I. Introduction
In the vertical mobility of modern architecture, elevators, manufactured by elevator manufacturing companies, are not just a mode of transportation but the arteries of urban life and an extension of a building's functionality.According to the "Global Elevator and Escalator Market Research Report" (Research and Markets, 2021), with the acceleration of global urbanization and the renovation of old elevators in buildings, elevator companies are facing new growth opportunities.
Passenger elevators are a key indicator of a building's service level and technological advancement. In the "International Building Elevator Standards," the safety, comfort, efficiency, and elevator sizes and capacity are highlighted, underscoring their central role in modern architecture. Passenger elevators not only relate to the overall flow and usage efficiency of a building but also directly affect people's travel experience and sense of safety.
In this report, we will detail the types, design concepts, and technical features of passenger elevators provided by top elevator manufacturers. Furthermore, by integrating current domestic and international standards and best practices, including the "American Elevator Safety Standards" (ASME A17.1) and the "European Elevator Standards" (EN 81), we will discuss how to ensure the efficiency and cost-effectiveness of elevator systems while meeting user needs regarding elevator sizes and capacity.
II. Preparation for Passenger Elevator Installation
A. Needs Analysis
1) Purpose of the Building
The purpose of the building is the primary factor determining the type and specifications of the elevator. Different types of buildings such as residential, commercial, medical, educational, and industrial require elevators with specific performance characteristics and features. For instance, commercial buildings may require high-speed elevators to improve efficiency, while residential buildings might prioritize the quietness and comfort of the elevator. For hospitals, the elevator sizes and capacity should accommodate the transportation of hospital beds, with an elevator manufacturing company often providing custom solutions based on these needs.
2) Elevator Capacity Requirements
The capacity requirement of an elevator is closely related to the height of the building and the number of users. International standard ISO 4190-1:2010 "Basic Requirements for Elevator Design and Specifications" indicates that elevator capacities range from 630 kg (8 persons) to 1600 kg (21 persons). Calculating capacity requirements also takes into account the peak hour traffic (PHT) and the highest five-minute traffic volumes (5MHT), which help determine the number and size of elevators needed. For example, studies have shown that a busy elevator company may require elevators to support up to 160% of their standard capacity during peak workday periods.
B. Compliance with Regulations and Standards
● Ensuring Passenger Safety: Compliant elevator design and installation minimize the risk of malfunctions and accidents.
● Avoiding Legal Liability: Elevators that meet regulations help prevent lawsuits and fines due to legal violations.
● Increasing Trust: Adhering to industry standards enhances passenger confidence in elevator safety.
C. Site Condition Assessment
1) Building Structure Analysis
The first step in installing a passenger elevator is a thorough analysis of the building structure. This involves a detailed inspection of the building's main structure to ensure it can withstand the dynamic and static loads of elevator operation. Assessments should include, but are not limited to:
● The number of floors, floor-to-floor height, and load-bearing capacity of each level in the building.
● Determining the location for the elevator shaft and assessing its potential impact on the building structure, such as the position and strength of beams, columns, and load-bearing walls.
● Seismic impact assessment, ensuring that the elevator design and installation meet seismic requirements in earthquake-prone areas.
2) Elevator Shaft Provision and Conditions
The elevator shaft is the central space for elevator operation, and its design and construction quality directly affect elevator safety. Assessments of shaft provisions and conditions include:
● Accuracy of shaft dimensions to meet the requirements of the elevator manufacturer as well as national and local standards.
● The level and plumbness within the shaft, which determines the smooth installation and operation of the elevator equipment.
● The environmental conditions inside the shaft, such as temperature, humidity, ventilation, must meet specific technical requirements.
● The shaft must be free of obstructions like pipes, cables, etc., which must be relocated or reconfigured before elevator installation by the elevator manufacturing company.
