Method and apparatus for monitoring a state of a passenger transport system by using a digital double

Abstract

This application relates to a method and an apparatus for monitoring a state of a passenger transport system such as, for example, an escalator. The method includes monitoring the state of the passenger transport system using an updated digital double data record that reflects characterizing properties of components of the passenger transport system in an actual configuration of the passenger transport system in a machine-processable manner after the assembly and installation thereof in a building. The updated digital double data record can be obtained, for example, by accurately surveying the passenger transport system and using signal values from sensors housed in the passenger transport system, and allows conclusions as to the present or future state of the passenger transport system, based on which maintenance measures can be planned efficiently and adequately.

Claims

1. A method for monitoring a state of a passenger transport system, the method comprising: creating an updated digital double data record that reflects characterizing properties of components of the passenger transport system in a machine-processable manner and represents the passenger transport system in an actual configuration after its assembly and installation in a building, wherein creating the updated digital double data record comprises: creating a commissioning digital double data record with planning data, which reflects the characterizing properties of components of the passenger transport system in a planned configuration; creating a completion digital double data record based on the commissioning digital double data record by measuring actual data, which reflects characterizing properties of components of the passenger transport system in the actual configuration of the passenger transport system after the assembly and installation thereof in a building and replacing of planned data in the commissioning digital double data record with corresponding actual data; and creating the updated digital double data record based on the completion digital double data record by modifying the completion digital double data record during the operation of the passenger transport system taking into account measurement values, which reflects changes in the characterizing properties of components of the passenger transport system during operation; and monitoring a state of a passenger transport system by using the updated digital double data record, wherein, by monitoring, changes and trends in the characterizing properties of the components can be tracked and assessed.

2. The method of claim 1, wherein the updated digital double data record comprises data which were ascertained by measuring characterizing properties on the completed passenger transport system.

3. The method of claim 1, wherein the characterizing properties of a component are selected from a group comprising geometric dimensions of the component, weight of the component, material properties of the component and surface properties of the component.

4. The method of claim 1, wherein the monitoring of the state of the passenger transport system comprises simulating future characterizing properties of the passenger transport system by using the updated digital double data record.

5. The method of claim 1, further comprising planning of maintenance work to be carried out on the passenger transport system based on information about the monitored state of the passenger transport system.

6. The method of claim 1, further comprising assessing quality properties of a type of component based on an analysis of updated digital double data records of a plurality of passenger transport systems containing the component in question.

7. The method of claim 1, wherein the creation of the commissioning digital double data record comprises creating commissioning data taking into account customer specifications and creating production data by modifying the commissioning data taking into account production specifications.

8. The method of claim 7, wherein when the commissioning data is created, a virtual image of the passenger transport system is generated using generic component model data records of the passenger transport system and including the customer specifications.

9. The method of claim 7, wherein, when creating the commissioning data, at least one simulation is performed that is selected from a group comprising static and dynamic simulations, and wherein the commissioning digital double data record is created taking into account the results of the at least one simulation.

10. The method of claim 1, wherein the passenger transport system is selected from a group comprising escalators and moving walkways, and wherein the components of the passenger transport system are selected from a group comprising: components of a framework comprising a plurality of components selected from a subgroup comprising upper straps, lower straps, uprights, cross struts, diagonal struts, gusset plates, support angles, and framework separation points; and components of a conveyor comprising at least one component selected from a subgroup comprising driving stages, driving pallets, conveyor chains, conveyor belts, deflection sprockets, deflection disks, drive machines, service brakes, and controllers.

11. The method of claim 1, wherein the passenger transport system is an elevator and wherein the components of the passenger transport system are selected from a group comprising: components of a support structure comprising a plurality of components selected from a subgroup comprising guide rails, wall fastenings, drive frames, floor fastenings, cross struts, longitudinal struts, and diagonal struts; and components of a conveyor comprising at least one component selected from a subgroup comprising elevator cabs, counterweights, suspension devices, drive machines, braking apparatuses, and controllers.

