Patent Description:
Manually mapping an elevator shaft for installation of an elevator system can take an extensive amount of time and may be inexact. Similarly, manually inspecting an elevator shaft with an installed elevator system can also take an extensive amount of time and may be inexact. A solution is desired for reducing manual power required for these activities. <CIT> discloses an elevator inspection and maintenance system including a mechatronic body movable via remote or automatic operation and an inspection and maintenance head installed on the mechatronic body. <CIT> discloses an orienting device and a method for mounting a guide rail in an elevator shaft of an elevator system. <CIT> discloses a marking positioning device for an elevator in which a marking can be applied at a designated position inside a hoistway.

Disclosed is an elevator inspection system, having: a sensor implement; a robotic platform supporting the sensor, the robotic platform configured to inspect a hoistway; a controller operationally connected to the robotic platform and the sensor, wherein the controller is configured to define hoistway model data for the hoistway, from sensor data, corresponding to locations and shape boundaries of the hoistway and doorway openings formed in the hoistway.

According to some examples disclosed herein, the controller is configured to define a three-dimensional hoistway model from the hoistway model data.

According to some examples disclosed herein, the controller is configured to utilize the hoistway model data as a reference point for installing and/or maintaining one or more components in the hoistway.

According to some examples disclosed herein, the controller is configured to define elevator car guide rail data, corresponding to a virtual elevator guide rail, in the hoistway model data.

According to some examples disclosed herein, the controller is configured to determine, from the hoistway model data, sill to sill distances, guide rail to guide rail distances, and sill to guide rail distances for each of the doorway openings.

According to some examples disclosed herein, the controller is configured to determine, from the hoistway model data, tilt and twist of the hoistway, locations and sizes of doorway openings.

According to some examples disclosed herein" the controller is configured to define installation locations within the hoistway model data for elevator components.

According to some examples disclosed herein, the controller is configured to control movement of the robotic platform in an hoistway, wherein the controller is operated manually, on SLAM (simultaneous localization and mapping), and/or on CAD (computer aided design) models.

According to some examples disclosed herein, the sensor implement is one or more of a video sensor; an acoustic sensor; a LIDAR sensor; a camera; a laser sensor, a photogrammetry sensor, and a time of flight sensor.

According to some examples disclosed herein, the robotic platform is a drone.

Further disclosed is a method of developing hoistway model data for a hoistway, including defining, by a controller, the hoistway model data for the hoistway, from sensor data, corresponding to locations and shape boundaries of the elevator hoistway shaft and doorway openings formed in the elevator hoistway shaft, wherein the sensor data is captured from a sensor implement that is supported by a robotic platform, wherein the robotic platform is configured to inspect the hoistway, and wherein the controller controls the robotic platform and the sensor implement.

According to some examples disclosed herein, the method includes defining, by the controller, a three-dimensional hoistway model from the hoistway model data.

According to some examples disclosed herein, the method includes utilizing, by the controller, the hoistway model data as a reference point for installing and/or maintaining one or more components in the hoistway.

According to some examples disclosed herein, the method includes defining, by the controller, elevator car guide rail data, corresponding to a virtual elevator guide rail, in the hoistway model data.

According to some examples disclosed herein, the method includes determining, by the controller from the hoistway model data, sill to sill distances, guide rail to guide rail distances, and sill to guide rail distances for each of the doorway openings.

According to some examples disclosed herein, the method includes determining, by the controller from the hoistway model data, tilt and twist of the hoistway, locations and sizes of doorway openings.

According to some examples disclosed herein, the method includes defining, by the controller, installation locations within the hoistway model data for elevator components, including the virtual guide rail.

According to some examples disclosed herein, the method includes controlling, by the controller, movement of the robotic platform in the hoistway, where the controller is operated manually, on SLAM (simultaneous localization and mapping), and/or on CAD (computer aided design) models.

Further disclosed is an elevator inspection system, having: a sensor implement; a robotic platform supporting the sensor implement, the robotic platform configured to inspect a hoistway; and a controller operationally connected to the robotic platform and the sensor implement, wherein the controller is configured to define hoistway model data, for the hoistway, from maintenance and performance data collected from disparately located elevator systems connected to communicate over a network.

According to some examples disclosed herein, the controller is configured to define the hoistway model data from maintenance and performance data collected over the Internet and utilize cloud computing for analytics.

According to some examples disclosed herein, the controller is configured to identify maintenance and performance trends from the collected maintenance and performance data.

According to some examples disclosed herein, the controller is configured to define the hoistway model data to include, for an elevator car in the hoistway, one or more of: maintenance needs; ride quality; a motion profile; and door performance.

According to some examples disclosed herein, the controller is configured to determining a frequency of monitoring the hoistway from the hoistway model data.

According to some examples disclosed herein, the controller is configured to determine to substantially continuously monitor the hoistway from the hoistway model data.

According to some examples disclosed herein, the controller is configured to further define the hoistway model data from sensed locations and shape boundaries of the hoistway and doorway openings formed in the hoistway.

According to some examples disclosed herein, the controller is configured to define the hoistway model data to include sill to sill distances, guide rail to guide rail distances, sill to guide rail distances, and tilt and twist of the hoistway.

According to some examples disclosed herein, the controller is configured to transmit an alert upon identifying, from sensor data compared with hoistway model data, when a component of an elevator system installed in the hoistway is positioned or operating outside of predetermined positioning and operating tolerances.

Further disclosed is a method of determining whether components of an elevator system are positioned and operating within predetermined positioning and operating tolerances, including: defining, by a controller, hoistway model data, for a hoistway, from maintenance and performance data collected from disparately located elevator systems connected to communicate over a network, wherein the controller is operationally connected to a robotic platform supporting a sensor implement, and wherein the robotic platform configured to inspect the hoistway.

According to some examples disclosed herein, the method includes defining, by the controller, the hoistway model data from maintenance and performance data collected over the Internet and utilizing cloud computing for analytics.

