Patent Description:
Elevator roller guides operate in harsh environments. These harsh environments are characterized by relatively high temperatures, high loads and requirements for high speed rotational action. The elevator roller guides may, therefore, experience damage and/or degraded conditions over time. To prevent such damage and degraded conditions, elevator mechanics often need to periodically check the elevator roller guides for signs of wear. This typically requires that the corresponding elevator be shut down, which is costly and time consuming. <CIT> discloses equipment and methods for reducing vibrations of a lift cage. <NPL> discloses a signal processing scheme of a smart sensor node for the Internet-of-Elevators.

According to an aspect of the invention, there is provided a guide for individual movement machinery as defined by claim <NUM>.

In accordance with a set of embodiments, the frame includes lever arms coupled to the frame and lever arm control assemblies configured to limit movements of each of the lever arms relative to the frame, the guide further includes slider assemblies rotatably coupled to each of the lever arms, the lever arms include opposed front-to-back lever arms and a side-to-side lever arm and the slider assemblies include opposed front-to-back slider assemblies rotatably coupled to the front-to-back lever arms, respectively, and a side-to-side slider assembly rotatably coupled to the side-to-side lever arm.

In accordance with a set of embodiments, the lever arm control assemblies each include at least one of a spring or damping unit and a mechanical stop.

In accordance with a set of embodiments, the arrays of sensors include micro-electrical mechanical system (MEMS) devices in a size range of twenty micrometers to one millimeter.

The arrays of sensors include a base sensor array affixed to the base and additional sensor arrays respectively affixed to the frame.

In accordance with a set of embodiments, the base sensor array is disposed at or near to a center of the base.

The base sensor array includes at least acceleration, tilt and rotation sensors.

In accordance with a set of embodiments, the additional sensor arrays are respectively disposed proximate to slider assemblies at lever arms of the frame.

In accordance with a set of embodiments, each of the additional sensor arrays includes at least acceleration, shock and vibration sensors.

In accordance with a set of embodiments, an indicator is configured to display a status indication based on the readings.

In accordance with a set of embodiments, the indicator includes light emitters, which are respectively associated with each of the roller guide conditions and which are configured to emit light of various colors to generate the status indication.

In accordance with a set of embodiments, the indicator is communicative with at least one of an elevator system controller and an external computing device.

In accordance with a set of embodiments, an elevator system is provided and includes at least first and second guides. The readings are generated from comparisons between complementarily sensed guide conditions of the at least first and second guides.

According to an aspect of the invention, an elevator system is provided for use in a structure formed to define a hoistway. The elevator system includes a hoistway rail extending along the hoistway, a drive system and an elevator car, which is movably disposed in the hoistway and drivable to move along the hoistway rail by the drive system. The elevator car includes one or more elevator roller guides that respectively engage with the hoistway rail and sensors. The sensors are affixed to each of the one or more of the elevator roller guides and are configured to sense elevator roller guide conditions and to generate readings accordingly.

In accordance with a set of embodiments, the sensors include micro-electrical mechanical system (MEMS) devices in a size range of twenty micrometers to one millimeter.

In accordance with a set of embodiments, the sensors are provided in arrays of sensors that include a base sensor array and lever arm sensor arrays. The base sensor array is affixed to a base of each of the one or more elevator roller guides and includes at least acceleration, tilt and rotation sensors. The lever arm sensor arrays are respectively affixed to each lever arm of each one of the one or more of the elevator roller guides and include at least acceleration, shock and vibration sensors.

In accordance with a set of embodiments, an elevator system controller is configured to control at least the drive system based on the readings.

According to an aspect of the invention, a method of operating an elevator system for use in a structure formed to define a hoistway is provided as defined by claim <NUM>.

In accordance with a set of embodiments, the method further includes remote monitoring of the elevator system.

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.

As will be described below, an automated roller guide monitoring system is provided for use with a system for transporting one or more individuals or people, such as an elevator system, an escalator system, etc. The automated roller guide monitoring system is configured to detect, for example, specific problems with the elevator guidance system and could be employed in such a way as to permit or at least substantially reduce the elimination of the manual work of a field crew.