12. An apparatus for monitoring a state of a passenger transport system, the apparatus being configured to monitor the state of the passenger transport system, wherein that monitoring is carried out by using an updated digital double data record that reflects characterizing properties of components of the passenger transport system in an actual configuration of the passenger transport system in a machine-processable manner after the assembly and installation thereof in a building, and that changes and change trends in the characterizing properties of components are traceable and assessable by monitoring, with the apparatus also being configured to produce the updated digital double data record step by: creating a commissioning digital double data record having planning data, which reflects the characterizing properties of components of the passenger transport system in a planned configuration using generic component model data records and defined component model data records; creating a completion digital double data record based on the commissioning digital double data record by measuring actual data, which reflects characterizing properties of components of the passenger transport system in the actual configuration of the passenger transport system directly after the assembly and installation thereof in a building and replacing of planning data in the commissioning digital double data record with corresponding actual data; and creating the updated digital double data record based on the completion digital double data record by modifying the completion digital double data record during the operation of the passenger transport system taking into account measurement values, which reflects changes in the characterizing properties of components of the passenger transport system during operation.

13. A passenger transport system, comprising the apparatus of claim 12.

14. A non-transitory computer readable medium comprising instructions that, when executed, configure a processor to monitor a state of a passenger transport system by: creating an updated digital double data record that reflects characterizing properties of components of the passenger transport system in a machine-processable manner and represents the passenger transport system in an actual configuration after its assembly and installation in a building, wherein creating the updated digital double data record comprises: creating a commissioning digital double data record with planning data, which reflects the characterizing properties of components of the passenger transport system in a planned configuration; creating a completion digital double data record based on the commissioning digital double data record by measuring actual data, which reflects characterizing properties of components of the passenger transport system in the actual configuration of the passenger transport system after the assembly and installation thereof in a building and replacing of planned data in the commissioning digital double data record with corresponding actual data; and creating the updated digital double data record based on the completion digital double data record by modifying the completion digital double data record during the operation of the passenger transport system taking into account measurement values, which reflects changes in the characterizing properties of components of the passenger transport system during operation; and monitoring a state of a passenger transport system by using the updated digital double data record, wherein, by monitoring, changes and trends in the characterizing properties of the components can be tracked and assessed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the disclosure will be described in the following with reference to the accompanying drawings, although neither the drawings nor the description should be construed as limiting the invention.

(2) FIG. 1 shows a passenger transport system in the form of an escalator, with respect to which a method according to the disclosure can be carried out.

(3) FIG. 2 shows a supporting framework for an escalator.

(4) FIG. 3 shows a passenger transport system in the form of an elevator, with respect to which a method according to the disclosure can be carried out.

(5) FIG. 4 illustrates the creation of a digital double data record using the example of a simplified component.

(6) The drawings are merely schematic and not true to scale. Like reference signs refer to like or equivalent features in the various drawings

DETAILED DESCRIPTION

(7) First, passenger transport systems to be monitored are described briefly and only very schematically with regard to the components used therein.

(8) FIG. 1 shows a passenger transport system 1 in the form of an escalator 3, the state of which can be monitored using the method described herein. FIG. 2 shows a supporting framework 5 of an escalator 3, which is not shown in FIG. 1 for reasons of clarity.

(9) The escalator 3 connects areas E1 and E2 in a building which are arranged at different heights and horizontally spaced apart from one another. The framework 5 here forms a supporting structure and abuts at the opposite ends thereof with the support angles 7 on the support points 9 of the building. The framework 5 comprises a plurality of components 11, in particular of upper straps 13, lower straps 15, cross struts 17, diagonal struts 19, uprights 21, framework separation points 23 and gusset plates 25. Many of the components 11 of the framework 5 comprise at least partially elongated metal profiles. Dimensions of the components 11 are selected so that the framework 5 can span a space between opposite support points 9 of the building on the one hand and on the other hand is sufficiently stable to withstand the forces acting on the escalator 3 formed with the framework 5.