According to some examples disclosed herein, the method includes identifying, by the controller, maintenance and performance trends from the collected maintenance and performance data.

According to some examples disclosed herein, the method includes defining, by the controller, the hoistway model data to include, for an elevator car in the hoistway, one or more of: maintenance needs; ride quality; a motion profile; and door performance.

According to some examples disclosed herein, the method includes determining, by the controller, a frequency of monitoring the hoistway from the hoistway model data.

According to some examples disclosed herein, the method includes determining, by the controller, to substantially continuously monitor the hoistway from the hoistway model data.

According to some examples disclosed herein, the method includes further defining, by the controller, the hoistway model data from sensed locations and shape boundaries of the hoistway and doorway openings formed in the hoistway.

According to some examples disclosed herein, the method includes defining, by the controller, the hoistway model data to include sill to sill distances, guide rail to guide rail distances, sill to guide rail distances, and tilt and twist of the hoistway.

According to some examples disclosed herein, the method includes transmitting, by the controller, an alert upon identifying, from sensor data compared with hoistway model data, when a component of an elevator system installed in the hoistway is positioned or operating outside of predetermined positioning and operating tolerances.

According to an aspect of the present invention there is provided an elevator inspection system, having: a sensor implement; a robotic platform, which is portable, supporting the sensor implement, the robotic platform configured for inspecting and performing maintenance in a hoistway; a controller operationally connected to the robotic platform and the sensor implement, wherein the controller is configured to: control movement of the robotic platform within a hoistway; and inspect one or more components in the hoistway to determine, from sensor data compared with hoistway model data, that an operational parameter or an alignment of the one or more components is outside predetermined positioning and operating tolerances.

In a set of embodiments of the elevator inspection system of the present invention, the controller is configured to utilize the hoistway model data as a reference point for installing and/or maintaining one or more components in the hoistway.

In a set of embodiments of the elevator inspection system of the present invention, the controller is configured to control the robotic platform to execute one or more of: guide rail realignment; rope/belt inspection; ride quality tests; door couple alignment inspection; door switch test; and sill cleaning, to thereby determine that the operational parameter or the alignment of the component is outside predetermined positioning and operating tolerances.

In a set of embodiments of the elevator inspection system of the present invention, the controller is configured to determine a current position of the component relative to global positioning system (GPS) data.

In a set of embodiments of the elevator inspection system of the present invention, the controller is configured to engage a segment of an elevator guide rail of the hoistway shaft, to position the segment within predetermined positioning and operating tolerances, upon determining, from sensor data compared with hoistway model data, that the segment is positioned outside the predetermined positioning and operating tolerances.

In a set of embodiments of the elevator inspection system of the present invention, the controller is configured to define the hoistway model data from sensed locations and shape boundaries of the hoistway shaft and doorway openings formed in the hoistway shaft.

In a set of embodiments of the elevator inspection system of the present invention, the controller is configured to define the hoistway model data to include sill to sill distances, guide rail to guide rail distances, sill to guide rail distances, and tilt and twist of the hoistway.

In a set of embodiments of the elevator inspection system of the present invention, the controller is configured to define the hoistway model data as a three-dimensional model of the hoistway.

According to a second aspect of the present invention, there is provided a method of performing maintenance within a hoistway, including: controlling, by a controller, movement of a robotic platform within the hoistway; and inspecting, by the controller, one or more components in the hoistway to determine, from sensor data compared with hoistway model data, that an operational parameter or an alignment of the one or more components is outside predetermined positioning and operating tolerances, wherein the robotic platform is configured to inspect and perform maintenance in the hoistway, and wherein the controller is operationally connected to the robotic platform and a sensor implement supported by the robotic platform, and wherein the sensor implement is configured to capture the sensor data.

In a set of embodiments of the present invention, the method includes utilizing, by the controller, the hoistway model data as a reference point for installing and/or maintaining one or more components in the hoistway.

In a set of embodiments of the present invention, the method includes controlling, by the controller, the robotic platform to execute one or more of: guide rail realignment; rope/belt inspection; ride quality tests; door couple alignment inspection; door switch test; and sill cleaning, to thereby determine that the operational parameter or the alignment of the component is outside predetermined positioning and operating tolerances.

In a set of embodiments of the present invention, the method includes determining, by the controller, a current position of the component relative to global positioning system (GPS) data.

In a set of embodiments of the present invention, the method includes defining, by the controller, the hoistway model data from sensed locations and shape boundaries of the hoistway shaft and doorway openings formed in the hoistway shaft.

In a set of embodiments of the present invention, the method includes defining, by the controller, the hoistway model data to include sill to sill distances, guide rail to guide rail distances, sill to guide rail distances, and tilt and twist of the hoistway.

In a set of embodiments of the present invention, the method includes defining, by the controller, the hoistway model data as a three-dimensional model of the hoistway.

Further disclosed is an elevator inspection system, the system having: a robotic platform configured to inspect a hoistway; a platform propulsor operationally connected to the robotic platform; and a controller operationally connected to the platform propulsor, wherein the controller is configured to control the platform propulsor to propel the robotic platform vertically within the hoistway.

According to some examples disclosed herein" the controller is configured to control friction pullies operationally connected between the robotic platform and a rope extending to a mechanical room atop the hoistway, to thereby propel the robotic platform.

According to some examples disclosed herein, the controller is configured to control vacuum suction cups operationally connected between the robotic platform and hoistway side walls, to thereby propel the robotic platform.

According to some examples disclosed herein, the controller is configured control rubber wheels operationally connected between the robotic platform and hoistway side walls, to thereby propel the robotic platform.

According to some examples disclosed herein, the controller is configured control mechanical legs operationally connected between the robotic platform and hoistway side walls, to thereby propel the robotic platform.

According to some examples disclosed herein, the controller is configured to control propellers operationally connected to the robotic platform, wherein the robotic platform is supported by a balloon, to thereby propel the robotic platform.

According to some examples disclosed herein, the controller is configured to control a rail climber operationally connected to the robotic platform, to thereby propel the robotic platform.

