IRJET- Design and Manufacturing of Ladder Roof Lift for Material Lifting
Consumption and Conservation of Elevators
1. 1
A REPORT
ON
ENERGY CONSUMPTION AND CONSERVATION OF ELEVATORS
BY
TANIA STANLY 2010A3PS279U
AT
THYSSENKRUPP ELEVATOR
DUBAI, UAE
A Practice School – II station of
BITS Pilani, Dubai Campus
Dubai International Academic City, Dubai
UAE
(August 2013– January 2014)
2. 2
A REPORT
ON
ENERGY CONSUMPTION AND CONSERVATION OF ELEVATORS
BY
TANIA STANLY 2010A3PS279U EEE
Prepared in Partial Fulfillment of the
Practice School – II Course
AT
THYSSENKRUPP ELEVATOR
DUBAI, UAE
A Practice School – II station of
BITS Pilani, Dubai Campus
Dubai International Academic City, Dubai
UAE
(August 2013– January 2014)
3. 3
BITS PILANI, DUBAI CAMPUS
Dubai International Academic City, Dubai
UAE
Station: ThyssenKrupp Elevator U.A.E LLC Centre: Dubai
Duration: 04.08.2013 - 09.01.2014 Date of Start: 04.08.2013
Date of Submission: 09.01.2014
Title of the Project: ENERGY CONSUMPTION AND CONSERVATION OF ELEVATORS
ID No. / Name of the student: 2010A3PS279U / TANIA STANLY
Discipline of Student: B.E. (Hons) Electrical and Electronics Engineering
Name(s) and Designation(s) of the Expert(s): Ms. Stefanie Heidester (HR Manager & PS
Coordinator), Mr. Sukhminder Aushat (Service Manager) , Mr. Bibin Thomas (Service Sales
Engineer), Mr. Afan Basu (Service Engineer)
Name of the PS Faculty: Dr. V. Kalaichelvi
Name of the PS Mentor: Mr. Aushat (Senior Sales Manager)
Key Words: Elevators , Regenerative drives , Sales , Quotation , Repair Request, Work Order,
Completion Certificate, Energy efficiency
Project Area(s): Company history, Products, Service Department, Service Process
Abstract:
In this report, few of the most innovative energy efficient technologies are discussed. Factors
affecting energy consumption, how this can reduced without compromising on the quality of
service and how such technologies prove to be a great investment. The report also discusses
the various procedures undertaken during maintenance works, the legal procedures and
documentations associated with it. The report concludes with how such technologies can be out
to practice.
Signature of Student Signature of PS Faculty
Date: Date:
4. 4
Chapter 1 ThyssenKrupp Elevators – An Epitome
1.1 History
Based in Duisberg and Essen, Germany, ThyssenKrupp AG is a multi industry
company. It was formed as a result of two companies, Thyssen AG and Krupp, founded
in 1891 and 1911 respectively decided to merge togerther.
The company combined Sthier flat steel activities as early as 1997 and after a lot of
negotiations, in 1999 March, TK came into being. Along with provision of services and
components for elevators, escalators, material trading and industrial sevices, TK is also
the largest producers of steel in the world! [4]
Thyssen Krupp is ranked 122 in the Global500 of the annual ranking of the world's best
corporations.
Heinrich Hiesinger is the CEO of the company and has about 150,000 emplyess
worldwide.
As of 2013, TKEwith their global business spread all over the world, with units
operating. When it comes to the competition among the escalators and even the
elevators, TKE is ranked 3rd in the world. Also, about 1% of the overall market share is
owned by TKE.[5]
1.2 Structure of the Company
60% of their activities revolve around maintenance, disassembling and assembling of
elevators units, modernization and repair, all of which come under the service
department.
The remaining 40% comprises of Manufacturing of elevators, installation of
manufactured elevators and (R&D) Research and Development Department, all of
which comes under the new installation and sales department.
About 150,000 humans and resources are working under the Thyssen Krupp company
in about 80 different countries!
5. 5
CHAPTER 2 THYSSEN KRUPP PRODUCT RANGE
2.1 Introduction
For high rise buildings, warehouses, restaurants or even private villas, name it and
Thyssen Krupp is also able to supply and also offer transportation for any kind!
As you can see, different products that are sold in the different parts of the world are
mentioned for your kkind informaation.
(as shown in the figure 2.1)
Fig 2.1: Product range of Thyssen Krupp in the world
6. 6
2.2 Elevators
• For any kinds requirements, be it elevators for passengers or car lifts or
dumbwaiters, TKE is able to offer its expertise.