With reference to <FIG>, an elevator system <NUM> in particular is provided for use in a structure <NUM>, such as a multi-level building, which is formed to define a hoistway <NUM>. The elevator system <NUM> includes a hoistway rail <NUM> extending along the hoistway <NUM>, a drive system <NUM> and an elevator car <NUM>. The elevator car <NUM> is movably disposed in the hoistway <NUM> and is drivable to move along the hoistway rail <NUM> by the drive system <NUM>. The elevator car <NUM> includes an elevator car body <NUM>, which is formed to accommodate one or more passengers and one or more elevator roller guides <NUM> (e.g., first and second elevator roller guides <NUM>) that are coupled to the elevator car body <NUM> and respectively engage with the hoistway rail <NUM>.

With continued reference to <FIG> and with additional reference to <FIG>, each elevator roller guide <NUM> includes, for example, a base <NUM>, a frame <NUM> that is affixed to the base <NUM>, slider assemblies <NUM> and a monitoring system <NUM>. The base <NUM> is a generally planar and rigid feature that should be oriented in parallel with a floor and a ceiling of the elevator car body <NUM>. The frame <NUM> is affixed to the base <NUM>. The frame <NUM> includes first, second and third lever arms <NUM>, <NUM> and <NUM> and first, second and third lever arm control assemblies <NUM>, <NUM> and <NUM>. The first and second lever arms <NUM> and <NUM> may be provided as opposed front-to-back lever arms and the third lever arm <NUM> may be provided as a side-to-side lever arm that is oriented orthogonally relative to the first and second lever arms <NUM> and <NUM>.

It is to be understood that the embodiments of the elevator roller guide <NUM> described above and in the description below are merely exemplary and that other configurations are possible.

A lower portion of the first lever arm <NUM> is connected to a lower portion of the frame <NUM> via connection <NUM>. The first lever arm control assembly <NUM> includes at least one of a spring or damping unit <NUM> and a mechanical stop <NUM> and is coupled to an upper portion of the first lever arm <NUM> and an upper portion of the frame <NUM> such that some degree of movement of the first lever arm <NUM> relative to the frame <NUM> is permitted. Where the first lever arm <NUM> is provided as a front-to-back lever arm, the movement of the first lever arm <NUM> relative to the frame <NUM> is generally in the front-to-back plane about the connection <NUM>. The first lever arm control assembly <NUM> is configured to limit movements of the first lever arm <NUM> relative to the frame <NUM> and, more particularly, to limit the movements of the first lever arm <NUM> about the connection <NUM> in the front-to-back plane relative to the frame <NUM>.

A lower portion of the second lever arm <NUM> is connected to a lower portion of the frame <NUM> via connection <NUM>. The second lever arm control assembly <NUM> includes at least one of a spring or damping unit <NUM> and a mechanical stop <NUM> and is coupled to an upper portion of the second lever arm <NUM> and an upper portion of the frame <NUM> such that some degree of movement of the second lever arm <NUM> relative to the frame <NUM> is permitted. Where the second lever arm <NUM> is provided as a front-to-back lever arm, the movement of the second lever arm <NUM> relative to the frame <NUM> is generally in the front-to-back plane about the connection <NUM>. The second lever arm control assembly <NUM> is configured to limit movements of the second lever arm <NUM> relative to the frame <NUM> and, more particularly, to limit the movements of the second lever arm <NUM> about the connection <NUM> in the front-to-back plane relative to the frame <NUM>.

A lower portion of the third lever arm <NUM> is connected to a lower portion of the frame <NUM> via connection <NUM>. The third lever arm control assembly <NUM> includes at least one of a spring or damping unit <NUM> and a mechanical stop <NUM> and is coupled to an upper portion of the third lever arm <NUM> and an upper portion of the frame <NUM> such that some degree of movement of the third lever arm <NUM> relative to the frame <NUM> is permitted. Where the third lever arm <NUM> is provided as a side-to-side lever arm, the movement of the third lever arm <NUM> relative to the frame <NUM> is generally in the side-to-side plane about the connection <NUM>. The third lever arm control assembly <NUM> is configured to limit movements of the third lever arm <NUM> relative to the frame <NUM> and, more particularly, to limit the movements of the third lever arm <NUM> about the connection <NUM> in the side-to-side plane relative to the frame <NUM>.

The slider assemblies <NUM> are rotatably coupled to each of the first, second and third lever arms <NUM>, <NUM> and <NUM> and are configured to engage with the hoistway rail <NUM> of <FIG> as the elevator car <NUM> moves through the hoistway <NUM>. Each slider assembly <NUM> includes a rotatable wheel <NUM> and a bearing <NUM> by which the rotatable wheel <NUM> is coupled to one of the first, second and third lever arms <NUM>, <NUM> and <NUM>.