According to some examples disclosed herein, the controller is configured to control a rail climber operationally connected to the robotic platform, where the rail climber operationally engages a first rail that is adjacent a first hoistway sidewall, and a balance wheel of the rail climber is operationally positioned against a second hoistway side wall, to thereby propel the robotic platform.

According to some examples disclosed herein, the controller is configured to control a drone that is, or is operationally connected to, the robotic platform, to thereby propel the robotic platform.

According to some examples disclosed herein, the controller is configured to control one or more controllable tools supported on the robotic platform, whereby the robotic platform is configured for scanning and inspecting the hoistway, taking measurements, grinding, marking drilling points and drilling.

Further disclosed is a method of propelling a robotic platform within a hoistway, including: controlling, by a controller, a platform propulsor to propel the robotic platform vertically within the hoistway, wherein the robotic platform configured to inspect the hoistway, the platform propulsor is operationally connected to the robotic platform, and the controller is operationally connected to the platform propulsor.

According to some examples disclosed herein, the method includes controlling, by the controller, friction pullies operationally connected between the robotic platform and a rope extending to a mechanical room atop the hoistway, to thereby propel the robotic platform.

According to some examples disclosed herein, the method includes controlling, by the controller, vacuum suction cups operationally connected between the robotic platform and hoistway side walls, to thereby propel the robotic platform.

According to some examples disclosed herein, the method includes controlling, by the controller, rubber wheels operationally connected between the robotic platform and hoistway side walls, to thereby propel the robotic platform.

According to some examples disclosed herein, the method includes controlling, by the controller, mechanical legs operationally connected between the robotic platform and hoistway side walls, to thereby propel the robotic platform.

According to some examples disclosed herein, the method includes controlling, by the controller, propellers operationally connected to the robotic platform, wherein the robotic platform is supported by a balloon, to thereby propel the robotic platform.

According to some examples disclosed herein, the method includes controlling, by the controller, a rail climber operationally connected to the robotic platform, to thereby propel the robotic platform.

According to some examples disclosed herein, the method includes controlling, by the controller, a rail climber operationally connected to the robotic platform, where the rail climber operationally engages a first rail that is adjacent a first hoistway sidewall, and a balance wheel of the rail climber is operationally positioned against a second hoistway side wall, to thereby propel the robotic platform.

According to some examples disclosed herein, the method includes controlling, by the controller, a drone that is, or is operationally connected to, the robotic platform, to thereby propel the robotic platform.

According to some examples disclosed herein, the method includes controlling, by the controller, one or more controllable tools supported on the robotic platform, whereby the robotic platform is configured for scanning and inspecting the hoistway, taking measurements, grinding, marking drilling points and drilling.

Further disclosed is an elevator inspection system, configured to inspect multiple elevator cars in a group of elevator cars, the system having: a sensor implement; a robot supporting the sensor implement; and a controller operationally connected to the robot and the senor, wherein the controller is configured to transmit an alert responsive to determining, from sensor data compared with elevator operational data, that an operational parameter of an elevator car in which the robot is located is outside a predetermined threshold.

According to some examples disclosed herein, the controller is configured to determine whether ride-quality is outside the predetermined threshold, to thereby determine that the operational parameter is outside the predetermined threshold.

According to some examples disclosed herein, the controller is configured to determine whether acceleration is outside the predetermined threshold, to thereby determine that the ride-quality is outside the predetermined threshold.

According to some examples disclosed herein, the controller is configured to determine whether operational acoustics are outside the predetermined threshold, to thereby determine that the ride-quality is outside the predetermined threshold.

According to some examples disclosed herein, the controller is configured to communicate with an elevator car control panel, to thereby determine that the operational parameter is outside the predetermined threshold.

According to some examples disclosed herein, the controller is configured to instruct the elevator car control panel to execute one or more of runs between levels, emergency stops, and open/close door cycles, to thereby determine that the operational parameter is outside the predetermined threshold.

According to some examples disclosed herein, the controller is configured to: verify operation of COP lights; confirm elevator car leveling accuracy; clean the elevator car via the robot; and/or change elevator car controller settings to minimize effects of a bed quality of a ride.

According to some examples disclosed herein, the controller is configured communicate with the elevator car control panel over a wireless network.

According to some examples disclosed herein, the controller is configured to control the sensor implement to obtain the sensor data during predetermined periods of time and/or when the elevator car is without passengers.

According to some examples disclosed herein, the controller, which is onboard the robot, is configured to transmit the alert to an elevator group controller over a cellular network.

Further disclosed is a method of performing an elevator operational inspection with a robot, including: transmitting, by a controller, an alert responsive to determining, from sensor data compared with elevator operational data, that an operational parameter of an elevator car in which the robot is located is outside a predetermined threshold, wherein the controller is operationally connected to the robot and a senor implement supported by the robot, and wherein the controller is configured to control the sensor implement to obtain the sensor data.

According to some examples disclosed herein, the method includes determining, by the controller, whether ride-quality is outside the predetermined threshold, to thereby determine that the operational parameter is outside the predetermined threshold.

According to some examples disclosed herein, the method includes determining, by the controller, whether acceleration is outside the predetermined threshold, to thereby determine that the ride-quality is outside the predetermined threshold.

According to some examples disclosed herein, the method includes determining, by the controller, whether operational acoustics are outside the predetermined threshold, to thereby determine that the ride-quality is outside the predetermined threshold.

According to some examples disclosed herein, the method includes communicating, by the controller, with an elevator car control panel, to thereby determine that the operational parameter is outside the predetermined threshold.

According to some examples disclosed herein, the method includes instructing, by the controller, the elevator car control panel to execute one or more of runs between levels, emergency stops, and open/close door cycles, to thereby determine that the operational parameter is outside the predetermined threshold.

According to some examples disclosed herein, the method includes verifying, by the controller, operation of COP lights; confirming, by the controller, elevator car leveling accuracy; clean, by the controller via the robot, the elevator car; and/or changing, by the controller, elevator car controller settings to minimize effects of a bed quality of a ride.