Fig 2.2: Various types of elevators produced by Thyssen Krupp
None of the high rise buildings that you see no would have been possible without the
industrial revolution. Cities expansion is also another important factor. All of which
began about a hundred and fifty years ago. Dubai wants to be the best in everything
hen it comes to architecture, tourism or surveys. And elevator technology has helped it
achieve what it wanted to achieve. Neither the Burj Khalifa nor the greatest and oldest
world trade center would have been possible. When it comes to safety, nothing can beat
that of the amazing elevators which is the greatest mode of transport for all those
people on earth. [8]
7. 7
TKE just like any other elevator companies provide geared and gearless elevators and
also those that might require machine rooms and the ones that might not depending on
the requirements, governments etc.
How can one describe the awesome Thyssen Krupp elevators without talking about
their much acclaimed and greatest innovation of the TWIN elevators? These are those
in which one car acts as the counterweight for the other, and they travel at different
kilometer per hours and in different directions. This helped reduce the elevator traffic,
saving the energy and time, things once lost that can never be gotten back.
Fig 2.3: Figure showing amount of space saved when using TKE’s TWIN Elevator.
8. 8
Fig 2.4: TWIN Elevator
2.3 Escalators/Moving walks
See, when we talk about moving freely in the airports or office complexes or shops,
bargain place, department stores, blue marts etc, elevators play a key role. Of all the
things that it can do, its major purpose is to transport homo sapiens over small distance
steadily fast and comfortably. And nothing can beat the qualities of our Thyssen Krupp
elevators.
Fig 2.5: Thyssen Krupp manufactured elevators, high in quality and style.
9. 9
Fig 2.6: Deira City Centre (TKE Escalators)
If you have noticed, these moving walks are very slow. Testing our patience’s to the
maximum. TKE recognized this problem especially for the passengers who want to
travel long distances on landing their native countries after long breaks. So they came
up with the Turbo Track, which travels upto two meters per second. The first of its kind
was installed in Toronto Airport way before Dubai.
2.4 INNOVATIONS
Of all the products Thyssen Krupp offer, the major ones are elevators be it traction or
the hydraulic elevators and even the escalators and even the freight elevators. Mainly
includes the tracks, the moving walks, the turbo tracks, and most of the escalators. all of
these for tenders and the dumbwaiters and the chairs and the stand lifts and also the
PPC's (Passenger Boarding Connections).
Of all their innovations, the that are significant would be the TWIN and the High speed
double Decker elevators.
10. 10
2.4.1 TWIN ELEVATORS
The creative innovation of the TWIN Elevator not only condenses building spaces, it
also sees to it that the passenger waiting time is considerable reduced, a considerable
amount of elevator traffic is considerably reduced and also saves heck loads of time. All
of this being possible because of journey's end variety controller (DSC) which gives the
impression very useful in high rise buildings. What it actually does is maneuver two self-
regulating elevators in the same shaft.
Fig 2.7: Shaft of TWIN elevator
11. 11
CHAPTER 3: SERVICE DEPARTMENT
3.1 Introduction
Service sector plays a decisive role in the smooth functioning of TKE. Below mentioned
are a few of their major highlights.
3.2 Structure of the Service Department
The service department is the most important department in the company as this is
what gives revenue to the same. This mainly consists of the Call Back Team, the PPM
(Preventive Personal Maintenance) team and last but not the least, the Repair team.
These teams together work to compose the framework of the dissection.
Fig 3.1 Service Department Structure
12. 12
3.2.1 Maintenance & Service
Maintenance and the servicing of Thyssen Krupp is as well as third party elevators are
also dealt by the Thyssen Krupp elevators.
3.2.2 Third Party Maintenance
This section of the company, apart from drawing considerable profit, also increases the
the exposure of the company and hence, the marketability shoots up.
This section, also carries out the compulsory monthly checks on elevators and then,
servicing of those elevators which would have had problems during the PPM.
Major brands that are serviced and maintained would include the great Otis, Schindler
Mitsubishi and even Kone!
Fig 3.2: Unit of Third Party
13. 13
3.2.3 Conducting Enquiries
When the call centre locks in on a call, the first step done is the initial scrutiny. And then
comes the launch of the conversational convention. This in turn is always supported by
the some service sales department. Here the main ales executive would question and
guide them toa sole owner who attend to the basic needs and steps or repairs to be
carried out. Once it’s approved, the same department old request the engineers to
proceed with whatever is necessary.
