Patent Description:
Precise positioning of components within a conveyance system, such as, for example, elevator systems, escalator systems, and moving walkways, plays and important role in the optimal operation of the conveyances system and may be difficult and/or costly to determine.

<CIT> discloses a device including a detector that is configured to detect at least one reference feature in a vicinity of a desired position of the elevator door component. A processor is configured to use information from the detector to determine the desired position of the elevator door component relative to the at least one detected feature. An indicator is configured to provide at least one indication corresponding to the desired position of the elevator door component.

According to an aspect of the invention, a method of monitoring an alignment of a component of a conveyance system according to claim <NUM> is provided. The method including: capturing, using a camera system, a follow-on image of the component of the conveyance system; determining a follow-on location of the component using photogrammetric measurements of the follow-on image; comparing the follow-on location to a baseline location of the component; and determining whether the component has shifted away from the baseline location based on the follow-on location and the baseline location.

Further embodiments may include: capturing, using the camera system, a baseline image of the component of the conveyance system; and determining the baseline location of the component using photogrammetric measurements of the baseline image.

Further embodiments may include determining whether a shift away from the baseline location is greater than an acceptable variance amount which indicates that an angular misalignment or a linear misalignment of the component is outside of an acceptable range.

Further embodiments may include activating an alert on a computing device when the angular misalignment or the linear misalignment of the component is outside of the acceptable range.

Further embodiments may include creating a new maintenance event on a calendar when the angular misalignment or the linear misalignment of the component is outside of the acceptable range.

Further embodiments may include moving a previously scheduled maintenance event on a calendar when the angular misalignment or the linear misalignment of the component is outside of the acceptable range.

Further embodiments may include that the conveyance system is an elevator system.

Further embodiments may include that the component is a door lock component of a door lock for a hoistway door of the elevator system.

Further embodiments may include that the camera system further includes: a first camera at a first location relative to the door lock; and a second camera at a second location relative to the door lock.

Further embodiments may include that the first camera is located above the door lock looking down onto the door lock, and wherein the second camera is located on a side of the door lock looking axially down the door lock.

According to another aspect of the invention, a component alignment monitoring system for monitoring an alignment of a component of a conveyance system according to claim <NUM> is provided. The component alignment monitoring system including: a camera system; a controller for the camera system, the controller including: a processor; and a memory including computer-executable instructions that, when executed by the processor, cause the processor to perform operations, the operations including: determining a follow-on location of the component using photogrammetric measurements of a follow-on image captured by the camera system; comparing the follow-on location to a baseline location of the component; and determining whether the component has shifted away from the baseline location based on the follow-on location and the baseline location.

Further embodiments may include that the operations further include: determining the baseline location of the component using photogrammetric measurements of a baseline image captured by the camera system.

Further embodiments may include that the operations further include: determining whether a shift away from the baseline location is greater than an acceptable variance amount which indicates that an angular misalignment or a linear misalignment of the component is outside of an acceptable range.

Further embodiments may include that the operations further include: activating an alert on a computing device when the angular misalignment or the linear misalignment of the component is outside of the acceptable range.

Further embodiments may include that the operations further include: creating a new maintenance event on a calendar when the angular misalignment or the linear misalignment of the component is outside of the acceptable range.

Further embodiments may include that the operations further include: moving a previously scheduled maintenance event on a calendar when the angular misalignment or the linear misalignment of the component is outside of the acceptable range.

According to another aspect of the invention, a computer program product tangibly embodied on a non-transitory computer readable medium according to claim <NUM> is provided. The computer program product including instructions that, when executed by a processor, cause the processor to perform operations including: determining a follow-on location of the component using photogrammetric measurements of a follow-on image captured by a camera system; comparing the follow-on location to a baseline location of the component; and determining whether the component has shifted away from the baseline location based on the follow-on location and the baseline location.

Technical effects of embodiments of the present disclosure include monitoring the alignment of components within a conveyance apparatus using one or more cameras and photogrammetric measurements.

For example, embodiments may be employed in ropeless elevator systems using a linear motor or pinched wheel propulsion to impart motion to an elevator car.

Referring now to <FIG>, <FIG>, with continued referenced to <FIG>, a prospective view of a component alignment monitoring system <NUM> is illustrated in <FIG> and door lock <NUM> is illustrated in <FIG>, according to an embodiment of the present disclosure. <FIG> illustrates the door lock <NUM> in an aligned state and <FIG> illustrates the door lock <NUM> in a misaligned state. It should be appreciated that, although particular systems are separately defined in the schematic block diagrams, each or any of the systems may be otherwise combined or separated via hardware and/or software.