According to some examples disclosed herein, the method includes communicating, by the controller, with the elevator car control panel over a wireless network.

According to some examples disclosed herein, the method includes controlling, by the controller, the sensor implement to obtain the sensor data during predetermined periods of time and/or when the elevator car is without passengers.

According to some examples disclosed herein, the method includes transmitting, by the controller, which is onboard the robot, the alert to an elevator group controller over a cellular network.

The counterweight <NUM> is configured to balance a load of the elevator car <NUM> and is configured to facilitate movement of the elevator car <NUM> concurrently and in an opposite direction with respect to the counterweight <NUM> within an (elevator shaft) hoistway <NUM> and along the guide rail <NUM>.

The position reference system <NUM> may be mounted on a fixed part at the top of the hoistway <NUM>, such as on a support or guide rail, and may be configured to provide position signals related to a position of the elevator car <NUM> within the hoistway <NUM>. For example, without limitation, the position reference system <NUM> can be an encoder, sensor implement, or other system and can include velocity sensing, absolute position sensing, etc., as will be appreciated by those of skill in the art.

The controller <NUM> is located, as shown, in a controller room <NUM> of the hoistway <NUM> and is configured to control the operation of the elevator system <NUM>, and particularly the elevator car <NUM>. When moving up or down within the hoistway <NUM> along guide rail <NUM>, the elevator car <NUM> may stop at one or more landings <NUM> as controlled by the controller <NUM>.

The machine <NUM> may include a traction sheave that imparts force to tension member <NUM> to move the elevator car <NUM> within hoistway <NUM>.

The following figures illustrate additional technical features associated with one or more disclosed embodiments. Features disclosed in the following figures having nomenclature similar to features disclosed in <FIG> may be similarly construed though being positively reintroduced with numerical identifiers that may differ from those in <FIG>. Further, process steps disclosed hereinafter may be sequentially numbered to facilitate discussion of one or more disclosed embodiments. Such numbering is not intended to identify a specific sequence of performing such steps or a specific requirement to perform such steps unless expressly indicated.

Turning to <FIG>, an elevator inspection system (inspection system) <NUM> is shown, which may be utilized to install an elevator system in a hoistway <NUM>. The inspection system <NUM> provides high precision over an entire height (or length) of the hoistway <NUM>. The inspection system <NUM> includes a position reference system that is able to precisely identify height and also twist (or rotation) and tilt (or bend) of the hoistway <NUM>. The inspection system <NUM> includes a sensor implement <NUM> (or more than one sensor implement <NUM>, including peripheral and onboard sensor implements, etc.) that enables a definition of a reliable reference point, which is beneficial for robotic systems, for defining hoistway data, which may represent a three-dimensional (3D) hoistway model (e.g., a virtual model). The hoistway data may function as reference data for installing, upgrading, maintaining, and/or inspecting an elevator system.

The inspection system <NUM> includes a robotic platform <NUM>, which can move along the hoistway <NUM>. The hoistway data may be embedded in electronics stored in a platform controller (controller) <NUM> that is onboard the robotic platform <NUM>. The reference system may be an earlier defined map of the hoistway <NUM>, serving as a reference point. Alternatively, the controller <NUM> may utilize software, such as a computer aided engineering or design (CAE or CAD) software to define a map as it travels, using laser (which may utilize one, two or three dimensional scanning), camera, or acoustic sensor. The inspection system <NUM> may allow for identifying height, sill to sill, rail to door, rail to rail, wall to wall measurements. Collected data may be used for installation, inspection or service. With the utilization of a high precision position robot, robotic platforms may be equipped with power tools and perform precision tasks.

Benefits of the disclosed embodiments includes a decreased time to market for an elevator system, freeing time for a mechanic, providing a competitive advantage based on a quickly and precisely installed elevator system, increased precision of an installation, an extended product life time, and an increased installation quality and an improved ride quality.

In <FIG>, the robotic platform <NUM> is a drone and in <FIG> the robotic platform <NUM> is shown as supporting a robotic arm <NUM>. Herein, reference to one form of the robotic platform (or robotic arm) is not intended on limiting the type of robotic platform (or robotic arm) utilized for the inspection system <NUM>. The robotic platform <NUM> may be equipped with the sensor implement <NUM>, suitable for reference and scanning operations, including but not limited to a stereovision camera, an acoustic sensor, a LIDAR (light and radar detection) sensor, a photogrammetry sensor, a laser sensor, which allow for the build of a substantially complete three dimensional image of the hoistway <NUM>. Hoistway measurements for the hoistway data are obtained from the inspection system <NUM> within the hoistway. The measurements include rail to rail, door width, hoistway depth and width, rail to rail, etc., which would otherwise be performed manually for each landing in the hoistway.

Further, an elevator mechanic may desire to receive hoistway measurements from a general contractor to check whether the installed elevator system <NUM> is built and maintained according to predetermined specifications. The hoistway model, which may have been developed before an initial install of the elevator system <NUM>, may function as a reference system that virtually marks installation locations for substantially each component in the hoistway <NUM>. The hoistway model may be utilized for identifying skew (twist/tilt) in the hoistway <NUM>, and damage to the hoistway <NUM>, which is not readily attainable from manual discrete landing measurements.

According to an embodiment, the inspection system <NUM> may be utilized in different applications for elevator installation and subsequent service. The disclosed application may be beneficial for time and cost saving which may lead to higher field efficiency. Measurements taken by the inspection system <NUM> include, as indicated, a three dimensional model showing tilt, twist, and/or deformation (e.g., defects in the structure) of the hoistway, guide rail to guide rail measurements, guide rail to sill measurements, sill to sill measurements, etc. The measurements provide a reference to specific landing and global reference points. The robotic platform <NUM> may be stationary (for example, located in a hoistway pit <NUM> or on a landing) or may move in the hoistway <NUM>.