Fig 3.3: Third Party Maintenance flow process
3.2.3.1 Call Back Report
When we get a call at the call centre, from the passenger either due to sudden
breakdown or other such sudden problems, or technical assistances, the assistant at
the call centre would collect details of the lift, the unit details, the problem, timing of the
call and the caller name.
Once this is done, the operator would coordinate between the technicians and the
nearest trouble shooter and dispatch the technicians to the site. They would attend to
the problem. Some might be genuine and some might be just false calls.
On arriving at the site, the technician would first check the lift to see whether it’s a major
problem or not. If its a minor fault, the technicians would do the repair works, else not he
would call the repair team. On completion of the necessary repair works, the technicians
14. 14
would fill up a repair completion report and is sent back to the call centre. The repair
completion report consists of the work done, date and time of work done and the unit
details, the name of technicians who did the work and the duration of time spent in
completing the work.
Fig 3.4: Report (Call Back)
15. 15
3.2.3.2 Repair Request
After all this is done, the repair request form will be entered into the software View.
Then the engineers, mainly service sales engineers will use the information and then
prepare quotations for those items that are required and need to be replaced. All if this
varies depending on the type of contract. Before all of this, a repair costing is prepared
which has list of items, man hours required for repairing and their cost with 10% profit.
And finally, this list would be sent to the client for approval and changes if any.
Fig 3.5: Repair Request
16. 16
3.2.3.3 Inspection Report
Monthly inspections are conducted on the various sites. Some with and others without
prior notice. These inspections are conducted based on a pre assembled format and
series of methods.
3.3 Preparing Quotation
This is that document that will be submitted to the client once you have fixed the prices
and got approval from the client for the proposed rates. This document generally
consists of the list of items that needs to be replaced or those that had already been
replaced, the number of spares, cost per spare, man hours spent for each item and then
in the end, net price with the margin
[3]
.
19. 19
3.4 Preparing Repair Work Order
On getting approvals from the client for the submitted quotations, especially those
repairs that haven’t been done but needs to be replaced, we prepare a repair work
order.
This repair work order consists of the specific SAP number, the reference number from
the quotation, the list of spares and their quantity.
Once all the details of the work unit are entered in SAP, its sent to the warehouse. At
the warehouse, the coordinator would check in SAP whether the mentioned SAP
number is there in the software.
If so they would give approval to the technician and release the required spare parts to
the technician. He would in turn complete the works and submit the completion report to
the service sales engineers.
And this document would prove to be a proof of the completed works. On completing
the necessary works, completion reports would be prepared and send for approval.
An example of a work order is shown in the next page.
20. 20
Fig 3.7: Repair Work Order Form
3.5 Work Completion Report
Work completion report is proof of the repair works being completed. On receiving the
approved work order, this report is prepared. This is proof that all the works have been
completed by Thyssen Krupp Elevators and the next step is invoicing.
22. 22
3.6 VIEW Dubai
VIEW will have details of the different units, the technicians that had worked there, the
amount f time spend by each technician on various projects and the days in which these
had been undertaken.
Fig 3.9: VIEW – Unit search
24. 24
CHAPTER 4: ENERGY EFFICIENT ELEVATOR TECHNOLOGIES
4.1 Legislative Provisions
The increasing dependence of European Community on external energy sources has
lead to people finding possible ways to reduce energy consumption and improvement in
energy efficiency.
[8]
The Energy Performance of Buildings Directive was published by the European Union in
June 2002.
An Energy White Paper was published by the UK Government in February 2003 and
then the energy provisions were revised of the Building Regulations Part L.
all of which were begun from April 2006 as Building Regulations 2000 Approved
Document L2A: Conservation of Fuel and Power.
As a result of these consultations, the 2010 edition of Approved Document L2A was
published and came into effect from April 2011.
4.2 Energy Consumption and Conservation
Fig 4.1: Relationship of lifts to other energy consumers in an office building
25. 25
Of any equipment, their entire life cycle has to be taken into consideration for total
energy conservation such as manufacture, installation, operation, dismantling and
disposal.
The operational phase is the most important of these phases. The following figure
illustrates the relationship of energy consumption of lifts with that of the other energy
uses in an office building.
The traffic requirements of the occupant’s in a building determine the type of
transportation equipments installed in a building. Designers should keep in mind that the
transportation requirements can be minimized through good building layout.
Just by reducing the number of units, energy cannot be sensibly saved. It can only be
done through appropriate selection of components to meet traffic demands, good
equipment design and efficient operational control of the transportation equipment.
Modernization of elevators for efficient use might involve higher initial capital
investment, but over time this can be recovered through energy savings. With new and
cheaper speed drives, capital and operational costs have been reduced.
