ME 4407

Measurement, Instrumentation & Control

Title of The Assignment: Discussion on Mechatronics System of

An Elevator

Name: Jawad Mahdi

Date of Submission: 18/03/22 Student ID: 190012124
Department: MPE
Program: IPE
INTRODUCTION................................................................................................................................................. 3
EVOLUTION HISTORY ........................................................................................................................................ 3
SYSTEM FLOW DIAGRAM .................................................................................................................................. 5
CONTROL SYSTEM ............................................................................................................................................. 9
SENSORS OF AN ELEVATOR............................................................................................................................... 9
ACTUATORS OF AN ELEVATOR........................................................................................................................ 11
COMPARISON OF DIFFERENT STANDARD MODELS ........................................................................................ 12
CONCLUSION................................................................................................................................................... 13
REFERENCES .................................................................................................................................................... 13
A mechanical, electrical, telecommunications, control, and computer science technology all
together involved in a system is referred to as a Mechatronics system. Mechatronics is a
multidisciplinary engineering discipline. Mr. Tetsuro Mori, an engineer at Yaskawa Electric
Corporation, first applied the term "Mechatronics," which was registered as a trademark by the
firm in Japan with the registration number "46-32714" in 1971. However, the firm then released
the right to use the word to the general public, and the term "Mechatronics" became not only a
Japanese term, but also a native English term. The word is now adapted into every language and
is regarded an important term in manufacturing.

In this discussion, we will focus on a particular example of a mechatronics system named elevator.

A car that travels in a vertical shaft to transport passengers or goods between the floors of a high-
rise building is known as an elevator. Electric motors with a counterweight operate most
commercial elevators through a configuration of wires and sheaves (pulleys). For the vertical
movement, an elevator uses cables, roller track or hydraulic cylinder.

Nowadays, there are mainly four types of elevator we see commercially. Those are:

1. Traction Elevators with Machine Room (geared and gearless)

2. Pneumatic Elevators
3. Hydraulic Elevators

Moving ahead, we will focus on how an elevator works as a complete mechatronics system, how
it is controlled using different types of sensors and actuators and comparison between different
models available commercially.

The oldest recorded mention of an elevator can be found in the writings of Roman architect
Vitruvius, who claimed that Archimedes constructed his first elevator around 236 BC. Later
sources describe elevators as carriages suspended from a hemp cord and driven by living creatures.

Hoists and windlasses were employed to power ancient and medieval elevators. The introduction
of a screw drive mechanism, which led to the establishment of modern passenger elevators, was
possibly the most major step in elevator technology since olden days. Although there may have
been an initial concept by Leonardo da Vinci, Ivan Kulibin developed the very first screw-drive
elevator in 1793 and set it in the Winter Palace. A few years later, in the Arkhangelskoye
neighborhood of Moscow, another of Kulibin's elevators was installed.
But when humankind reached the industrial era, there was a huge demand of quick movement of
raw materials mostly in the form of coal and woods. This necessity resulted in the invention of a
working elevator.

Elevators were first employed in coal mines in the mid-nineteenth century, and they utilized steam
power to move commodities in mass in mines and factories. These devices were quickly put to a
variety of uses. Burton and Homer, two London architects, developed and ran the ‘ascending
room’, a revolutionary tourist hotspot that lifted guests to a significant height in the heart of
London, affording a spectacular perspective.

In the following decade, crude steam-driven elevators were developed. The Teagle, an innovative
elevator, was constructed by Frost and Stutt in England in 1835. It had a counterweight for added
power and was operated by a belt system.

The "Flying Chair", an elevator ahead of its time, was erected at the Royal Palace of Caserta by
Neapolitan architect Gaetano Genovese in 1845. It had a light, two benches, and a hand-operated
signal that could be turned on from the outside with no effort on the part of the passengers. A
motor mechanic used a set of toothed wheels to control traction. If the ropes snapped, a safety
device comprised of a beam pushed outside by a steel spring was supposed to take effect.