Benefits of the disclosed embodiments include a reduced field time for a mechanic to discover and address issues during and subsequent to installation, thereby providing a competitive advantage, along with an increased precision of an elevator car <NUM> and an extended product life time. System performance tracking is also enhanced. A global data base for condition based monitoring (CBM) and predictive maintenance may also be performed. The reference system defined by the hoistway model, and a global data base (discussed in greater detail below), may allow for precise installation of the equipment in the hoistway <NUM>. The robotic platform <NUM> may be used to map the hoistway <NUM> with higher resolution than can be obtained by individual, discrete landing measurement. The disclosed system may allow for the use advance automation commercial off the shelf solutions such as robotic arms.

Thus, as indicated (<FIG>), the elevator inspection system includes the sensor implement <NUM> and the robotic platform <NUM> supporting the sensor implement <NUM>, where the robotic platform <NUM> is configured to inspect the hoistway <NUM>. The controller <NUM> is operationally connected to the robotic platform <NUM> and the sensor implement <NUM>. In one embodiment the sensor implement 210is a video sensor and/or acoustic sensor. In one embodiment the robotic platform <NUM> is a drone.

Turning to <FIG>, a method is disclosed for developing hoistway model data for a hoistway <NUM>. The hoistway <NUM> may not yet include an elevator system (elevator car <NUM>, guide rail <NUM>, etc.), and the hoistway model may be utilized for the installation process. Alternatively the hoistway <NUM> may include elevator system (elevator car <NUM>, guide rail <NUM>, etc.), and the hoistway model may be utilized for the inspection and maintenance.

As shown in block <NUM> the method includes the controller <NUM> defining hoistway model data for the hoistway <NUM>, from sensor data, corresponding to locations and shape boundaries of the hoistway <NUM> and doorway openings (at various levels) formed in the hoistway <NUM>.

As shown in block 510A the method includes the controller <NUM> defining a three-dimensional hoistway model from the hoistway model data.

As shown in block 510B, the method includes the controller <NUM> utilizing the hoistway model data as a reference point for installing and/or maintaining one or more components in the hoistway.

As shown in block 510C the method includes the controller <NUM> defining elevator car guide rail data, corresponding to a virtual elevator guide rail <NUM>, in the hoistway model data. That is, in conditions where the elevator system is not yet installed, the model will include a virtual elevator guide rail at a location where the actual elevator guide rail <NUM> is to be installed.

As shown in block <NUM>, the method includes controller <NUM> determining, from the hoistway model data, sill to sill distances, guide rail to guide rail distances, and sill to guide rail distances for each of the doorway openings.

As shown in block 520A, the method includes the controller <NUM> determining, from the hoistway model data, tilt and twist of the hoistway <NUM>, locations and sizes of doorway openings.

As shown in block <NUM>, the method includes the controller <NUM> defining (e.g., marking) installation locations within the hoistway model data for elevator components, including the virtual guide rail.

According to some embodiments the model comprises a <NUM> dimensional model representation of the hoistway. The model may also comprise a CAD model or a video rendering of the hoistway. In additional embodiments the model may comprise a rendering of the elevator components including a listing of components for the elevator installation.

As shown in block <NUM>, the method includes the controller controlling movement of the robotic platform <NUM> in the hoistway <NUM>, where the controller is operated manually, on SLAM (simultaneous localization and mapping), and/or on CAD models. As indicated above, in some embodiments the robotic platform <NUM> is stationary.

According to an additional aspect of the disclosed embodiments, in the growing market of internet of things (IoT), data is a valuable asset. Having easy-to-access information on system performance and operational parameters and a system that can self-diagnose adds value to the field. Additionally, historic performance data, trends and patterns from tests performed on elevator systems locally, regionally and globally may be utilized to monitor quality and service performance of an elevator system.

Thus, utilizing the inspection system <NUM>, different types of measurements can be collected to capture a set of variables that defines system operational performance in different operational stages of the elevator system <NUM>. Such measurements include, for example, straightness of the hoistway <NUM>, landing to landing (sill to sill) measurements, a three dimensional model of hoistway <NUM>, guide rail to guide rail <NUM>, 109A (<FIG>) measurements, and wall to wall <NUM>, 228A, measurements. Collecting this data allows for significant time savings in the field. Maintenance, ride quality, motion profile, door performance, amount of light in the car, cabin operation panel (COP) buttons, may all be monitored and maintained based on recorded data. Constant or periodic monitoring of system performance without a need of an onsite mechanic may allow for cost savings and for marketing new products.

Benefits of the utilizing data as described herein is a decreased time to market, freeing mechanic time, providing a competitive advantage due to decreased costs on manpower, increased precision, increased mechanic safety. The embodiments enable building a digital data base of global measurements, will improve design approaches and enable new products and services.

Thus, as indicated (<FIG>), the inspection system <NUM> includes the sensor implement <NUM>, the robotic platform <NUM> supporting the sensor implement <NUM>, and a controller <NUM> operationally connected to the robotic platform <NUM> and the sensor implement <NUM>. The sensor implement <NUM> may be one or more of a video sensor; an acoustic sensor; a LIDAR (light and radar) sensor; a camera; a laser sensor, a photogrammetry sensor, and a time of flight sensor. As indicated the robotic platform <NUM> is configured for inspecting the hoistway <NUM>.

Turning to <FIG>, a flowchart shows a method of determining whether components of an installed elevator system <NUM> are positioned and operating within predetermined positioning and operating tolerances based on the utilization of datasets, e.g., collected over the internet.

As shown in block <NUM>, the method includes the controller <NUM> defining hoistway model data for the hoistway <NUM>, from maintenance and performance data collected from disparately located elevator systems connected to communicate over a network. The hoistway model data may be utilized to build a virtual model for a new installation of an elevator system.

As shown in block 610A, the method includes the controller <NUM> defining the hoistway model data from maintenance and performance data collected over the Internet.

As shown in block 610B, the method includes the controller <NUM> identifying maintenance and performance trends from the collected maintenance and performance data.