(10) The escalator 3 comprises a conveyor 27, which is held by the framework 5 and by means of which passengers can be transported between the two areas E1 and E2. The conveyor 27 comprises, among other things, driving stages 29, conveyor chains 31, a drive machine 33, a service brake 35, a controller 36, deflection sprockets 37 driven by the drive machine 33 and deflection disks 39. The escalator 3 further comprises a balustrade 41 having a handrail 43 running thereon.

(11) Alternatively, the passenger transport system 1 can also be configured as a moving walkway (not shown) which is constructed similarly or identically to an escalator 3 with regard to many of its components 11.

(12) In a further alternative embodiment, the passenger transport system 1 is configured as an elevator 51. An elevator 51 is shown by way of example in FIG. 3. The elevator 51 has an elevator shaft 53 in which a conveyor 66 and a support structure 80 holding this conveyor 66 are housed. An elevator cab 55 and a counterweight 57 are suspended from suspension means 59 in the form of belts. A drive machine 61 and a braking apparatus 63 drive the suspension means 59 or brake them if necessary. A controller 65 controls the operation of the elevator 51. The elevator cab 55 and possibly also the counterweight 57 are guided by guide rails 67 as they move through the elevator shaft 53. The guide rails 67 are connected to supporting structures within the elevator shaft 53 via wall fastenings 69 and floor fastenings 73. Furthermore, cross struts 75, longitudinal struts 77, and diagonal struts 79 may ensure sufficient mechanical stabilization of the guide rails 67. The guide rails also carry a drive frame 71 to which the ends of the suspension means 59 and the drive machine 61, the braking apparatus 63, and the controller 65 are fastened.

(13) The product life cycle of an escalator 3, a moving walkway, or an elevator 51 is accompanied by various software systems and databases. These are generally not linked to one another to such an extent that the data they contain is automatically available throughout all systems. Although product development, order-specific configuration through sales and production documents and data specified on the basis of this configuration are already more or less well interlinked, there is generally no consistent support and documentation in the after-sales area. This can lead, for example, to the fact that a service technician often first has to examine a passenger transport system 1 on site in order to then carry out appropriate measures, such as, for example, procure the required material, set deadlines for maintenance and repair, dispose of the dismantled material properly, etc.

(14) The method according to the disclosure provides for the real product to be accompanied by a digital double, preferably continuously for the entire product life cycle, e.g., not only during the manufacture of the passenger transport system 1, but also after its completion and during its subsequent operation.

(15) An updated digital double record representing the digital double can be created as a commissioning digital double data record, for example using CAD data used during planning, during the production process based on commissioning data, taking into account customer specifications. Components can be commissioned based on previously defined component model data records or generic component model data records.

(16) The commissioning digital double data record can then be modified taking into account production specifications. The commissioning digital double data record comprises hereby planned data that represent a virtual image of the passenger transport system 1 to be produced. The passenger transport system 1 can then be produced based on the commissioning digital double data record.

(17) After completion of the passenger transport system 1, the planned data contained in the commissioning digital double data record can be replaced or supplemented by actual data, such as can be obtained by surveying the actual configuration of the passenger transport system 1 produced. The completion digital double data record is hereby created.

(18) This completion digital double data record already contains data which reflect the characterizing properties of the components 11 installed in the passenger transport system 1 in their actual configuration, e.g., after the passenger transport system has been completed and installed in the building. The completion digital double data record can thus already be used as an updated digital double data record for monitoring properties of the passenger transport system 1. For this purpose, the completion digital double data record can be stored and processed, for example, in a monitoring apparatus 87, which can be arranged in a remote control center.