3) Machine Room Location and Conditions
The machine room houses the elevator control systems and other important equipment, and its location and conditions directly affect the maintenance and operational efficiency of the elevator. Assessments of machine room location and conditions include:
● The choice of machine room location should allow easy access for maintenance personnel and ensure sufficient space for routine maintenance.
● The structural strength of the machine room must be able to support the weight of the elevator equipment, especially the traction machine and control cabinets, which is a critical consideration for the elevator company during installation.
III: Design and Planning Stage
A. Structural Design
1) Shaft Dimensions and Structure
An elevator manufacturing company must pay close attention to the design of the elevator shaft, as it is the central space for elevator operation. The dimensions and structure of the shaft have a direct impact on the elevator's design selection and operational performance.The width, depth, and height of the elevator shaft must be sufficient to accommodate various elevator sizes and capacity, ensuring that there is enough space for the elevator car, its operation, maintenance, and emergency situations.
The shaft walls must possess the necessary strength and rigidity to withstand the forces exerted during elevator operation. The design must include reserved brackets for the guide rails, ensuring that they are securely connected to the shaft walls. A critical safety feature is the buffer installed at the bottom of the shaft, which must meet shock absorption requirements allowing the elevator to stop safely during extreme situations.
2) Machine Room Layout
The layout of the machine room is crucial for the efficient maintenance and operation of the elevator. An elevator company typically positions the machine room at the top of the shaft; however, advancements in technology have led to the development of machine room-less elevators.
Machine room-less elevators integrate related equipment into the shaft or car, which necessitates that the elevator company's shaft structure reserve space for equipment installation right from the design stage. Regardless of the elevator system type, the conditions of the machine room or equipment space-temperature, humidity, and cleanliness-must meet the environmental requirements for the operation of the elevator, ensuring its stability and longevity.
3) Elevator Car Design
The design of the elevator car is integral to passenger comfort and directly influences the elevator's transport efficiency. The car dimensions should be tailored to the building's usage requirements, considering factors such as traffic flow and the building's function. The elevator manufacturer must also factor in the weight and material selection of the car, as these affect the load on the traction machine and overall system performance.
B. Elevator System Design
1) Drive System
The drive system is at the heart of an elevator's operation, a component that guarantees the lift's functionality. An elevator manufacturing company must select an appropriate drive system to ensure optimal performance and a smooth installation process. Drive systems vary, including hydraulic, traction, and machine-room-less (MRL) types.
a) Hydraulic drive systems are often chosen for low-rise buildings, offering a simple structure and cost-effectiveness. Installation considerations include the location of the hydraulic machine room, pipeline layout, and the effect of oil temperature on the system's performance.
b) Traction drive systems suit mid to high-rise buildings better. The installation requires careful consideration of the traction machine's configuration, the tension balance of the steel cables, and the equilibrium between the car and the counterweight. The drive system's installation location can also affect the architectural design, especially since traditional traction drives need a machine room space at the building's summit.
c) Machine-room-less drive systems are increasingly favored in contemporary architecture for their space-saving advantages and installation convenience. When installing MRL systems, it is vital to ensure the elevator shaft is precisely sized for the proper positioning and installation of the drive equipment.
2) Control System
The control system, the brains behind elevator automation, manages the operations, monitoring, and scheduling of the elevator. Installation considerations for the control system include:
a) Selecting a location for the control cabinet that facilitates easy maintenance and debugging while adhering to electrical safety standards.
b) The control system's compatibility and expandability are fundamental, especially as intelligent buildings progress and elevator systems must communicate efficiently with building automation systems.
c) Setting and debugging the control system parameters is a critical step in the installation process, requiring skilled technicians to make precise adjustments based on actual conditions to ensure the smooth and accurate operation of the elevator.