Fig 4.2: Elevator operating modes
26. 26
4.3 Energy Consumption of Lifts
The four major motivations or reasons behind energy consumption estimation and lift
system’s energy measurement are mentioned below
[9]
.
• To understand the energy consumption of one specific installation.
• This would answer the common question, ‘’How much energy does the
installation consume?’’.
• To compare the energy consumption of two different types of lifts (e.g. different
drives).
• This would answer the common question, ‘How much energy can be
saved by replacing drive A with drive B?’’.
• To minimize the energy consumption of lifts on a journey by journey basis.
• This would answer the common question, ‘What is the optimum speed
profile for the next journey that would minimize the energy consumed
based on the load, travel distance and direction?’’.
• To predict the energy consumed by a lift system based on its various parameters
(eg: travel distance, speed, capacity, gearing, type of drive etc).
• This would answer the common question, ‘What would the energy
consumption of a new design of lift system be with a certain configuration
and a specified set of components?’’.
When taking into consideration the configurations of new lifts and predicting energy
consumption improvements or changes for modernization, the above mentioned points
need to b carefully analyzed. The last method takes into consideration the lift
parameters.
27. 27
4.4 Factors Affecting Lift Energy Consumption
The following mentioned factors affect the energy consumed by lifts:
• Mechanical system
• Compensation system
• Counterbalancing ration
• Guidance system (rails/slider/rollers)
• Roping (reeving) ration (1:1/2:1 etc)
• Idler sheave efficiency
• Drive sheaves efficiency (traction etc.)
• Drive system
• Brake consumption
• Creeping/leveling time
• Acceleration/deceleration profile
• Drive regeneration
• Gear efficiency
• Motor efficiency including any cooling fans
• Control system
• Traffic (dispatcher) efficiency
• Door system (drive, passenger detection etc)
• Controller (traffic and drive) consumption
• Electrical system
• Well/machine room/car lighting
• Heating and cooling
• Power factor
• Operational Aspects
28. 28
• Number of starts
• Travel distance
• Speed
• Load
• Duty
The operational aspects describe about the way the lifts are used and they are the
crucial factors concerned with energy consumption.
Factors such as number of possible stops, rated speed, car capacity and travel
distance, which are fundamental to providing transportation service, cannot be changed
and should be considered at the design and specification stage itself. These affect
energy consumption too.
Fig: 4.3: Elevator Energy Consumption for various systems
29. 29
4.4.1 Mechanical System
In a lot of instances, the type of gearing employed affect consumption. Worm
Gearboxes are less efficient than Helical Gearboxes. The efficiencies of worm type
gearboxes approach 70% for high torque systems. Modern gearboxes are have
efficiencies as high as 70-90%. [9]
Fig 4.4: Helical Gearboxes
Fig 4.5: Spring Gearboxes
30. 30
Another important factor is the roping systems such as 1:1, 2:1 etc. and single wrap and
double wrap. Generally simple roping systems (1:1), lead to more efficiency.
Fig 4.6: Elevator Roping Systems
In order to reduce the sudden changes in torque, flywheels are used at times. Using
flywheels can reduce efficiency of the system as the inertia of other moving masses
should always be minimized.
Lift systems need to overcome friction in the guide rails, guide shoes etc. and air
resistance to the car moving in the pit. The weight of the car should be kept minimum
and has an important effect. While maintaining traction, the empty car should weigh
31. 31
twice that of rated load for larger car sizes. Reduced weight of empty car would imply
lighter counterweight and hence, conserved energy.
4.4.2 Drive System
The main drive systems available today are based on VVVF, which is variable voltage
and variable frequency. A VVVF system without regeneration back to the supply
conserves more energy.
Fig 4.7: VVVF Drives used in Elevators
Same is the case with traction and hydraulic drives. Conventional hydraulic drives are
unable to recover any of the energy consumed in driving the lift up during the return
downward journey. And so, these days, pressurized accumulators are used to recover
some of the energy during the down trip. Some of the systems also use a VVVF pump
system to control oil flow more accurately.
4.4.3 Control System
The drive control system can allow the drive to operate competently by profiling the
movement between stops in the best possible manner. The standards selected for
speed and also its acceleration and even the jerk (all of this are often dictated by the
ride comfort requirements and traffic design) can affect the energy conservation.
32. 32
Some traffic control systems move lifts to parking floors during the idle hours. This
comes in handy during peak hours, but is wasteful during out of hours or in light duty
environments.