(19) For example, the actual values of component properties contained in the completion digital double data record, as they actually exist in the passenger transport system 1, can be compared with planned values assumed during commissioning. Conclusions about properties of the passenger transport system 1 to be expected in the future can be drawn, for example, from any differences between the actual values and the planned values. For example, based on such differences, it can be predicted when certain signs of wear are to be expected, which in turn can be used to estimate when and/or how first maintenance measures are likely to be necessary. In other words, based on the completion digital double data record, an estimation or simulation of future characterizing properties of the passenger transport system 1 can take place and maintenance work to be carried out in the future can thus be planned. Additionally, assessment criteria associated with the characterizing properties of components, such as a maximum chain elongation of conveyor chains 31, an upper limit of the power consumption of the drive machine 33, maximum and/or minimum dimensions at wear points and the like, can be stored in the monitoring device 87. These specify the maximum permissible deviations based on the planned values of the characterizing properties of components. The characterizing properties of components of the updated digital double data record can then also be compared with these assessment criteria.

(20) In order to be able to provide a digital double of the passenger transport system 1 even during operation, at least some of the data contained in the completion digital double data record are updated from time to time during the operation of the passenger transport system. For this purpose, sensors can be provided in the passenger transport system 1, by means of which measurement values can be ascertained which reflects changes in the characterizing properties of components 11 of the passenger transport system 1 during their operation Taking these measurement values into account, the data contained in the completion digital double data record can be modified. The updated digital double data record generated in this way thus also represents a virtual image of a continuously updated state of the passenger transport system 1 in its actual configuration during operation.

(21) By using the digital double, statements about the present prevailing state of the passenger transport system 1, for example by comparison with setpoints or expected values, as well as statements about a future state of the passenger transport system 1, for example by means of simulations or extrapolations based on the data of the updated digital double data record can thus be made. Hereby, for example, maintenance work to be carried out can be planned according to the situation and in a targeted manner.

(22) In order to be able to measure the currently prevailing actual characterizing properties of components 11 in the passenger transport system 1, various sensors 81 can be provided in the passenger transport system 1, by means of which certain characterizing parameters can be monitored, which allow conclusions to be drawn about changes in the characterizing properties of the components 11 of the passenger transport system 1. A plurality of different sensors 81 can generally be used for this purpose. Force sensors 83 are shown in the elevator 51 only by way of example, which can measure forces acting on the various wall fastenings 69, on the drive frame 71 and floor fastenings 73, as a result of which conclusions can be drawn with regard to forces acting on the guide rails 61 and thus, for example, any mechanical tension. For a passenger transport system 1 in the form of an escalator 3, a camera system 85 is only shown by way of example, by means of which the state of, for example, driving stages 29 or the conveyor chains 31 can be monitored for any wear that may occur. In addition, force sensors 83 can also be provided in the framework 5, for example, similarly to the elevator 51. The sensors can transmit the signals thereof to the monitoring apparatus 87, for example by wire or via a radio network.

(23) In summary and in other words, the creation of the digital double can be started first, for example by creating a digital double in the engineering stage from specific and generic component model data records, including the customer specifications (e.g., an order-specific, generated parts list, as it is sometimes called) EBOM (“Engineering Bill of Materials”). The generic component model data records contain component data such as their dimensions, tolerances, surface structures, other characterizing properties, interface information on adjacent components and the like. Various simulations such as static simulations, for example in the form of tolerance considerations, and dynamic simulations, for example for collision checking, can then be carried out. From the order-specific, generated parts list (EBOM), a production-compatible parts list (production BOM—MBOM) and the associated production data are generated by applying production-specific rules.