As shown in block 610C the method includes the controller <NUM> defining the hoistway model data to identify, for an elevator car <NUM> in the hoistway <NUM>, one or more of: maintenance needs; ride quality; a motion profile; and door performance requirements.

As shown in block <NUM>, the method includes the controller <NUM> determining a frequency of monitoring the hoistway <NUM> from the hoistway model data.

As shown in block 620A, the method includes the controller determining to substantially continuously monitor the hoistway <NUM> from the hoistway model data.

As shown in block <NUM>, the method includes the controller <NUM> further defining the hoistway model data from sensed locations and shape boundaries of the hoistway <NUM> and doorway openings formed in the hoistway <NUM>.

As shown in block 630A, the method includes the controller <NUM> defining the hoistway model data to include sill to sill distances, guide rail to guide rail distances, sill to guide rail distances, and tilt and twist of the hoistway. In one embodiment the hoistway model data defines a three-dimensional model of the hoistway <NUM>.

As shown in block 630B, the method includes the controller <NUM> utilizing the hoistway model data as a reference point for installing and/or maintaining one or more components in the hoistway.

As shown in block <NUM>, the method includes the controller <NUM> transmitting an alert upon identifying, from sensor data compared with hoistway model data, when a component of an elevator system installed in the hoistway <NUM> is positioned or operating outside of predetermined positioning and operating tolerances. In one embodiment the component is the guide rail <NUM>.

According to another aspect of the disclosed embodiments, precise hoistway measurements are important for maintenance purposes. Mechanics may receive a hoistway assignment from a general contractor and check if components in the hoistway <NUM> are installed and/or operating according to specifications. If the mechanic builds a reference system and marks installation locations for each component in the hoistway, the mechanic may not realize from this process whether there is hoistway skew.

The disclosed embodiments provide measurement applications of the robotic platform <NUM> with the utilization of a reference system for an elevator installation and subsequent service. Described utilizations are beneficial for time and cost saving which leads to higher field efficiency.

Turning to <FIG>, as one example, maintenance of a guide rail requiring realignment is shown. Such maintenance may include loosening bolts, aligning the guide rail <NUM>, and then tightening the bolts. Other examples may include rope/belt inspections and maintenance, periodic and scheduled ride quality tests, door coupler alignment, door switch tests and sill cleaning. The robotic platform <NUM> is assigned/mounted in the hoistway <NUM>, or, e.g., a portable device is provided that may be installed in the hoistway <NUM>, e.g., on the rail(s). In an alternate embodiment the robotic arm <NUM> may be mounted to the top of an elevator car.

Benefits of the disclosed embodiments is a field time reduction for mechanics, improved safety for the mechanics as robotic platforms may be utilized in relatively dangerous locations, a competitive advantage based on fewer mechanic hours needed for maintenance, an increased precision and an extended product life time for the elevator system. In addition, system performance tracking is available as well as a global data base for CBM and predictive maintenance.

For example in <FIG>, the robotic platform <NUM> is controlled to loosen each the guide rail <NUM> and adjust and tighten each guide rail <NUM>, as the robotic platform <NUM> moves heightwise along the hoistway <NUM>. During this process, the robotic platform <NUM> may make test runs on each guide rail <NUM> to verify the adjustment using the sensor implement <NUM>, which may be one or more onboard ride quality sensor implements. The maintenance process may be repeated if needed on a full length of each guide rail <NUM>, or the maintenance process may be performed along a discrete section of each guide rail <NUM>.

The robotic platform <NUM> may be fully autonomous or may be provided with mechanic support. Other applications of the maintenance process may include hoistway door service, rope inspection and door couplers alignment. A robotic arm <NUM> (<FIG>) is supported on the robotic platform <NUM> one non-limiting example. However the robotic platform <NUM> may be adjusted to the task and may have a set of tools that can be changed.

As indicated (<FIG> and <FIG>), the elevator inspection system includes a sensor implement <NUM>, a robotic platform <NUM>, which is portable, supporting the sensor implement <NUM>, and a controller operationally connected to the robotic platform <NUM> and the sensor implement <NUM>. As indicated the robotic platform <NUM> is configured for inspecting and performing maintenance in the hoistway <NUM>.

Turning to <FIG>, a flowchart shows a method of performing maintenance within a hoistway <NUM>.

As shown in block <NUM>, the method includes the controller <NUM> controlling movement of the robotic platform <NUM> within the hoistway <NUM>.

As shown in block <NUM>, the method includes the controller <NUM> inspecting one or more components in the hoistway <NUM> to determine, from sensor data compared with hoistway model data, that an operational parameter or an alignment of the one or more components is outside predetermined positioning and operating tolerances. Such tolerances would be appreciated by one of ordinary skill.

As shown in block 1020A, the method includes the controller <NUM> utilizing the hoistway model data as a reference point for installing and/or maintaining one or more components in the hoistway.

As shown in block <NUM>, the method includes the controller <NUM> controlling the robotic platform <NUM> to execute one or more of: guide rail realignment; rope/belt inspection; ride quality tests; door couple alignment inspection; door switch test; and sill cleaning, to thereby determine that the operational parameter or the alignment of the component is outside predetermined positioning and operating tolerances.

As shown in block 1030A, the method includes the controller <NUM> engaging a segment <NUM> of an elevator guide rail <NUM> of the hoistway <NUM>, to position the segment <NUM> within predetermined positioning and operating tolerances, upon determining, from sensor data compared with hoistway model data, that the segment <NUM> is positioned outside the predetermined positioning and operating tolerances.

As shown in block 1030B, the method includes the controller <NUM> engaging the guide rail <NUM> by loosening rail securing bolts, aligning the guide rail, and tightening rail securing bolts.

As shown in block <NUM>, the method includes the controller <NUM> periodically or within scheduled timeframes engaging the one or more components to determine that the operational parameter or the alignment of the component is outside predetermined positioning and operating tolerances.

As shown in block <NUM>, the method includes the controller defining the hoistway model data from sensed locations and shape boundaries of the hoistway and doorway openings formed in the hoistway.