4.4.4 Electrical System
When it comes to electrical systems, efficiencies of each components are important.
There are always losses due to system running at power factors less than unity and
also motor and generators incur copper and iron losses that would suffer internal
windage losses. Connecting wires can cause additional losses.
The drive and traffic controller uses energy (standby power) even when the lift is not
moving. A system of powering-off a controller during low traffic conditions should be
considered in a way similar to the MG (motor generator) set shut down progression
used on older Ward- Leonard systems.
Fig: 4.8 Drives used in Elevators
Energy is also utilized for car and machine room lighting, heating, cooling etc. If the car
lighting can be concentrated when the lift is inoperative, significant energy savings are
possible. Pit lighting can often be left on inadvertently and contemplation should be
given to routinely turning it off after (say) five hours.
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For low-use lifts, the energy harried on standby maybe superior than that used when
operating.
The Hong Kong Government had proposed limiting the size of the hoist motor as a
means of limiting energy consumption
[8]
. This however can have a substantial
consequence on the management capability, person along for the ride waiting and
person along for the ride waiting period and would not be sufficient in most situations.
4.4.5 Duty
The following factors have a significant effect on energy consumption.
• Car mass
• inoperative time
• Travel course
• Load disparity in the car
• Number of journeys made by occupants and their destinations
• Number of occupants demanding service
The following figure shows the potential amount of energy that can be recovered back
to the power supply for a 75% encumbered down trip.
Lifts are generally designed to be counter unprejudiced at 40-50% rated load. This can
be prepared by assembling the mass of vacant car plus 40-50% of rated load equal to
counterweight. Figure 13.2 assumes that the setting up has a 42% counterbalancing.
Thus the most well-organized use, in this case, is when car is 42% encumbered.
The traffic control algorithm can have an authority on how some of the traffic stipulate is
handled. For example, when under high stipulate conditions, what happens is that the
identical floors at the same time together. It is also possible for the traffic controller to
provide an algorithm designed for energy saving operation.
Another scheme to diminish energy convention is to eliminate lifts from service outside
the climax periods. This has the consequence of increasing the car habitation levels and
hence brings the lift system closer to equilibrium condition. There can be an augment in
person along for the ride waiting times using this practice.
4.4.6 Regenerating Energy Back into Supply
In any hoisting function, latent energy is power
[9]
. When a lift system is in operation up
empty (or down full), it is ‘overhauling’. The motor is efficiently driven by the load, under
34. 34
the pressure of gravity thus braking the lift structure and preventing plummeting. Lifts
always need to fritter away unnecessary energy from the system, either as waste heat
into banks of resistors, or by rejuvenation. Whether the energy can be regenerated and
the mechanism for achieving it depends on the brand of drive.
Regenerating lift drive systems return the stored energy back to the supply through the
supply metering structure.
Fig 4.9: Regenerating Energy Working Principle
On the other hand, not every meter can testify this repeal power and abstract units from
the total. A unique meter has to be built-in by conformity with the utility company. Where
this is not possible arrangements should be made for the regenerated power to be used
by other energy ‘sinks’ in the building, such as lighting, HVAC, etc. it is important to bear
in mind that regeneration can cause the supply voltage to rise at the lift input terminals,
unless it is coupled to a low impedance supply.
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Chapter 4: CONCLUSION
4.1 Conclusion
Installing energy efficient elevator technologies might cost more initially, however in the
lost run, these are a much better bet than investing in stock markets or in banks. As we
know, the two major reasons behind saving energy is so as to reduce resource
depletion and then the most important reason being, saving money.
In this report, we have discussed the various technologies that can be installed to save
energy. Right from installing motion detectors ad presence sensors to save cabin light
energy wastage, to appropriate use of controllers, perfect combination of the different
operating modes to save startup energy.
We have also concluded that machine-roomless, gearless elevators save upto 75%
more energy than the traditional hydraulic elevators. A lot of energy is dissipated as
heat into the shaft. Instead of wasting this energy, this can be regenerated using
regenerative drives and used to power cabin lightings or other office equipments.
As gearless elevators use permanent magnets, thereby reducing internal losses and
reducing size of motors and hence saves space.
4.2 Future Works
I would keep in mind all the technical knowledge I had learnt from this internship in my
future projects. Topics such as control systems, fuzzy logic, neural networks and
genetic algorithms are very important topics when it comes to elevators and other fields.
Through this internship, I was exposed to an entirely different perspective of how it is
like to work in an office atmosphere, deal with clients and negotiate. I would surely put
all my knowledge into practice.