C. Elevator Safety Design
1) Safety Features Consideration
When considering a reputable elevator manufacturing company, safety features are a paramount concern that should never be compromised. As elevator manufacturer known for its meticulous attention to detail, take pride in the robust safety systems install in elevators, regardless of elevator sizes and capacity.
a) Governor and Safety Claws
Elevator company installs state-of-the-art governor and safety claws, ensuring the heart of the elevator's safety system operates flawlessly. The governor is carefully calibrated to monitor the elevator's speed and the safety claws are tested for reliable engagement to guide rails, preventing any possibility of a dangerous free fall.
b) Overload Protection Device
The overload protection device is a critical component in our elevators. This feature not only safeguards against the risks associated with excessive load but also ensures compliance with the specific elevator sizes and capacity guidelines. Our technicians are trained to meticulously calibrate this device during installation.
c) Door Interlock Mechanism
The safety of passenger elevator is further enhanced by a sophisticated door interlock mechanism. This feature is indispensable, ensuring operational safety by preventing the elevator from moving unless the doors are securely closed.
d) Buffers
Select buffers that are appropriate for the elevator's speed and weight capacity, ensuring maximum performance stability and passenger safety. These buffers are a testament to our commitment as an elevator manufacturer to passenger protection.
e) Elevator Landing Door Protection
Installation process includes rigorous checks to ensure elevator landing doors are equipped with prevention devices against accidental opening. We also focus on the durability of these doors as part of our comprehensive approach to safety.
2) Emergency Equipment and Considerations
a) Emergency Lighting System
Recognizing the importance of emergency preparedness, elevators include an emergency lighting system designed to be effective and reliable, guiding passengers to safety in the event of a power outage.
b) Elevator Emergency Alarm Device
An elevator emergency alarm device is a standard feature in our installations. Whether it's a bell or a communication system, ensure its functionality is maintained even during power supply interruptions.
c) Automatic Rescue Device (ARD)
Elevator company takes great care in configuring the ARD system, ensuring that it reliably engages to bring passengers to the nearest floor for a safe exit in the event of an emergency stop.
d) Elevator Fire Safety Measures
Adherence to fire safety standards is non-negotiable. Elevator companies use fire-resistant materials throughout our elevators' structural components and ensure integration with the building's fire safety systems for optimal passenger protection.
IV. Installation Phase
A. Construction Preparation
1) Construction Drawings and Guidelines
Securing detailed construction drawings and guidelines from the elevator manufacturing company is the first critical step in preparing for an elevator installation project. These documents are vital as they outline key factors such as the elevator sizes and capacity, shaft dimensions, elevator machine room layout, load requirements, and the precise placement of the elevator equipment.
The installation guidelines, provided by the elevator manufacturer, offer a step-by-step approach, technical specifications, and the operational procedures necessary for a successful installation. It's imperative for the construction personnel to be well-acquainted with these documents to avoid any missteps during the installation process.
2) Construction Team Training and Preparation
Given the technical nature of elevator installation, it's essential that the construction team is provided with comprehensive training. This is to ensure they are adept with the latest advancements from the elevator manufacturing company, including installation techniques and safety protocols. The training, endorsed by the elevator company, should encompass a range of topics such as elevator mechanics, operational safety, fault diagnosis, and emergency measures, ensuring the team is fully prepared for the task at hand.
3) Safety Protection Measures
An elevator company prioritizes safety above all else during the installation phase. Prior to commencing construction, a robust safety protection plan must be in place. This plan should cover all necessary personal protective equipment for workers, which includes helmets, safety harnesses, and protective eyewear. Additionally, clear safety warning signs and notices should be prominent around the construction site. Regular checks should be conducted to ensure all tools and equipment adhere to the highest safety standards and are functioning correctly. Furthermore, an emergency response plan should be established to address any accidents effectively.
4) Construction Environment Preparation
Creating an optimal construction environment is crucial to the quality of the elevator installation. Preparations for the environment should involve cleaning the shaft and machine room to remove any debris, dust, and moisture that could interfere with the installation. Adequate lighting must be installed within the shaft to guarantee the safety of construction personnel. Space considerations are also important, as there should be sufficient area for storing elevator components and tools provided by the elevator manufacturer. Lastly, verifying the ventilation within the shaft is essential to ensure a continuous flow of air for the comfort and safety of the work team.
