Method and assembly device for carrying out an installation process in an elevator shaft of an elevator system

Abstract

In a method for carrying out an installation process in an elevator shaft of an elevator system, an assembly device is inserted into the elevator shaft. The assembly device includes a support component, a mechatronic installation component retained by the support component and a control apparatus. At least one assembly apparatus (tool, sensor or component) is arranged on the support component. The support component is fixed in a fixing position in the elevator shaft. After the support component has been fixed, an actual position of the at least one assembly apparatus is determined relative to the installation component. Using the determined actual position relative to the support component, the at least one assembly apparatus is received by the installation component and an assembly step is carried out using the received at least one assembly apparatus.

Claims

1. A method for carrying out an installation process in an elevator shaft of an elevator system comprising the steps of: inserting an assembly device into the elevator shaft, the assembly device including a support component, an installation component being a mechatronic installation component that is retained by the support component, a control apparatus for controlling the installation component, and an assembly means arranged on the support component; fixing the support component in a fixing position in the elevator shaft; determining an actual position of the assembly means relative to the installation component based on an initial position of the assembly means stored in the control apparatus and based on a deformation of the support component brought about by the fixing in the fixing position; receiving the assembly means by the installation component using the actual position of the assembly means; and carrying out an assembly step with the installation component using the received assembly means.

2. The method according to claim 1 including at least two magazines arranged on the support component for retaining the assembly means and a plurality of additional assembly means and determining an actual position of each of the assembly means in the magazines.

3. The method according to claim 1 including identifying the deformation of the support component from an actual position of at least one reference point of the support component measured by a sensor when the support component is in the fixing position and an initial position of the at least one reference point before the fixing of the support component, the initial position being stored in the control apparatus.

4. The method according to claim 3 including measuring the actual position of the at least one reference point contactlessly.

5. The method according to claim 3 including arranging the sensor on the installation component before the support component is fixed.

6. The method according to claim 5 wherein the sensor is rigidly arranged on the installation component.

7. The method according to claim 1 including arranging at least one deformation sensor on the support component for measuring a magnitude of the deformation of the support component.

8. The method according to claim 7 including measuring stresses in the support component by the at least one deformation sensor, and determining the deformation of the support component from the measured stresses.

9. An assembly device for carrying out an installation process in an elevator shaft of an elevator system comprising: a support component; an installation component being a mechatronic installation component retained on the support component; and a control apparatus for determining an actual position of an assembly means, arranged on the support component, relative to the installation component based on an initial position of the assembly means stored in the control apparatus and a deformation of the support component brought about by a fixing of the support component in a fixing position in the elevator shaft, and the control means actuating the installation component using the actual position of the assembly means to receive the assembly means and carry out an assembly step using the received assembly means.

10. The assembly device according to claim 9 including a sensor rigidly arranged on the installation component for measuring the actual position based on a reference point on the support component.

11. The assembly device according to claim 9 including at least one deformation sensor arranged on the support component for measuring a magnitude of the deformation of the support component.

12. The assembly device according to claim 11 wherein the at least one deformation sensor is adapted to measure stresses in the support component, and wherein the control apparatus determines the deformation of the support component from the measured stresses.

13. A method for carrying out an installation process in an elevator shaft of an elevator system comprising the steps of: inserting an assembly device into the elevator shaft, the assembly device including a support component, an installation component being a mechatronic installation component that is retained by the support component, a control apparatus for controlling the installation component, and an assembly means arranged on the support component; fixing the support component in a fixing position in the elevator shaft; determining an actual position of the assembly means relative to the installation component, wherein the installation component is retained by the support component by a retaining device, and the actual position of the assembly means is determined relative to the retaining device; receiving the assembly means by the installation component using the actual position of the assembly means; and carrying out an assembly step with the installation component using the received assembly means.

Description

DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of an elevator shaft of an elevator system with an assembly device received therein,

(2) FIG. 2 is a perspective view of an assembly device,

(3) FIG. 3 is a simplified side view of an assembly device in an elevator shaft before fixing a support component, and

(4) FIG. 4 is a simplified side view according to FIG. 3 after fixing a support component.

DETAILED DESCRIPTION

(5) FIG. 1 shows an elevator shaft 103 of an elevator system 101, in which an assembly device 1 according to an embodiment of the present invention is arranged. The assembly device 1 comprises a support component 3 and a mechatronic installation component 5. The support component 3 is designed as a framework comprising an upper part 30 and a lower part 31 (see FIG. 2), the mechatronic installation component 5 being mounted on the upper part 30 by means of a retaining device 109. This framework has dimensions that allow the support component 3 to be moved within the elevator shaft 103 in a main extension direction 108 of the elevator shaft 103, and therefore to be moved vertically in this case, i.e. for example to move into different vertical positions at different floors within a building. In the example shown, the mechatronic installation component 5 is designed as an industrial robot 7, which is attached to the upper part 30 of the support component 3 via the retaining device 109 so as to hang down. In this case, an arm of the industrial robot 7 can be moved relative to the support component 3 and for example can be moved toward a wall 105 of the elevator shaft 103.