As shown in block 1050A, the method includes the controller defining the hoistway model data to include sill to sill distances, guide rail to guide rail distances, sill to guide rail distances, and tilt and twist of the hoistway <NUM>. In one embodiment the hoistway model data defines a three-dimensional model of the hoistway <NUM>.

As shown in block 1050B, the method includes the controller <NUM> defining the hoistway model data as a three-dimensional model of the hoistway <NUM>.

According to another aspect of the disclosed embodiments, the robotic platform <NUM> enables best practices and enables opportunities for mechanics in the field to simplify, support, and/or automate tasks and increase overall field efficiency. The robotic platform <NUM> equipped with different tools for installation and service tasks to allow for partial or full automation of the more time-consuming procedures, for example, guide rail installation and maintenance.

Turning to <FIG>, different solutions for propelling the robotic platform <NUM> are shown with a focus on propulsion, safety and anchoring of the robotic platform in the hoistway <NUM>. The robotic platform <NUM> may operate in an empty hoistway <NUM> from a landing, or a pit, and may move inside the hoistway <NUM> using walls or dedicated ropes to move in the hoistway <NUM>. The robotic platform <NUM>, equipped with tools, may be utilized for scanning/inspecting the hoistway <NUM>, taking measurements, grinding, marking drilling points, drilling, hoisting or securing the rail/door entrances within the hoistway <NUM>. The robotic platform <NUM> may be self-propelled or be hoisted. The guide rail <NUM> may be utilized as a guide for the robotic platform <NUM>. The robotic platform <NUM> may be locked in a position along the hoistway <NUM> using brakes on the robotic platform <NUM> or on the rail <NUM>. When there are no guide rails, the robotic platform <NUM> may use friction against the hoistway walls <NUM>, 228A (<FIG>) to lock in place or, if available, lock against a rope.

The robotic platform <NUM> may be used for one or more of installation, maintenance and inspection. For example, the robotic platform <NUM> may be used for belt/rope monitoring, guide rail straightening, post earthquake hoistway inspection.

Benefits of the disclosed embodiments includes a decreased time to market a product, freeing mechanic time, competitive advantage from lower associated costs, increased precision and extended product life time, increased mechanic safety, decrease of repetitive motion injuries, and allowing for a more rapid design approach.

Each propulsion system illustrated in <FIG> may function based on decision making that can be executed on the edge of a doorway or wirelessly (e.g., through the internet). Each propulsion system may be equipped with remote controlled safety system. Additionally there may a reference system, such as a global positioning system or hoistway model data, utilized to assist in directing the each propulsion system.

As indicated in <FIG>, the inspection system <NUM> includes the robotic platform <NUM> configured to inspect the hoistway <NUM>, a platform propulsor <NUM> operationally connected to the robotic platform <NUM>, and a controller <NUM> (shown only in <FIG> for simplicity) operationally connected to the platform propulsor.

Turning to <FIG>, a flowchart shows a method of propelling the robotic platform <NUM> within the hoistway <NUM>.

As shown in block <NUM>, the method includes the controller <NUM> controlling the platform propulsor <NUM> to propel (e.g., vertically) the robotic platform <NUM> within the hoistway <NUM>.

As shown in block 1910A, the method includes the controller <NUM> controlling friction pullies 255A (<FIG>) operationally connected between the robotic platform <NUM> and a rope 255A1 extending to a mechanical room <NUM> atop the hoistway <NUM> (and the pit <NUM>), to thereby propel the robotic platform <NUM>.

As shown in block 1910B, the method includes the controller <NUM> controlling vacuum suction cups 225B (<FIG>) operationally connected between the robotic platform <NUM> and hoistway side walls <NUM>, 228A, to thereby propel the robotic platform <NUM>.

As shown in block 1910C, the method includes the controller <NUM> controlling rubber wheels 255C (<FIG>) operationally connected between the robotic platform <NUM> and hoistway side walls <NUM>, 228A, to thereby propel the robotic platform <NUM>.

As shown in block 1910D, the method includes the controller <NUM> controlling mechanical legs 255D (<FIG>; forming a spider-like set of supports) operationally connected between the robotic platform <NUM> and hoistway side walls <NUM>, 228A, to thereby propel (e.g., by stemming) the robotic platform.

As shown in block 1910E, the method includes the controller <NUM> controlling propellers 255E (<FIG>) operationally connected to the robotic platform <NUM>, where the robotic platform <NUM> is supported by a balloon 255E1, to thereby propel the robotic platform <NUM>.

As shown in block 1910F, the method includes the controller <NUM> controlling a rail climber 255F (<FIG>) operationally connected to the robotic platform <NUM>, to thereby propel the robotic platform <NUM>.

As shown in block <NUM>, the method includes the controller <NUM> controlling a rail climber 255F (<FIG>) operationally connected to the robotic platform <NUM>, where the rail climber 255F operationally engages a first rail <NUM> that is adjacent a first hoistway sidewall <NUM>, and a balance wheel 255F1 of the rail climber 255F is operationally positioned against a second hoistway side wall 228A, to thereby propel the robotic platform <NUM>.

As shown in block <NUM>, the method includes the controller <NUM> controlling a drone <NUM> (<FIG>; illustrated schematically; see the robotic platform <NUM> in <FIG>) that is, or is operationally connected to, the robotic platform <NUM>, to thereby propel the robotic platform <NUM>.

As shown in block <NUM>, the method includes the controller <NUM> controlling one or more controllable tools <NUM> (<FIG>; illustrated schematically) supported on the robotic platform <NUM>, whereby the robotic platform <NUM> is configured for scanning and inspecting the hoistway <NUM>, taking measurements, grinding, marking drilling points and drilling.