B. Installation Process
1) Scaffold Setup
The elevator manufacturing company must determine the type of scaffolding, whether bamboo poles or steel pipes, based on the elevator sizes and capacity as well as the position set for the counterweight. Regardless of the material used, the stability and sufficient load-bearing capacity of the scaffolding must be ensured by the elevator company. Each scaffold layer must have at least two planks, and their ends must be securely fastened to the beams. The scaffold should be positioned for convenient construction work by the elevator manufacturer's team.
2) Machine Room Equipment Installation
This mainly involves the installation of the traction machine, the governor, and the control cabinet by qualified personnel from the elevator manufacturing company.
3) Shaft Equipment Installation
a) Guide Rail Installation
Elevator manufacturer will install car guide rail brackets, counterweight guide rail brackets, guide rails, and straighten the guide rails to ensure smooth operation.
b) Car Installation
As an elevator company, it will proceed to install the car sling, suspension frame, car frame, guide shoes, car bottom, safety gear, and overload device, all while considering the specific elevator sizes and capacity.
c) Counterweight Installation
The elevator manufacturer installs supports and lifting gear for the counterweight, which should only be removed after the traction rope has suspended the car counterweight on the traction sheave.
d) Buffer Installation
Elevator company must determine the position of the buffers. Adjust the center of the buffers to align with the center of the strike plate of the car frame or counterweight frame, with an allowable error no greater than 20mm. When installing two buffers on the same foundation, their height difference should not exceed 2mm.
e) Traction Steel Rope and Rope Socket Assembly Installation
The specifications of the steel rope, provided by the elevator manufacturer, must meet design requirements, free from kinks, corrosion, loose strands, or broken wires, and the hemp core must be lubricated without drying out. The company ensures an adequate supply of babbitt (Babbitt alloy). Materials needed include copper wire with a cross-sectional area greater than 2.5mm2, No. 20 lead wire, gasoline, kerosene, and cotton yarn.
f) Compensation Chain Installation
For elevators with significant lifting height, a compensation device recommended by the elevator manufacturing company should be installed. The combined clearance between the guide shoes and the top surfaces of the guide rails in the compensation device should not exceed 3mm, and the permissible sag of the guide rail for the liner wheel in the compensation device should be less than 1mm over the full height. The distance from the compensation rope sheave frame to the ground channel steel should be 150-200mm, with the guide rail end protruding 200-250mm above the guide shoe and equipped with a retaining plate at the end of the guide rail to prevent the liner wheel frame from jumping out.
g) Traveling Cable Installation
Shaft cable brackets should be installed approximately 3.8m below the top floor slab on the shaft wall and secured with bolts by the elevator company.
The car bottom cable bracket should be set at the car steel beam and secured firmly with bolts by the elevator manufacturer's technicians.
When installing the flexible cable, first measure the length from the shaft cable bracket to the various electrical equipment in the machine room, thread each cable into the respective conduit or wireway, and then place the other end of the flexible cable in the pit, ensuring each cable is straight and untangled.
h) Electrical Wiring Installation
Lay out the wiring according to the wiring diagram for the machine room and shaft provided by the elevator manufacturer. Power lines, motor lines, brake lines, control lines, indicator light lines, button lines, and lighting lines should each run through separate conduits or wireways, without joints inside the conduit. Any wire joints should be made inside junction boxes.
i) Limit Switch and Sensor Device Installation
First, mount the limit switch onto the bracket, securing it with a clamping plate and bolts to the car guide rail. Then, based on the position of the limit switch roller, determine where to install the striking bow on the car. The same striking bow can be used for both limit and over-travel.
4) Elevator Door Mechanism Installation
When an elevator manufacturing company undertakes the installation of an elevator door mechanism, there are several precise steps that need to be followed to ensure the safety and functionality of the elevators. The process starts with connecting the bolts to the elevator car frame. This is a critical step that an experienced elevator manufacturer will carefully execute. Following this, the door operator frame support bolt is installed; then, all bolts are tightened securely to accommodate the required elevator sizes and capacity.