(6) The support component 3 is connected to a movement component 15 in the form of a motor-driven cable winch by means of a steel cable serving as a support means 17, which winch is attached to the ceiling of the elevator shaft 103 at a retaining point 107 at the top of the elevator shaft 103. Using the movement component 15, the assembly device 1 can be moved within the elevator shaft 103 in the main extension direction 108, i.e. vertically over the entire length of the elevator shaft 103.

(7) The assembly device 1 further comprises a fixing component 19 by means of which the support component 3 can be fixed within the elevator shaft 103 in the lateral direction, i.e. in the horizontal direction. The support component 3 is therefore brought into a fixing position in which the support component 3 is shown in FIG. 1. Props 25 (see FIG. 2) arranged on a rear face of the support component 3, of which a total of four are provided, two at the top and two at the bottom, may be moved backward and outward to fix the support component 3, and in this way lock the support component 3 between walls 105 of the elevator shaft 103 by means of the fixing component 19 and the props 25. In this case, the props 25 can for example be spread apart by means of hydraulics or similar, in order to fix the support component 3 in the elevator shaft 103 in the horizontal direction. It is likewise possible for the fixing component 19 to alternatively or additionally be moved outward.

(8) FIG. 2 is an enlarged view of an assembly device 1 according to an embodiment of the present invention.

(9) The support component 3 is designed as a cage-like framework in which a plurality of horizontally and vertically extending bars form a mechanically load-bearing structure, and in particular form the upper part 30 and the lower part 31.

(10) Retaining cables 27 that can be connected to the support means 17 are attached to the upper part 30 of the cage-like support component 3. By moving the support means 17 within the elevator shaft 103, i.e. for example by winding up or unwinding the flexible support means 17 onto or from a cable winch of the movement component 15, the support component 3 can thus be moved within the elevator shaft 103 in the main extension direction 108, and therefore vertically, so as to hang therein.

(11) The fixing component 19 is provided on the side of the support component 3. In the example shown, the fixing component 19 is formed by an elongate bar extending in the vertical direction. A total of four props 25, only one of which is visible at the bottom and at the top, are provided on the rear face of the support component 3 opposite the fixing component 19. The props 25 can be moved in the horizontal direction relative to the framework of the support component 3. For this purpose, the props 25 can for example be attached to the support component 3 by means of a lockable hydraulic cylinder or a self-locking motor spindle. When the prop 25 is moved away from the framework of the support component 3, it moves laterally toward one of the walls 105 of the elevator shaft 103. In this way, the support component 3 can be locked within the elevator shaft 103 between the fixing component 19 and the props 25, and therefore the support component 3 is fixed within the elevator shaft 103 in the lateral direction and therefore in the fixing position while an assembly step is being carried out, for example. Forces that are introduced into the support component 3 can be transmitted to the walls 105 of the elevator shaft 103 in this state, preferably without the support component 3 being able to move or vibrate within the elevator shaft 103 in the process. In particular when the fixing component 19 is not in contact with a wall 105 of the elevator shaft 103 over its entire length, deformation of the support component 3 may occur. This is in particular the case if the fixing component 19 projects into a door cut-out in the elevator shaft 103.

(12) In the embodiment shown, the mechatronic installation component 5 is implemented by means of an industrial robot 7. It is noted that the mechatronic installation component 5 can however also be implemented in another manner, for example by differently designed actuators, manipulators, effectors, etc. In particular, the installation component could comprise mechatronics or robotics specially adapted to use in an installation process within an elevator shaft 103 of an elevator system 1.

(13) In the example shown, the industrial robot 7 is equipped with a plurality of robot arms that can pivot about pivot axes. For example, the industrial robot may have at least six degrees of freedom, i.e. an assembly tool 9 guided by the industrial robot 7 can be moved with six degrees of freedom, i.e. for example with three rotational degrees of freedom and three translational degrees of freedom. For example, the industrial robot may be designed as a vertical articulated arm robot, a horizontal articulated arm robot or SCARA robot, or as a Cartesian robot or gantry robot.

(14) The robot can be coupled at its self-supporting end to various assembly tools or sensors 9 which are retained in a first magazine 32 arranged on the support component 3. The assembly tools or sensors 9 may differ from one another in terms of design and intended purpose. The assembly tools or sensors 9 may be retained on the support component 3 such that the self-supporting end 122 of the industrial robot 7 is moved toward said tools or sensors and can be coupled to one of said tools or sensors. By means of the assembly tools 9, the industrial robot can receive components 13 to be installed or fastening screws (not explicitly shown). The assembly tools and sensors 9, and the consumable materials in the form of components 13 to be installed and fastening screws, are referred to here as assembly means or assembly apparatuses.