The monitoring system <NUM> includes sensors <NUM> that are affixed to each elevator roller guide <NUM>. The sensors <NUM> may be provided as micro-electrical mechanical systems (MEMS) devices and can be provided with a size range of about twenty micrometers to about one millimeter. The sensors <NUM> are configured to sense elevator roller guide conditions and to generate readings accordingly without substantially or even minimally affecting a performance of the elevator roller guides <NUM>. The sensors <NUM> are arranged in a base sensor array <NUM> and in additional or lever arm sensor arrays <NUM> (hereinafter referred to as simply "lever arm sensor arrays <NUM>"). The sensors <NUM> of the base sensor array <NUM> are affixed to or embedded in the base <NUM> and the sensors <NUM> of the lever arm sensor arrays <NUM> are affixed to or embedded in each of the first, second and third lever arms <NUM>, <NUM> and <NUM>.

The use of MEMS devices for the sensors <NUM> is appropriate for health monitoring of elevator roller guides <NUM>. With the sensors <NUM> being MEMS devices, they can pick-up relatively high vibration levels and frequency changes in the case of worn bearings, increased run out, misalignment of roller axes, etc. In particular, where the sensors <NUM> are provided as MEMS capacitive accelerometers (VC), the sensors <NUM> can be operated with a relatively small current and can function in an open-loop configuration. Thus, the sensors <NUM> can operate wirelessly for long terms and are portable, reliable and durable. They can monitor temperature, moisture, strain and other data continuously.

In accordance with embodiments, the base sensor array <NUM> may be disposed at or near to a center of the base <NUM> and may include at least acceleration sensors <NUM>, tilt sensors <NUM> and rotation sensors <NUM>. In accordance with embodiments, the lever arm sensor arrays <NUM> may be respectively disposed proximate to the slider assemblies <NUM> at each of the first, second and third lever arms <NUM>, <NUM> and <NUM>. Each of lever arm sensor arrays <NUM> may include at least acceleration sensors <NUM>, shock sensors <NUM> and vibration sensors <NUM>.

The acceleration sensors <NUM> serve to measure an acceleration in various directions of the base <NUM> or to measure a bearing acceleration of the bearing assembly <NUM> of the corresponding one of the first, second and third lever arms <NUM>, <NUM> and <NUM>. In an exemplary case, readings of any one of the acceleration sensors <NUM> of the first, second and third lever arms <NUM>, <NUM> and <NUM> may be used to compute a bearing acceleration of the corresponding bearing assembly <NUM> in a noise/vibration fault diagnosis.

The tilt sensors <NUM> serve to measure a tilt of the base <NUM> to determine if the corresponding elevator roller guide <NUM> is parallel or plumb with respect to the hoistway rail <NUM> and/or the elevator car body <NUM>. In some cases, such as where the elevator car <NUM> includes first and second elevator roller guides <NUM>, readings of the tilt sensors <NUM> of each of the first and second elevator roller guides <NUM> can be compared with each other to determine whether one of the first and second elevator roller guides <NUM> is tilted or off-axis relative to the other. In other cases, such as where the elevator system <NUM> includes multiple elevator cars <NUM> and each elevator car <NUM> includes first and/or second elevator roller guides <NUM>, readings of the tilt sensors <NUM> of each of the first and/or second elevator roller guides <NUM> of each elevator car <NUM> can be compared with each other to determine whether any of the first and second elevator roller guides <NUM> are tilted or off-axis relative to the others.

The rotation sensors <NUM> serve to measure a rotation of the base <NUM>. Where the elevator car <NUM> includes first and second elevator roller guides <NUM>, readings of the rotation sensors <NUM> of each of the first and second elevator roller guides <NUM> can be compared with each other to determine whether one of the first and second elevator roller guides <NUM> is misaligned. Where the elevator system <NUM> includes multiple elevator cars <NUM> and each elevator car <NUM> includes first and/or second elevator roller guides <NUM>, readings of the rotation sensors <NUM> of each of the first and/or second elevator roller guides <NUM> of each elevator car <NUM> can be compared with each other to determine whether any of the first and second elevator roller guides <NUM> are misaligned.

The shock sensors <NUM> serve to measure shock and can be used to verify that the first, second and third lever arm control assemblies <NUM>, <NUM> and <NUM> are set and calibrated correctly. The vibration sensors <NUM> serve to measure velocity, acceleration and/or displacement from vibration amplitudes and/or frequencies. Readings from the vibration sensors <NUM> can be employed to determine whether the elevator car <NUM> is subject to abnormal vibration frequencies that would be uncomfortable or indicative of a dangerous condition, for example.