The component alignment monitoring system <NUM> includes a camera system <NUM> that includes including one or more cameras <NUM>. The one or more cameras <NUM> of the component alignment monitoring system <NUM> may be operably arranged and located in order to monitor an alignment of components of the elevator system <NUM> and detect a miss-alignment of the components of the elevator system <NUM>. In an embodiment, the components are door lock components of a door lock <NUM> of the elevator system <NUM>. It is understood that while the component alignment monitoring system <NUM> is illustrated and described herein as being capable of detecting misalignment of a door lock <NUM>, the embodiments described herein may be applicable to the component alignment monitoring system <NUM> being capable of detecting misalignment of any component of the elevator system <NUM>, any component of any conveyance system, or any component of any other mechanical system.

<FIG> illustrates a top down view of the door lock <NUM>. It is understood that the door lock <NUM> illustrated in <FIG>, <FIG> is an exemplary door lock and the embodiments disclosed herein may be applicable to any door lock or any component of an elevator system <NUM>. The door lock <NUM> comprises a first arm <NUM> and a second arm <NUM> that interlocks with the first arm <NUM>. The first arm <NUM> may be referred to as a first component and the second arm <NUM> may be referred to as a second component. The door lock <NUM> is configured to ensure that the hoistway door <NUM> opens and closes properly during operation of the elevator system <NUM>. The hoistway door <NUM> may be composed of a first hoistway door <NUM> and a second hoistway door <NUM>. The hoistway door <NUM> is located on a landing <NUM> of the elevator system <NUM>. The hoistway door <NUM> is in a facing spaced relationship with an elevator car door <NUM> of the elevator car <NUM>. The elevator car door <NUM> is located on the elevator car <NUM> of the elevator system <NUM>. The elevator car door <NUM> may be composed of a first elevator car door <NUM> and a second elevator car door <NUM>. The elevator car door <NUM> and the hoistway door <NUM> may open simultaneously or near simultaneously to allow a passenger to enter the elevator car <NUM> at the landing <NUM>.

The component alignment monitoring system <NUM> may include a first camera 210a and a second camera 210b, although only one camera <NUM> may be required as discussed further herein. The first camera 210a may be located above the door lock <NUM> looking down onto the door lock <NUM> at a first location. The second camera 210b may be located on a side of the door lock <NUM> looking axially down the first arm <NUM> and/or the second arm <NUM> of the door lock <NUM> at a second location. The second camera 210b may be oriented at about a right angle relative to the first camera 210a. The first location and second locations provide different perspectives for the first camera 210a and the second camera 210b to monitor the door lock <NUM>.

In an embodiment, one camera <NUM> may be utilized in place of two or more cameras <NUM>. In one example, the single camera <NUM> may be movable to capture multiple views/angles of the component, such as, for example, moving the camera between the first location to the second location. In another example, the camera <NUM> may utilize one or more mirrors to capture multiples views/angles of the component, such as, for example a view from the first location and/or a view from the second location.

The term "camera <NUM>" is utilized herein to refer to both the first camera 210a and the second camera <NUM> collectively, while the terms "first camera 210a" and "second camera 210b" are used to refer individually to the first camera 210a at the first location and the second camera 210b at the second location.

The camera <NUM> may be any type of camera. The camera may be a still image camera or a compared video camera. The camera <NUM> may be configured to take still photos (i.e., follow-on images) at selected time intervals. The follow-on images may be compared to baseline images in order to determine whether there are any alignment issues in the door lock <NUM> using comparative analysis and/or photogrammetric measurements to determine magnitude of change.

The camera <NUM> may include or be operably connected to a controller <NUM>. The controller <NUM> may be an electronic controller including a processor <NUM> and an associated memory <NUM> comprising computer-executable instructions (i.e., computer program product) that, when executed by the processor <NUM>, cause the processor <NUM> to perform various operations. 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 but is not limited to a random access memory (RAM), read only memory (ROM), or other electronic, optical, magnetic or any other computer readable medium. The first camera 210a and the second camera 210b may each have a dedicated controller <NUM> or they may share a single controller <NUM>.

The controller <NUM> may include a computer program product or software saved on the memory <NUM> that is capable of performing photogrammetric measurements on images captured by the camera <NUM>. Photogrammetry has the advantage of being capable of sub-millimeter measurements based on pixel density in short distances from a camera to an object. The software capable of performing photogrammetric measurements may include but is not limited to simultaneous localization and mapping (SLAM) software. Alternatively, the remote server <NUM> may include the computer program product or software saved that is capable of performing photogrammetric measurements on images captured by the camera <NUM>. Thus, analysis and comparison of the images captured by the camera <NUM> may be performed locally by the controller <NUM> and/or remotely by the remote server <NUM>, or any desired component in between.