(15) One of the assembly tools 9 may be designed as a drilling tool, similar to a drilling machine. By coupling the industrial robot 7 to a drilling tool of this type, the installation component 5 can be configured to allow holes to be drilled for example in one of the walls 105 of the elevator shaft 103 so as to be controlled in an at least partly automated manner. Here, the drilling tool can for example be moved and handled by the industrial robot 7 such that the drilling tool drills holes for example in the concrete of the wall 105 of the elevator shaft 103 in an intended position using a drill, into which holes fastening screws can for example be subsequently screwed in order to fix fastening elements.

(16) Another assembly tool 9 may be designed as a screwing device for at least semi-automatically screwing fastening screws into previously drilled holes in a wall 105 of the elevator shaft 103.

(17) A second magazine 11 may also be provided on the support component 3. The magazine 11 can be used to store components 13 to be installed and to provide said components to the installation component 5.

(18) In the example shown, the industrial robot 7 may for example automatically pick up a fastening screw from the magazine 11 and screw said screw into previously drilled fastening holes in the wall 105 using an assembly tool 9 designed as a screwing device, for example.

(19) In the example shown, it is clear that, using the assembly device 1, assembly steps of an installation process in which components 13 are mounted on a wall 105 can be carried out in a completely or partly automated manner by the installation component 5 first drilling holes in the wall 105 and screwing fastening screws into said holes.

(20) To control the installation component 5 and in particular the industrial robot 7, the assembly device 1 comprises a control apparatus 21 arranged on the upper part 30 of the support component 3. The control apparatus 21 is connected by signals to a sensor 121, which is arranged on a self-supporting end 122 of the industrial robot 7. The sensor 121 may be used as an alternative to a sensor 9 from a magazine 32. The sensor 121 is for example designed as a laser scanner, by means of which a distance from any desired object can be determined. The control apparatus 21 can therefore in particular determine the distance between the sensor 121 and a reference point 23 arranged on the lower part 31 of the support component 3. Since the control apparatus 21 knows the position of the industrial robot 7 and therefore also the position of the sensor 121 relative to the retaining device 109 and therefore relative to the support component 3, it can determine therefrom the position of the reference point 23 relative to the installation component 5, in particular relative to the retaining device 109. Therefore, the control apparatus 21 can determine an actual position of the reference point 23 in the fixing position, i.e. after the support component 3 has been fixed. By comparing the actual position with an initial position of the reference point 23 stored in the control apparatus 21 before the support component 3 is fixed, deformation of the support component 3 brought about by the fixing can be deduced. Proceeding from stored initial positions of the assembly means in the form of assembly tools 9 and components 13 to be installed and from the information regarding the deformation of the support component 3, the actual positions thereof can be determined. It is likewise possible for the actual positions of the two magazines 11, 32 to be determined, and for the actual positions of the individual assembly means 9, 13 to be determined relative thereto.

(21) The approach when determining the actual positions of the assembly means 9, 13 is explained in greater detail on the basis of FIGS. 3 and 4. FIG. 3 is a simplified side view of the assembly device 1 in an elevator shaft 103 before the support component 3 is fixed, i.e. in an initial state, and FIG. 4 shows said support component after it has been fixed. The installation component 5 is not shown for the sake of clarity. Only the retaining device 109 is shown, which is arranged on the upper part 30 of the support component 3. In this case, the assembly device 1 is located in the region of a door cut-out 123 in a wall 105 in the form of a front wall 124 of the elevator shaft 103. The assembly device 1 is positioned such that the upper part 30 of the support component 3 is located in the region of the door cut-out 123 and the lower part 31 is located below the door cut-out 123. The fixing component 19 of the support component 3 may therefore be supported on the front wall 124 in the region of the lower part 31, but in the region of the upper part 30 there is no abutment to provide support. When locking the support component 3 by moving the props 25 toward a wall 105 in the form of a rear wall 125 of the elevator shaft 103, the support component 3 is pushed into the door cut-out 123 in the region of the upper part 30 and is contact with the front wall 124 in the region of the lower part 31 via the fixing component 19. Deformation of the support component 3 occurs as a result. This state is shown in FIG. 4.

