance with an embodiment of the disclosure. In an embodiment, the conveyance system is an elevator system <NUM> and the conveyance apparatus is an elevator car <NUM>. In an embodiment, the method <NUM> is performed by the data conversion module <NUM>, which may be located on the controller <NUM> of primary sensing apparatus <NUM>. Although not shown in <FIG>, the method <NUM> may initiate with moving the conveyance apparatus for a commissioning phase. At block <NUM>, a vibratory signature <NUM> is detected at a primary location during a commissioning phase using a primary sensing apparatus <NUM> located at the primary location. In an embodiment, the primary location is located on the conveyance apparatus. At block <NUM>, a vibratory signature <NUM> is detected at a secondary location during the commissioning phase using a secondary sensing apparatus <NUM> located at the secondary location. In an embodiment, the secondary location is located on the conveyance apparatus.

At block <NUM>, a transfer algorithm <NUM> is determined in response to the vibratory signature <NUM> at the primary location during the commissioning phase and the vibratory signature <NUM> at the secondary location during the commissioning phase. Although not shown in <FIG>, the method <NUM> may include between block <NUM> and <NUM> moving the conveyance apparatus for a normal operation phase, during which the secondary sensing apparatus <NUM> have been removed from the conveyance system. At block <NUM>, a vibratory signature <NUM> is detected at the primary location during a normal operation phase using the primary sensing apparatus <NUM> located at the primary location. At block <NUM>, the vibratory signature <NUM> at the primary location during the normal operation phase is converted to a vibratory signature at the secondary location during the normal operation phase using the transfer algorithm <NUM>.

The method <NUM> may further comprise: determining an abnormality in response to the vibratory signature at the secondary location during the normal operation phase without the secondary sensing apparatus <NUM>. An alarm may be activated in response to the determination of the abnormality. The method may also comprise tracking component degradation level in response to the vibratory signature at the secondary location during the normal operation phase without the secondary sensing apparatus <NUM>. An alarm may be activated in response to the component degradation level. The alarm may be audible, visual, and/or vibratory. An abnormality may be an unusual vibration that may indicate inspection and/or replacement of a component may be required.

Claim 1:
A method of monitoring a conveyance apparatus (<NUM>) within a conveyance system (<NUM>), wherein the conveyance system (<NUM>) is an elevator system (<NUM>) and the conveyance apparatus (<NUM>) is an elevator car (<NUM>) or wherein the conveyance system is an escalator system and the conveyance apparatus is a moving stair, the method comprising:
detecting a vibratory signature (<NUM>) at a primary location (104e) in the conveyance system during a commissioning phase using a primary sensing apparatus (<NUM>) located at the primary location (104e);
detecting a vibratory signature (<NUM>) at a secondary location in the conveyance system during the commissioning phase using a secondary sensing apparatus (<NUM>) located at the secondary location;
determining a transfer algorithm (<NUM>) in response to the vibratory signature (<NUM>) at the primary location (104e) during the commissioning phase and the vibratory signature (<NUM>) at the secondary location during the commissioning phase;
detecting a vibratory signature (<NUM>) at the primary location (104e) during a normal operation phase using the primary sensing apparatus (<NUM>) located at the primary location (104e); and
converting the vibratory signature (<NUM>) at the primary location (104e) during the normal operation phase to a vibratory signature (<NUM>) at the secondary location during the normal operation phase using the transfer algorithm (<NUM>).