Sir William Armstrong designed the hydraulic crane in 1846, particularly for freight loading at the
Tyneside shipyards. They swiftly replaced the previous steam-powered elevators, utilizing Pascal's
law to deliver significantly more force. An adjustable level of water pressure was delivered by a
water pump to a plunger sealed inside a vertical cylinder, enabling the platform to be lifted and
descended while bearing a large load. To boost lifting force, counterweights and balances were
also used.

Throughout the years many people tried to improve the existing elevator technology. For instance,
J. W. Meaker developed a system for safely opening and closing elevator doors in 1874. Six years
later, first electric elevator was built by Werner Von Siemens.

By the beginning of the 20th century, automated elevators were available but people were unsure
of using them. A 1945 elevator operator strike in New York City assisted their acceptance, as did
the provision of an emergency stop button, emergency call, and a calming explanatory recorded
speech.

Nowadays in the modern industrialized age, a lot of multinational companies like KONE,
Schindler Group, etc. are producing commercial elevators and almost all the high-rise buildings
all over the world has an elevator system.
Elevator is a complex mechatronic system with various mechanical and electrical components
including sensors, actuators, safety system, speed governor, buffer, etc. Let’s first see the details
of its components.

▪ Elevator Car: This is the major component of an elevator that is designed to move
passengers and cargo in a confined environment.
▪ Cable: It's utilized to both support and pull the car (by passing across the driving sheave
to the counterweight). The number of lays is usually determined by the weight and the
speed of the machine.
▪ Elevator Machine: On all types of traction elevator equipment, a traction machine is used.
A traction machine's standard components are a motor, drive sheave, brake, and machine
bed plate. To turn the drive sheave, the traction machine motor turns the drive sheave shaft.
The hoist ropes pass over the driving sheave and pull the car through the hoist way as the
sheave rotates.
▪ Control Unit: Elevator controllers are systems that control manual or mechanized
elevators. Only the motor requires 3-phase power supply, which is normally tuned down
to between 12V and 24V by the controller. The elevator's controlling component and
fixtures are powered by a low-voltage power supply.
▪ Counterweight: A counterweight is used in an elevator to balance the weight of the cab
mainly. When the cab moves downward, the counterweight moves upward and vice-versa.
The counterweight lowers the amount of energy required by the motor and decreases the
frequency of breaking.
▪ Guide Rails: It is a T-shaped structure to direct and assist the travel route of the elevator
as well as the counterweight.
▪ Hoistway: A hoistway, also known as a shaftway, is an enclosed structure where the
elevator moves between levels of the building. This space will extend vertically from the
ground to the top floors. The hoistway should always be constructed in accordance with
local building requirements and elevator manufacturer specifications.
▪ Buffer: The buffer is a device
that protects people by slowing or
stopping a falling vehicle by
gathering or dissipating the
vehicle's kinetic energy. It is
mounted at the bottom of the
elevator.
▪ Speed Governor: The
Elevator Speed Governor is an
instrument that enables the
elevator to stop if it exceeds the set
speed. The governor constantly
monitors the pace of a moving
elevator via the rope tied to it.
▪ The Safety Brake: It ensures
passenger safety if the cable
breaks. Each carrier is guided by
two vertical guide rails with
strong metal teeth along the length
of them. A spring-loaded
mechanism with hooks is affixed
to the top of each carrier. If the
cable fails, the hooks surge
outward and jam into the guide
rails' metal teeth, securely locking
the carrier in place.
▪ Elevator Door: It is used for
the entry and exit purpose. Manual
and automatic are the two types
door available.

▪ Sensor: In order to operate

smartly, an elevator needs
multiple number of sensors. Level
sensor, infrared sensor, load
sensor are some of them.
 ▪ Motor: Motors are used primarily to ascend and descend the elevator along with the help
of the counterweight. In addition, door motors are used to close and open the door.

▪ Power Supply: Supplies power to the whole system.