The monitoring system <NUM> can further include an indicator <NUM>. The indicator <NUM> can be affixed to the base <NUM> or the frame <NUM> and is configured to display a status indication based on the readings generated by the sensors <NUM>.

With continued reference to <FIG> and with additional reference to <FIG>, the indicator <NUM> can include or be coupled to a processing unit <NUM>, a memory unit <NUM>, a networking unit <NUM> and, in some cases, a servo or electronic control unit <NUM>. The processing unit <NUM>, the memory unit <NUM>, the networking unit <NUM> and, where applicable, the servo or electronic control unit <NUM> may be locally disposed with respect to the indicator, the elevator car <NUM> or the elevator system <NUM> or may be remote from the elevator system <NUM> entirely. In any case, the processing unit <NUM> is communicative with the sensors <NUM> and external computing devices <NUM> by way of the networking unit <NUM>. Where the servo or electronic control unit <NUM> is available, the processing unit <NUM> can control various operations of the elevator system <NUM> (e.g., by stopping, slowing or speeding up the drive system <NUM>). The memory unit <NUM> has executable instructions stored thereof, which are readable and executable by the processing unit <NUM>. The executable instructions are configured such that, when they are read and executed by the processing unit <NUM>, they cause the processing unit <NUM> to operate as described herein.

In accordance with embodiments, the indicator <NUM> can be affixed or disposed on the base <NUM> and may include light emitters <NUM>. Each light emitter <NUM> can be respectively associated with a type of sensor <NUM> and/or with a roller guide condition that is sensed by one of the sensors <NUM>. Thus, one light emitter <NUM> may be associated with acceleration, one light emitter <NUM> may be associated with tilt, one light emitter <NUM> may be associated with rotation, one light emitter <NUM> may be associated with shock and one light emitter <NUM> may be associated with vibration. Moreover, each light emitter <NUM> may be configured to emit light of various colors to generate the status indication (e.g., green for ok, yellow for a warning and red for an issue that needs to be resolved).

The processing unit <NUM> may be receptive of data reflective of readings of the sensors <NUM> from each of the sensors <NUM> via the networking unit <NUM> and configured to analyze the data to determine whether any of the roller guide conditions sensed by the sensors <NUM> are problematic. If not, the processing unit <NUM> controls the light emitters <NUM> directly or by way of the servo control unit <NUM> to emit the green lights. If any of the roller guide conditions are problematic, the processing unit <NUM> controls the corresponding light emitters <NUM> directly or by way of the servo or electronic control unit <NUM> to emit the appropriate color. In some cases, the processing unit <NUM> can determine that a roller guide condition is in effect which requires that the elevator system <NUM> be shut down or that the drive system <NUM> for the corresponding elevator car <NUM> needs to be shut down, slowed or sped up. In these instances, the processing unit <NUM> can control the elevator system <NUM> or the drive system <NUM> directly or by way of the servo or electronic control unit <NUM> accordingly.

With reference to <FIG>, a method of operating an elevator system, such as the elevator system <NUM> described above is provided. The method includes affixing sensors to each of the one or more of the elevator roller guides (block <NUM>), activating the sensors to sense elevator roller guide conditions during operations of the elevator system and to generate readings accordingly (block <NUM>), controlling at least the drive system during the operations of the elevator system based on the readings (block <NUM>) and remote monitoring of the elevator system (block <NUM>).

Benefits of the features described herein are that an automated roller guide monitoring system is provided for use with an elevator system. In addition, the automated roller guide monitoring system detects, for example, specific problems with the elevator guidance system and could be employed in such a way as to permit the elimination or at least the substantial reduction of the manual work of a field crew.

Claim 1:
A guide (<NUM>) for an elevator (<NUM>), the guide (<NUM>) comprising:
a base (<NUM>);
a frame (<NUM>); and
a monitoring system (<NUM>) comprising arrays of sensors (<NUM>; <NUM>; <NUM>) affixed to each of the base (<NUM>) and the frame (<NUM>) to respectively sense guide conditions and to generate readings accordingly;
wherein the arrays of sensors (<NUM>; <NUM>; <NUM>) comprise:
a base sensor array (<NUM>) affixed to the base (<NUM>); and
additional sensor arrays (<NUM>) respectively affixed to the frame (<NUM>); and
characterized in that
the base sensor array (<NUM>) comprises at least acceleration (<NUM>), tilt (<NUM>) and rotation sensors (<NUM>).