The component alignment monitoring system <NUM> may first capture a baseline image of the door lock <NUM>. The baseline image of the door lock <NUM> may be captured when the door lock <NUM> is first installed, when the component alignment monitoring system <NUM> is first installed, when the door lock <NUM> is realigned, when maintenance is performed on the door lock <NUM>, or at any other time a baseline image is desired.

The baseline image establishes a baseline location for each component of the door lock <NUM> within the baseline image. The baseline location may be established in a cartesian coordinate system <NUM> including one or more axis, such as, for example an x-axis <NUM>, a y-axis <NUM>, and a z-axis <NUM>. The z-axis <NUM> may be oriented parallel with a direction of travel of the elevator car <NUM> through the elevator shaft <NUM> or any other desired system.

A follow-on image may be captured by the camera <NUM> after the baseline image. The baseline image establishes a follow-on location for each component of the door lock <NUM> within the follow-on image. The follow-on location may be established in a cartesian coordinate system <NUM> including one or more axis, such as, for example an x-axis <NUM>, a y-axis <NUM>, and a z-axis <NUM>. The follow-on location may be compared to the baseline location to determine if any component of the door lock <NUM> (i.e., door lock component) has shifted from the baseline location. A shift away from the baseline location greater than an acceptable variance amount may indicate that an angular or linear misalignment of the door lock component is outside of an acceptable range, which may then automatically trigger an alert on a computing device <NUM>, add a new maintenance event on a calendar, or move a previously scheduled maintenance event to an earlier date on the calendar. An alert may be activated on a computing device <NUM> when a new maintenance event is created, or a previously scheduled maintenance event is moved to an earlier date on a calendar. The calendar may be stored on a remote server <NUM> and/or directly on the computing device <NUM>.

The controller <NUM> also includes a communication device <NUM>. The communication device <NUM> may be capable of wired and/or wireless communication including but not limited to Wi-Fi, Bluetooth, Zigbee, Sub-GHz RF Channel, cellular, or any other wireless signal known to one of skill in the art. The communication device <NUM> may be configured to communicate directly with a computing device <NUM>. Alternatively, or additionally, the communication device <NUM> may be configured to communicate with the computing device <NUM> through the internet <NUM> and/or a remote server <NUM>.

The computing device <NUM> may be a desktop computer, a laptop computer, or a mobile computing device that is typically carried by a person, such as, for example a phone, a smart phone, a PDA, a smart watch, a tablet, a laptop, or any other mobile computing device known to one of skill in the art.

The computing device <NUM> includes a controller <NUM> configured to control operations of the computing device <NUM>. The controller <NUM> may be an electronic controller including a processor <NUM> and an associated memory <NUM> comprising computer-executable instructions (i.e., computer program product) that, when executed by the processor <NUM>, cause the processor <NUM> to perform various operations. 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 but is not limited to a random access memory (RAM), read only memory (ROM), or other electronic, optical, magnetic or any other computer readable medium.

The computing device <NUM> includes a communication device <NUM> configured to communicate with the internet <NUM> through one or more wireless signals. The one or more wireless signals may include Wi-Fi, Bluetooth, Zigbee, Sub-GHz RF Channel or any other wireless signal known to one of skill in the art. Alternatively, the computing device <NUM> may be connected to the internet <NUM> through a hardwired connection. The computing device <NUM> is configured to communicate with the component alignment monitoring system <NUM> through the internet <NUM>. Communication between the computing device <NUM> and the component alignment monitoring system <NUM> may have to pass through the internet <NUM> and through the remote server <NUM>.

The computing device <NUM> may include a display device <NUM>, such as for example a computer display, an LCD display, an LED display, an OLED display, a touchscreen of a smart phone, tablet, or any other similar display device known to one of the skill in the art. A user operating the computing device <NUM> is able to view the computer application <NUM> through the display device <NUM>.

The computing device <NUM> includes an input device <NUM> configured to receive a manual input from a user (e.g., human being) of computing device <NUM>. The input device <NUM> may be a keyboard, a touch screen, a joystick, a knob, a touchpad, one or more physical buttons, a microphone configured to receive a voice command, a camera or sensor configured to receive a gesture command, an inertial measurement unit configured to detect a shake of the computing device <NUM>, or any similar input device known to one of skill in the art. The user operating the computing device <NUM> is able to enter feedback into the computer application <NUM> through the input device <NUM>. The input device <NUM> allows the user operating the computing device <NUM> to enter feedback into the computer application <NUM> via a manual input to input device <NUM>. For example, the user may respond to a prompt on the display device <NUM> by entering a manual input via the input device <NUM>. In one example, the manual input may be a touch on the touchscreen. In an embodiment, the display device <NUM> and the input device <NUM> may be combined into a single device, such as, for example, a touchscreen.