If we consider the system of a simple commercial elevator, it goes through various states while
being in operational mode. Some major states involved are mentioned below:

• Idle
• Downward Movement
• Upwards Movement
• Stopping
• Door Opening
• Door Closing
• Processing Next Stop
• Open Door
Using these phases of a commercial elevator, a logical system flow diagram is depicted

Figure: System Flow Diagram of a Commercial Elevator

In general, primary components of an elevator include various types of sensors, command buttons,
display unit, logical control unit, power supply, motors etc. These components work as a whole
being guided by the logical control unit which operates under certain logic programmed into it. A
flow diagram of the control system is illustrated below.

To define in widest terms is, a sensor an instrument, component, machine, or subsystem that senses
events or changes in its surroundings and transmits the data to other electronics, most commonly
a computer processor. Sensors are frequently used in conjunction with other technologies.

To sense the various conditions of an elevator, several types of sensors are used and according to
their output data logical control unit sends command to the actuators.

Several types of sensors installed in an elevator and their usage is discussed below.
➢ Commercial Thermostats: Thermostats are utilized as an over-temperature switch in the
elevator system control panel to help prevent the system from overheating.

➢ Hall-effect Digital Speed Sensors: The elevator motor speed is controlled by speed
sensors. The magnetic field is detected by the sensors, which give electric signals to the
control unit. These devices allow for the detection of a moving ferrous metal or magnetic
target's motion, trajectory, and location. The sensor is not in contact with the target, and
there are no moving elements, resulting in little mechanical wear on the sensor and target.

➢ Position Sensors: This type of sensor is used for the elevator’s position control. When the
elevator reaches the desired floor, this sensor sends the signal to the control unit and upon
control units command, the elevator slows down gradually and levels to the floor. This
product indicates the location of a magnet mounted to an object moving by combining
ASIC (Application-Specific Integrated Circuit) technology with an array of MR
(magnetoresistive) sensors. The
output of the MR sensors
installed along the magnet's
movement direction is measured
by the MR array. The output and
MR sensor sequence are used to
calculate the closest pair of MR
sensors to the magnet
position's center. The output of
these two MR sensors is then
used to figure out where the
magnet between them is located.
The magnet is mounted to the
elevator, and the SMART
position sensor is affixed to the
floor in this application. The
elevator decelerates and comes to
a halt when the linear array
detects the magnet.

➢ Load Cells: Load cells are

used to measure the load in the
elevator when it starts to operate.
If overweight is detected, output signal is sent which in turn stops the motion of the elevator
until the load is within the safety limit. Example: Low profile ‘pancake’ type, bonded foil,
strain gage load cells.
 ➢ Packaged Temperature Probes: To detect the overheating issues in the motor windings
and bearings and send related signals to then control unit, packaged temperature probes are
used.

➢ Door Sensors (Photoelectric or Infrared Sensors): These sensors detect whether a

person or an object is blocking the door. If so, they send outputs so that the door does not
close until there is no obstacle in between. If the doors are left open for longer than the set
time, the elevator will enter nudge mode, gradually closing the doors with a periodic beep.

➢ Micro Switch Limit Switches: Limit switches are used in commercial elevators to identify
the elevator or lift floor position, as well as in the buffer system.

An actuator is a control system component that converts the system's output into a controlling
action on a machine or device.

In traction type commercial elevators, Electric Motor (AC/DC) linked with a counterweight is the
most used actuator. An electric motor is a device that converts electrical energy into mechanical
energy. Most electric motors work by generating force in the form of torque applied to the motor's
shaft through the interaction of the motor's magnetic field and electric current in a wire winding.
Elevators used to be powered by DC motors because their RPM was easy to control and they were
much cheaper. However, DC motors had poor torque characteristics, resulting in jerks and bumps
for users.

Since the DC motors are not suitable due to the bumps, AC induction motors along with variable
frequency drive (VFD) since controlling the speed of the AC motor is tough and that’s where the
VFDs come in handy.

In hydraulic elevators, along with electric motor, a system of hydraulic actuator is used. The
electric motor forces oil into the cylinder, causing the piston (which propels the lift car) to rise.
When the lift car is lowered, the valve opens, allowing oil to flow back into the reservoir and being
pushed back by the lift car's gravitational force.