(24) As an example of the interaction of generic component model data records and the customer specification, the generation of an order-specific generated parts list (EBOM) of a framework 5 for the escalator 3 can be used. The customer defines in his customer specification the information relevant for the design of the framework 5, such as an area of application (department store, public building such as a train station, subway etc.), a head, a step width (and thus a funding capacity), a length (an angle of the inclined area between the access areas is ascertained from the length and the conveying height) and the type of balustrade (e.g. glass balustrade, balustrade for traffic stairs). The individual component parts 11 of the framework 5, such as upper straps 13, lower straps 15, cross struts 17, support angles 7, framework separation points 23, etc., and defined component model data records such as uprights 21, diagonal struts 19, gusset plates 25, etc. are present as generic component model data records, wherein, for example, the length of the upper straps 13 and lower straps 15, the length of the cross struts 17 and the number of uprights 21 are dependent on the customer specifications. According to the entered customer specifications, the individual components 11 of the framework 5 with their specific dimensions are generated from the generic and defined component model data records. The design is carried out, for example, in such a way that a so-called virtual wire frame of the framework 5 is created by means of the customer specifications “delivery height,” “horizontal spacing of the support angles,” “step width,” and/or “delivery capacity.” The individual components 11 are now configured on the basis of this virtual wire frame, in particular with regard to their dimensions, in particular their lengths, and their number. The customer specifications also show how many framework separation points 23 are to be made so that the escalator 3 can be brought into the edifice in segments, for example. Because of the framework separation points 23, other parts may be required and the upper straps 13 and lower straps 15 must generally consist of multiple parts.

(25) In an analogous manner, an EBOM can also be created for an elevator 51 by ascertaining a planned configuration for a conveyor 66 and a support structure 80, taking into account customer specifications. For example, a size of the elevator cab 55, a weight of the counterweight 57, a design of the suspension means 59, the drive machine 61 and the braking apparatus 63, and the controller 65 can be suitably selected. Furthermore, dimensions and other characterizing properties of the guide rails 67, the wall fastenings 69, the drive frame 71, the floor fastenings 73, the cross struts 75, the longitudinal struts 77, the diagonal struts 79 and shaft doors and cab doors (not shown) can be selected appropriately. Associated data can be stored in the commission digital double data record.

(26) The framework 5 can again function as an example of the MBOM generated from the EBOM. Production-specific rules concern, for example, the material qualities available at the production site or the present production quality of the means of production depending on the production site. Additionally, another influencing factor can be the production layout of the manufacturing facility, which may not allow all desirable production processes. Characterizing properties of the component model data records are modified accordingly, flow plans are added, and the like.

(27) The production of the passenger transport system takes place on the basis of the production data (MBOM), with the production data being replaced by the physical data, e.g., actual values taken from the physical product, as production progresses. Here, for example, the real component dimensions and the assembly-relevant data such as tightening torques of screw connections, points of use of lubricants and the like are recorded and transferred to the digital double or commissioning digital double data record, thereby mutating it into the completion digital double data record. When the passenger transport system is delivered, a digital double or completion digital double data record exists in parallel to it, which ideally corresponds exactly to the physical product.

(28) When installing the passenger transport system in the building and during commissioning, additional data such as the operating data and measurement data transmitted by sensors can be updated in the digital double, so that the completion digital double data record is mutated to the updated digital double data record. This happens continuously or periodically even after commissioning.

(29) Periodic queries on the digital double such as wear-related geometric changes can be evaluated using collision simulations and maintenance work can be planned. Maintenance instructions for maintenance personnel can also be generated with the help of the digital double. Consequently, when components are replaced during maintenance, their component model data records are updated in the digital double of this passenger transport system with the actual data corresponding to the newly installed physical component. In the end, the individual components can be evaluated and disposed of in an environmentally friendly manner for further use, processing or disposal before the system is shut down.

(30) In order to clarify possible embodiments of method steps which are to be carried out when creating a digital double data record based on generic component model data records, this process is explained by way of example with reference to FIG. 4. It shows how a digital double data record is created for a very simple component in the form of a parallelogram-shaped sheet.

(31) First, a generic component model data record is generated as part of a research and development (R&D) (see FIG. 4(a)). In doing so, planned values for the characterizing properties to be achieved are ascertained for the component. In the example shown, planned variables A, B, α of geometric properties, that is to say a width, a height, and an angle of the parallelogram, are ascertained. Furthermore, an associated tolerance range T.sub.A, T.sub.B, T.sub.C is determined for each planned variable. The sheet thickness is the same for all design variants of this component and thus belongs to the defined characterizing properties of this generic component model data record.