According to an addition aspect of the disclosed embodiments, and turning to <FIG>, the disclosed embodiments provide a mobile robot (for simplicity, a robot <NUM>), which may also be considered a robotic platform. The robot <NUM> is capable of monitoring, cleaning, adjusting elevator parameters, measuring performance and requesting maintenance of an elevator car <NUM> or elevator groups in a building. The robot <NUM> is configured for performing tests using a built-in sensor implement <NUM>, such as a camera (to monitor sill conditions, and landing alignments), an accelerometer, and/or a microphone (to monitor ride quality). The robot <NUM> is able to communicate with the elevator car <NUM> and execute runs, emergency stops, open/close door cycles and modify basic parameters. The robot <NUM> may also perform measurements during predetermined time conditions (e.g., off peak, no passengers). The robot <NUM> may or may not be equipped with propulsion and may or may not require human intervention to move between elevator cars. The inspection system <NUM> of this embodiment may utilize a built-in or external gateway that is connected using different protocols for example, Bluetooth low energy (BLE) to a phone, and thereafter a cellular protocol such as Global System for Mobile Communications (GSM) to bridge the robot <NUM> to the Internet.

Benefits of the disclosed embodiments include field time reduction for mechanics, automated periodic testing and system adjustments, continuous system performance tracking, historical data base supporting CBM and the development of predictive maintenance. A competitive advantage may be realized from the decreased operational costs and increased launch and up-time.

Thus, the disclosed embodiments provide a non-propelled robot <NUM> to execute maintenance tasks, e.g., as a mechanics helper. The robot <NUM> may communicate with the elevator system <NUM> to place commands, as well as support the sensor implement <NUM> such as a camera and a ride-quality sensor (an accelerometer and/or microphone). The robot <NUM> may conduct inspections and make recommendations as to daily maintenance tasks.

As indicated (<FIG>) an elevator inspection system <NUM>, configured to inspect multiple elevator cars in a group of elevator cars, is disclosed that includes a sensor implement <NUM>, a robot <NUM> supporting the sensor implement <NUM> and a controller <NUM> operationally connected to the robot and the senor. The robot <NUM> is configured to be positioned in an elevator car <NUM>.

<FIG> is a flowchart showing a method of performing an elevator operational inspection with the robot <NUM>.

As shown in block <NUM>, the method includes the controller <NUM> transmitting an alert, e.g., to a mechanic, responsive to determining, from sensor data compared with elevator operational data, that an operational parameter of an elevator car <NUM> in which the robot <NUM> is located is outside a predetermined threshold (where such threshold values would be understood by one of ordinary skill).

As shown in block 2110A, the method includes the controller <NUM> determining whether ride-quality is outside the predetermined threshold, to thereby determine that the operational parameter is outside the predetermined threshold.

As shown in block 2110B, the method includes the controller <NUM> determining whether acceleration is outside the predetermined threshold, to thereby determine that the ride-quality is outside the predetermined threshold.

As shown in block 2110C, the method includes the controller <NUM> determining whether operational acoustics are outside the predetermined threshold, to thereby determine that the ride-quality is outside the predetermined threshold.

As shown in block 2110D, the method includes the controller <NUM> communicating with an elevator car control panel <NUM>, to thereby determine that the operational parameter is outside the predetermined threshold.

As shown in block 2110E, the method includes the controller instructing the elevator car control panel to execute one or more of runs between levels, emergency stops, and open/close door cycles, to thereby determine that the operational parameter is outside the predetermined threshold.

As shown in block <NUM>, the method includes the controller <NUM>: verifying operation of car operation panel (COP) lights; confirming elevator car leveling accuracy; cleaning the elevator car via the robot; and/or changing elevator car controller settings to minimize effects of a bed quality of a ride.

As shown in block <NUM>, the method includes the controller <NUM> communicating with the elevator car control panel <NUM> over a wireless network, which may be a personal area network.

As shown in block <NUM>, the method includes the controller <NUM> controlling the sensor implement to obtain the sensor data during predetermined periods of time and/or when the elevator car is without passengers.

As shown in block <NUM>, the method includes the controller <NUM>, which is onboard the robot <NUM>, transmitting the alert to an elevator group controller over a cellular network <NUM>.

As used herein an elevator controller may be a microprocessor-based controller that controls many aspects of the elevator operation. A series of sensor implements, controllers, sequences of operation and real-time calculations or algorithms that balance passenger demand and car availability. Elevator sensor implements may provide data on car positions, car moving direction, loads, door status, hall calls, car calls, pending up hall and down hall calls, number of runs per car, alarms, etc. The controllers may also have a function enabling the testing the systems without shutdown of the elevator. From collected data, a management system consisting of a workstation and software applications that may create metrics for a group or particular car such as total number of door openings, number of runs per car or call, up and down hall calls, etc. Some performance indicators may be related to passenger wait times and/or elevator car travel times. These metrics may indicate inadequate controls, misconfiguration or even equipment malfunction. Elevator monitoring may be provided as Software as a Service (SaaS). The monitoring may identify malfunctions or abnormal operating parameters and automatically dispatch a technician and/or provide alerts to relevant persons such as building owners. Some systems may provide customer dashboards accessible via a web browser and/or provide owners with information such as performance summaries and maintenance histories. As indicated, the elevator controller may communicate with the one or more elevators over a Controller Area Network (CAN) bus. A CAN is a vehicle bus standard that allow microcontrollers and devices to communicate with each other in applications without a host computer. CAN is a message-based protocol released by the International Organization for Standards (ISO). Downstream communications from the elevator system controller may be over a LAN.

Claim 1:
An elevator inspection system (<NUM>), comprising:
a sensor implement (<NUM>);
a robotic platform (<NUM>), which is portable, supporting the sensor implement (<NUM>), the robotic platform (<NUM>) configured for inspecting and performing maintenance in a hoistway (<NUM>);
a controller (<NUM>) operationally connected to the robotic platform (<NUM>) and the sensor implement (<NUM>), wherein the controller (<NUM>) is configured to:
control (<NUM>) movement of the robotic platform (<NUM>) within a hoistway (<NUM>); and
inspect (<NUM>) one or more components in the hoistway (<NUM>) to determine, from sensor data compared with hoistway model data, that an operational parameter or an alignment of the one or more components is outside predetermined positioning and operating tolerances.