(22) In the initial state in FIG. 3, an initial coordinate system is assigned to the installation component, which has its origin 126 in the center of the upper face of the retaining device 109. The x axis extends horizontally toward the rear wall 125. The z axis extends vertically downwards, i.e. in the main extension direction of the elevator shaft 103, and a y axis (not shown) extends into the drawing plane. A first reference point 23 is arranged directly on the lower part 31 of the support component 3, and has an x coordinate x1A and a z coordinate z1A. A second reference point 24 is arranged on a side part 33 of the support component 3 opposite the fixing component 19, and has an x coordinate x2A and a z coordinate z2A. The y coordinate is not relevant in this view. In this case, the x coordinate x1A of the first reference point 23 is less than the x coordinate x2A of the second reference point 24. In this case, the z coordinate z1A of the first reference point 23 is greater than the z coordinate z2A of the second reference point 24. Said coordinates denote an initial position of the two reference points 23, 24 and are stored in the control apparatus 21 of the installation component 5. The distance of the coupling of the first reference point 23 in the main extension direction from the retaining device 109 therefore corresponds to the z coordinate z1A and the distance of the coupling of the second reference point 24 corresponds to the z coordinate z2A.

(23) By fixing the support component 3 by means of the props 25 and the fixing component 19, the support component 3 is deformed such that the upper part 30 is displaced relative to the lower part 31 counter to the x direction, i.e. in the fixing direction. The origin of the coordinate system of the installation component 5 is therefore also displaced. The displaced origin is denoted by reference sign 126′. This results in an x′ and a z′ axis of the coordinate system. In a simplified manner, it is assumed that the distance between the upper part 30 and the lower part 31 remains the same, and that there is no displacement along the y axis and no rotation about one of the axes either. Therefore, the y and z coordinates of the reference points 23, 24 and of all the other elements of the installation component 3 remain unchanged and only the x coordinates change into x′ coordinates.

(24) In order to determine the x′ coordinates after fixing relative to the displaced origin 126′, the control apparatus 21 brings the sensor 121 into the vicinity of the first reference point 23 and, by means of the sensor 121, determines a distance in the x′ direction between the sensor 121 and the first reference point 23. Since the control apparatus 21 knows the position and therefore the x′ coordinate of the sensor 121, it can determine the x′ coordinate x1I of the first reference point 23 in the fixing position by means of the measured distance from the sensor 121. Said coordinates denote an actual position of the first reference point 23. By comparing the x coordinate x1A in the initial position and the x′ coordinate x1I in the fixing position, the control apparatus 21 can calculate the displacement of the origin 126′ compared with the original origin 126. The z coordinate of the reference point 23 remains the same (z1A=z1I).

(25) For all the assembly means that are likewise coupled to the support component 3 via the lower part 31, the x′ coordinate changes by the same magnitude as for the first reference point 23. For the assembly means of which the coupling to the support component is a lower distance in the main extension direction from the retaining device 109, the magnitude of the change in the x′ coordinate changes in proportion to the reduction in said distance.

(26) An assembly tool 9 can be received using the calculated actual position thereof, and an assembly step, for example drilling a hole in a wall of the elevator shaft, can be carried out.

(27) If the lower part 31 rather than the upper part 30 is displaced into the door opening 123 when fixing the support component 3, the same process is used. The only difference is that the origin 126 of the coordinate system remains unchanged and the first reference point 23 is displaced relative to the origin 126.

(28) In order to also very precisely determine the magnitude of the change in the x′ coordinate for assembly means of which the coupling to the installation component is a lower distance from the retaining device, in particular the same distance as the second reference point 24, the described method can be repeated using the second reference point 24 and the actual coordinate x2I of the second reference point 24 can be determined. With the second reference point 24 too, the z coordinate remains unchanged (z2I=z2A). For this purpose, in the same way as determining the actual position of the first reference point 23, the actual position of the second reference point 24 is determined. By comparing the coordinate in the initial position x2A and the actual coordinate x2I of the second reference point 24, the magnitude of the change in the x′ coordinate of the reference point 24 in the x direction can be identified. For the assembly means of which the coupling to the support component is the same distance in the main extension direction from the retaining device 109 as the second reference point 24, the x′ coordinate changes by the same magnitude as for the second reference point 24.

(29) The reference points 23, 24 each in particular denote a position of a magazine for receiving assembly means.

(30) Furthermore, actual positions of other reference points (not shown) can be determined, and can be analyzed and used as described.

(31) Additionally or alternatively, deformation sensors 127 in the form of strain gages may be arranged at corners of the support component 3, by means of which gages stresses in the support component 3 can be measured in the fixing position. On the basis of the measured stresses, the deformation of the support component 3 is determined by means of a finite element calculation by the control apparatus 21.

(32) Alternatively, the control apparatus 21 can also search for the actual position of relevant assembly means directly by means of the sensor 121, can store said positions and can then use them for planned assembly steps. In this case, the sensor 121 can in particular be designed as a 3D camera, the images from which are analyzed by means of image processing.

(33) In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.