(32) Then, customer specifications are determined during the distribution of the passenger transport system (see FIG. 4(b)). Based on these customer specifications, a planned value suitable for the specific passenger transport system is ascertained for each of the planned variables. In the example shown, the width is determined to A=5, the height to B=2, and the angle to α=70°. This definition turns the generic component model data record into a defined component model data record; described by commissioning data. This defined component model data record can function as EBOM.

(33) The commissioning data of the defined component model data record are then specified in such a way that the planned values previously ascertained only based on the customer specification are modified taking into account production specifications relative to production data. For example, material information from the country of production, an OEM manufacturer, or the like can be taken into account. Hereby, the commissioning data of the commissioning digital double data record are ultimately complemented in the form of an MBOM identified as production data, which can be used in the production of the component and serves as a virtual image of the component to be produced. In doing so, the ascertainment of tolerance specifications T.sub.A′, T.sub.B′, T.sub.C′ also takes into account the production specifications that are actually prevailing during production.

(34) Finally, at least some of the characterizing properties of the component produced using the production data are surveyed. In the case shown, the dimensions of the component are measured in their actual configuration (actual values) after their assembly to form the passenger transport system and the installation of the passenger transport system. Since the characterizing properties of the material do not change during production, it can only be checked, for example, whether the correct material was used, but without checking all the material properties such as tensile strength, shear strength, flexural fatigue strength, impact strength, corrosion behavior, crystalline structure, alloy components, and the like more. If necessary, the dimensions of the component in its actual configuration can also be repeatedly measured during operation of the passenger transport system based on sensor signals. Hereby, for example, deviations between the actual values on installed and possibly operated components can be ascertained from the associated planned values. In the example shown, such deviations are ΔA=0.06, ΔB=0.1 and ΔC=0.5°.

(35) The deviations found can, for example, be statistically analyzed for a plurality of components of a component type. Results can be taken into account, for example, when researching and developing a modified generic component model data record of the affected component type.

(36) In other words, the data from many digital double evaluations can also be used to assess the robustness of the design of a component type.

(37) Until now, this robustness could only be assessed, for example, with regard to the production quality, by checking whether production equipment corresponds to the required component quality by recording the actual dimensions of the physical components and comparing them with a tolerance band of the recorded dimensions. If, for example, the lengths of the same components of a component type are always within the tolerance limits, this either means that the means of production are not good enough or that the tolerance band was chosen too narrow.

(38) The robustness of a component type can now also be assessed with regard to quality properties, that is, for example, quality of use, by using the digital doubles presented here, by assessing wear and/or failure of identical components of a component type. Here, not only can vulnerabilities be identified by means of statistical evaluations, but the full availability of the actual dimensions and the dynamic interaction of the components can also be used to determine possible causes of operational damage.

(39) If, for example, a plain bearing is subject to excessive wear in a production series of passenger transport systems, the cause can be an excessive load due to the customer specification. However, it is also possible that the actual dimensions of the bore and axis of a built-in production lot cause the bearing gap to be too narrow or too large. It is also possible that another component, for example, a rail joint that is too large, has caused loads for which the plain bearing was not designed. The corresponding cause can be found by means of dynamic simulations and statistical evaluations on the digital doubles. The cause found can be taken into account in a change in the design of the component type concerned or in a change in adjacent components or in a change in the permissible customer specifications in the sales process (for example, a reduction in the maximum delivery head).

(40) In summary, the method proposed here or a correspondingly configured apparatus allow the present state of a transport system to be monitored using the suitably created updated digital double data record, as a result of which maintenance measures can be planned more appropriately for the situation or corresponding to the actual requirements and thus considerable costs can be saved and/or whereby component types can be designed or modified in such a way that they better meet the requirements that actually arise in the operation of a passenger transport system.

(41) Finally, it should be noted that terms such as “having,” “comprising,” etc. do not preclude other elements or steps and terms such as “a” or “an” do not preclude a plurality. Furthermore, it should be noted that features or steps that have been described with reference to one of the above embodiments can also be used in combination with other features or steps of other embodiments described above. Reference signs in the claims should not be considered limiting.