Once the door operator and the elevator car are properly installed by the elevator manufacturing company, the door linkage mechanism must be adjusted. The clearance of the car door is critical and must meet the technical specifications outlined on the product drawings which vary based on elevator sizes and capacity.
Adjustments are also made when the landing door is in the closed position. The elevator manufacturer will ensure the position of the car door's opening knife blade is optimal. It should be positioned between the two rollers of the landing door lock, with similar gaps on either side of the rollers. The elevator company's technicians will initially tighten the anchor bolts or expansion bolts that fix the door frame's posts. They'll then adjust the verticality error of the landing door frame posts and the horizontality error of the transom to less than 1/1000. Once the gap deviation between the landing door guide rails and the sill groove at both ends and the middle of the guide rail is less than 1mm, all bolts must be secured firmly.
After these adjustments by the elevator manufacturer, the door leaf's linkage mechanism is installed. Once the landing door is installed properly, the elevator company will manually push and pull the door to ensure there is no noise or stiffness, which is a vital step to guarantee safety. Finally, the landing door electrical interlock device is installed, completing the elevator door mechanism installation process.
C. Safety Inspection
1) Preliminary Inspection
The preliminary inspection by the elevator manufacturing company is the first step after the elevator installation is completed. The inspection team will conduct an initial assessment of the quality of the elevator installation, including the accuracy and integrity of both mechanical and electrical components, to ensure they meet the elevator sizes and capacity standards.
2) Functionality Test
This step involves the verification of all the elevator's functions by the elevator company's technicians, including starting, running, accelerating, decelerating, stopping, and the precise opening and closing of doors as per the elevator manufacturer's design.
3) Safety Device Inspection
Elevator manufacturing company checks that all safety devices of the elevator, such as the speed governor, safety gear, door interlock device, overload protection, and emergency stop button, are functioning properly.
4) Load Test
The elevator company conducts no-load and full-load tests to ensure that the elevator operates safely and smoothly under different load conditions. The full-load test usually requires reaching 125% of the rated load capacity, which is determined by the elevator sizes and capacity.
5) Speed Test
Verify that the actual speed of the elevator operation conforms to the design speed and check for any instances of over-speeding or under-speeding.
6) Emergency and Fault Simulation
Simulate the elevator's response to faults or emergency situations, such as the activation of emergency lights during power failure, the operation of emergency communication devices, and the effectiveness of rescue procedures.
V. Operation and Maintenance
A. Operational Testing
1) Visual Inspection
An elevator manufacturing company must prioritize safety and efficiency during the installation process. To this end:
● Integrity Check: Ensure the elevator shaft, car, counterweight, and machine room components from the elevator manufacturer are completely installed, with no missing parts or screws.
● Cleanliness Check: Confirm that the interior and exterior of the elevator are clean, free from construction debris or other miscellaneous items, as this reflects on the elevator company's attention to detail.
● Signage Check: Inspect whether all the signage inside and outside the elevator is present, including elevator sizes and capacity, load capacity, manufacturer information, emergency contact details, etc.
2) Static Tests
Any reputable elevator company would insist on thorough static tests:
● Door System Test: Examine if the elevator doors, integral to elevator sizes and capacity, open and close smoothly, and whether the safety edges are sensitive and reliable.
● Electrical System Test: Test the elevator's electrical system, including the control panel, wiring terminals, signal systems, etc., to ensure there are no short circuits or leakage currents – a standard procedure in elevator manufacturing.
● Mechanical System Test: Check the car balance coefficient, counterweights, traction mechanisms, etc., to ensure mechanical components sourced from the elevator manufacturer are not loose or producing abnormal noises.