In pneumatic elevators, the actuation system is made up of hollow cylinder, piston and
motor/pump. The piston travels inside the cylinder to build air pressure, causing the cylinder to
move and provide enough linear force to cause motion in the elevator car, owing to the
motor/pump.
There are mainly three types of elevators available commercially. These are:

1. Traction Type Elevators: This is the simplest and cost-effective type of elevator available
where a motor is attached to a toothed pulley and a cable is looped around the pulley. The
rope is tied to the lift car on one end and a counterweight on the other.

The main advantages of traction type elevators are higher speed compared with other types,
energy efficiency, smoother ride experience.

The cost of installation may be higher than the cost of hydraulic elevators. Traction lifts
are tough to maintain since the machine's controls are located in the shaft region. It may be
tough to get to this location. The most difficult aspect will be obtaining spare parts, and
maintenance can only be performed by the original installation or a service partner.
Extraction of passengers in an accident can also be challenging since traction lifts require
particular expertise to operate and are tough to get access in the shaft.

2. Pneumatic Type Elevators: In this type of elevators, the major difference is the actuators
are pneumatic and the elevator can continue its operation even when there is no electricity.
The piston travels inside the cylinder to build air pressure, causing the cylinder to move
and provide enough linear force to cause motion in the elevator car, owing to the
motor/pump.

Pneumatic lifts are suitable for a number of applications, including those exposed to harsh
temperatures and other climatic conditions, because they do not require electricity.
Pneumatic systems are also more precise, capable of producing high force, and cost less
than hydraulic systems. For setup, it necessitates no or very little Pit (space beneath the
elevator vehicle) or headroom (room above the elevator shaft). It operates without the
usage of wires or belts and is easier to move to a different site if necessary. Also, Pneumatic
Type Elevators are less complicated to set up than traditional systems.

Not being able to use these lifts for high-speed travel, higher loads or higher elevation are
some clear disadvantages.

3. Hydraulic Type Elevators: In these type of elevators, hydraulic actuator system is

installed where oil is pumped into the cylinder by a motor causing the piston to rise and
resulting in lift movement.
 Although this type of elevator takes more space in a building, the cost is half compared to
the traction type. Moreover, equipment and maintenance costs are less expensive than with
a traction lift. When a large load capacity is required, this type is more effective.
Hydraulic type elevators have certain disadvantages also. The subsurface pressure of a
hydraulic lift can pose a concern if adequate maintenance is not performed on time. Since
hydraulic elevators lack a safety system to prevent them from falling, they rely on the
weight of the framework to maintain their position in the shaftway. Because the hydraulic
elevator's motor continues to operate in the upward motion, it consumes twice as much
energy as a traction elevator.

From the ages of roman empire to modern time of industrial revolution, humankind has come a
long way. In a similar manner, from elevators driven by living creatures to motor driven elevators
with smart sensors and safety system, we can say that great achievement is unlocked in the sector
of machine development and it is safe to assume that humankind will continue to thrive in this
sector in the upcoming future. Top lift companies like Otis, Schindler, Kone are big competitors
in the elevator market and they are investing huge amount of dollars to make their existing models
more suitable, relaxing and technologically sound. Green lifts (compatible with the ecosystem),
multiples cabs in the same shaft, more efficient control system and algorithms are some of their
research and development focuses. We hope to see the addition of latest innovations in the
commercial elevators very soon.

1. https://en.wikipedia.org/wiki/Elevator
2. https://www.eroselevators.com/elevators-component.php
3. S. Carter, A. Selvaraj, “Design and Implementation of PLC based Elevator”, Published 18
April 2013, International Journal of Computer Applications.
4. https://residentialelevators.com/traction-vs-hydraulic-elevator/
5. https://residentialelevators.com/hydraulic-vs-pneumatic-home-elevators/
6. https://www.tti.com/content/dam/ttiinc/manufacturers/honeywell/PDF/honeywell-
sensors-switches-commercial-traction-elevators.pdf
7. http://vintecelevators.com/difference-between-traction-and-hydraulic-lifts/