The computing device <NUM> device may also include a feedback device <NUM>. The feedback device <NUM> may activate in response to a manual input via the input device <NUM>. The feedback device <NUM> may be a haptic feedback vibration device and/or a speaker emitting a sound. The feedback device <NUM> device may activate to confirm that the manual input entered via the input device <NUM> was received via the computer application <NUM>. For example, the feedback device <NUM> device may activate by emitting an audible sound or vibrate the computing device <NUM> to confirm that the manual input entered via the input device <NUM> was received via the computer application <NUM>. The feedback device <NUM> may be activated when the alert on a computing device <NUM> is activated when it is detected that an angular or linear misalignment of the component is outside of an acceptable range, when a new maintenance event is added on the calendar, or when a previously scheduled maintenance event is moved to an earlier date on the calendar.

The component alignment monitoring system <NUM> may also include a power source <NUM>. The power source <NUM> is configured to store and supply electrical power to the camera <NUM> and controller <NUM>. The power source <NUM> may be electrical outlet and/or 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 camera <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.

Referring now to <FIG>, while referencing components of <FIG>, <FIG>, <FIG>, a flow chart of a method <NUM> of monitoring an alignment of a component of a conveyance system, in accordance with an embodiment of the disclosure. In an embodiment, the method <NUM> may be performed by the component alignment monitoring system <NUM> using the controller <NUM> and/or the remote server <NUM> of <FIG>. Also, in an embodiment, the component may be a component of the door lock <NUM> (i.e., a door lock component) of <FIG> and <FIG> or more specifically the first arm <NUM> and/or the second arm <NUM> of the door lock <NUM>. Further, in an embodiment, the conveyance system may be the elevator system <NUM> of <FIG>.

At block <NUM>, a camera system <NUM> captures a follow-on image of the component of the conveyance system. At block <NUM>, a follow-on location of the component is determined using photogrammetric measurements of the follow-on image. The component alignment monitoring system <NUM> may also perform mapping that includes incudes 3D images as opposed to just pixel measurements. The mapping would create multiple images than can be mapped together to create a 3D visual of the component.

At block <NUM>, the follow-on location is compared to a baseline location of the component.

At block <NUM>, it is determined whether the component has shifted away from the baseline location based on the follow-on location and the baseline location.

Prior to block <NUM>, the method <NUM> may further include that the camera system <NUM> captures a baseline image of the component of the conveyance system and determines the controller <NUM> may determine the baseline location of the component using photogrammetric measurements of the follow-on image.

The method <NUM> may further include that the controller <NUM> determines whether a shift away from the baseline location (in block <NUM>) is greater than an acceptable variance amount which indicates that an angular misalignment or a linear misalignment of the component is outside of an acceptable range. The method <NUM> may further include that an alert is activated on a computing device <NUM> when the angular misalignment or the linear misalignment of the component is outside of the acceptable range.

In another embodiment, there may be multiple thresholds at which alerts may be triggered. In one embodiment, a first threshold of misalignment may trigger an error that is stored and reported, then a second threshold of misalignment triggers a more decisive action such as an alarm, shut down, or an increased priority alert to mechanic. The second threshold of misalignment is greater than the first threshold of misalignment.

The method <NUM> may further include that a new maintenance event is created on a calendar when the angular misalignment or the linear misalignment of the component is outside of the acceptable range. The method <NUM> may further include that a previously scheduled maintenance event is moved on a calendar when the angular misalignment or the linear misalignment of the component is outside of the acceptable range.

As aforementioned, the component of method <NUM> may be a door lock component of the door lock <NUM> of <FIG>. The camera system <NUM> of method <NUM> may further include a first camera 210a at a first location relative to the door lock <NUM> and a second camera 210b at a second location relative to the door lock <NUM>. The first camera 210a may be located above the door lock <NUM> looking down onto the door lock <NUM> and the second camera 210b may located on a side of the door lock looking axially down the door lock <NUM>.

Claim 1:
A method (<NUM>) of monitoring an alignment of a component of a conveyance system (<NUM>), the method comprising:
capturing (<NUM>), using a camera system (<NUM>), a follow-on image of the component of the conveyance system;
determining (<NUM>) a follow-on location of the component using photogrammetric measurements of the follow-on image;
characterised by:
comparing (<NUM>) the follow-on location to a baseline location of the component; and
determining (<NUM>) whether the component has shifted away from the baseline location based on the follow-on location and the baseline location.