3) Dynamic Tests
During dynamic tests, an elevator manufacturing company must ensure:
● No-Load Operation: Initially operate the elevator without any load to observe if the elevator runs smoothly and without any unusual sounds, a key aspect of elevator sizes and capacity.
● Load Operation Test: Place the specified load (usually using special test weights) in the car to examine the elevator's performance under full load conditions, including whether the start, operation, and braking are smooth, and if the speed meets standards set by the elevator manufacturer.
● Brake Test: Test the elevator's braking system to ensure it can stop safely in emergency situations-a critical focus for any elevator company.
● Emergency Device Test: Test emergency equipment such as emergency power supply (e.g., UPS), emergency alarm devices, emergency lighting, etc., to ensure they function correctly in unexpected situations, which is a testament to the quality assurance of the elevator manufacturer.
4) Safety Device Testing
As part of safety device testing, the elevator manufacturing company must:
● Overspeed Governor Test: Test whether the overspeed governor acts reliably to ensure it can cut off the power and activate the safety gear promptly when the elevator exceeds the speed limit-a standard set by the elevator manufacturer for elevators of all sizes and capacity.
● Safety Gear Test: While performing the overspeed governor test, check if the safety gear can effectively brake, ensuring the car will not lose control and fall under any circumstances, which is essential for maintaining an elevator company's reputation for safety.
● Door Lock Interlock Test: Examine the elevator door locking mechanism to ensure the elevator cannot start unless the doors are completely closed, which is a critical safety feature emphasized by any elevator manufacturer.
By meticulously conducting these operational tests, an elevator manufacturing company can ensure that the elevators they produce are not only compliant with industry standards but also provide safe and reliable transportation for users of various elevator sizes and capacity.
B. Maintenance Plan
1) Daily Maintenance
Regular maintenance tasks are essential to ensuring the safe operation of elevators. This includes daily visual checks by the elevator manufacturing company's staff, such as cleaning inside and outside the elevator, ensuring that lighting, alarm devices, and door operations function properly. Additionally, listening for any unusual noises is crucial, as they may indicate the need for further inspection by the elevator manufacturer.
2) Periodic Inspections
Periodic maintenance, often conducted by the elevator company's trained technicians, is typically carried out monthly. They focus on the elevator's basic operational functions, such as elevator sizes and capacity, and key safety features. During these inspections, technicians from the elevator manufacturing company examine the elevator's speed, leveling accuracy, braking distance, and door opening and closing speed. All safety devices, such as speed governors, safety clamps, and buffers, are also tested for proper functionality.
VI. Conclusion and Recommendations
During the installation of passenger elevators, an elevator company should focus on the following key considerations:
● Safety: Safety is the primary consideration for passenger elevator installations. All design and installation work should aim to meet or exceed current safety standards to ensure the safety of passengers.
● Compliance: Elevator installations must adhere to relevant national and local regulations, including building codes, fire codes, and industry standards.
● Quality Control: A systematic quality control process should be employed by the elevator manufacturing company during installation to ensure the quality of all components and systems.
● Training and Maintenance: The installation team should receive professional training from the elevator manufacturer and perform appropriate maintenance on the elevators to ensure their long-term stable operation.
● Accessibility: Consideration should be given to the accessible design of passenger elevators, taking into account different elevator sizes and capacity, to ensure that everyone, including individuals with special needs, can use them conveniently.
● Energy Efficiency and Environmental Protection: The energy efficiency and environmental impact of passenger elevators should be considered during design and installation by the elevator company, opting for energy-saving and eco-friendly materials and technologies.
VII. References
● "International Building Code" (IBC)
● "American Safety Standard for Elevators" (ASME A17.1)
● "European Elevator Standards" (EN 81)
FUJI elevator factory was found in 1987, has a history of 37 years. Since 2008, we have cooperated with Japan's Fujitec company. FUJI elevator China has exporting elevator more than 20 year, and fuji elevators have reached over 100 countries.
If you are interesting in FUJI elevators, you can consult us at any time.