Hydraulic Elevator Design Overview
Figure 1
Principle operation
The car of a hydraulic elevator is lifted
from below by a hydraulic ram. A hydraulic
ram is a long piston that is driven into or out
of a hollow cylinder by pressure in a
hydraulic fluid. The hydraulic fluid, usually
oil or water, exerts a force on any surface it
touches, including the base of the piston. If
the pressure in the hydraulic fluid is high
enough, the force it exerts on the base of the
piston will exceed the weight of the piston and elevator car and they will
accelerate upward.
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But as the piston rises, the hydraulic fluid has more space to fill
and its pressure drops. To keep the piston moving upward, something
must continuously add high-pressure hydraulic fluid to the cylinder, that
is usually an electrically powered pump. This pump draws low-pressure
hydraulic fluid from a reservoir and pumps it into the cylinder. The pump
does work on the fluid and this work is what lifts the elevator car.
When the elevator car has reached the proper height, the pump
stops and the piston rests on the high-pressure hydraulic fluid beneath it.
As long as the amount of fluid in the cylinder doesnt change, the piston
and car will stay where they are as the passengers get on and off.
To let the car descend, the elevator opens a valve and permits the
high-pressure hydraulic fluid to return to the low-pressure reservoir. The
fluid naturally accelerates toward the lower pressure and the cylinder
begins to empty. The car descends. However, the fluid in the cylinder has
considerable pressure potential energy and that energy must go
somewhere. As it flows through the valve, the fluid accelerates and it
rushes into the reservoir at high speed. But its kinetic energy soon
becomes thermal energy as the fluid swirls around randomly. When the
swirling has stopped, the fluid in the reservoir will be warmer than it was
before the elevator made its trip up and down.
Because it lifts the car from below like a jackscrew, the hydraulic
elevator is naturally very safe. Even if the cylinder springs a leak, the
hydraulic fluid will probably not flow out of the cylinder fast enough for
the car to descend at a dangerous speed. But unlike a jackscrew, a
hydraulic ram encounters very little friction and wear, so its piston can
move in or out of the cylinder rapidly. As a result, the car of a hydraulic
elevator can be lifted as fast as the pump can deliver high-pressure
hydraulic fluid. Of course, the pump has to do a great deal of work on
that fluid in a short time, so it must be very powerful. Nonetheless, the
speed of a hydraulic elevator is limited only by the power of the pump
and the comfort of the passengers.
must be either metal, fire-retardant-treated wood, or some equally fireretardant approved materials.
2. Door Mechanism
3. Hydraulic System
Telescopic Cylinders
The great advantage of telescopic cylinders over conventional rodtype cylinders is their ability to provide an exceptionally long stroke
from a compact initial package. The collapsed length of typical
telescopic cylinders varies between 20% to 40% of their extended
length. Thus, when mounting space is limited and the application
needs a long stroke, a telescopic cylinder is a natural solution.
Telescopic hydraulic cylinders are relatively simple devices, but
their successful application requires an understanding of their
construction. Knowledge of how telescopic cylinders work and which
special application criteria to consider will help you design them
safely and economically into your equipment.
stages nested inside it will move first, and will complete its stroke
before the next stage begins to move. This procedure will continue for
each stage until the smallest-diameter stage is fully extended.
Conversely, when retracting, the smallest diameter stage will retract
fully before the next stage starts to move. This continues until all
stages are nested back in the main
To extend, the high pressure oil is directed by the control valve into
port A. The oil passes through the transfer tube in the rod to the base
of the cylinder.
To retract: with no oil pumps, the weight of the body pushes oil in
the cylinders to the tank and cylinder will be shorten.
Basic Cylinder Types
As with conventional cylinders, the two basic types of telescopic
hydraulic cylinders are single-acting and double-acting.
Single-acting telescoping cylinders extend under hydraulic
pressure and rely on gravity or some external mechanical force for
retraction. Single-acting cylinders are used in applications where some
form of load is always on the cylinders. Pressurized oil extends the
telescopic cylinder to raise one end of the dump body and expel its
load.
When pressure is released, the weight of the dump body forces oil
out of the cylinder and it retracts.
Double-acting telescopic cylinders are powered hydraulically in
both directions. They can be used in applications where neither gravity
nor external force is available. They are well suited to non-critical
positioning applications requiring out-and-back movement of a
substantial load. A classic application is the packer-ejector cylinder in
refuse vehicles and transfer trailers. The horizontally-mounted
cylinder pushes a platen to compress the load, then must retract with
the platen so that more material can be added. Gravity cannot assist,
so a double-acting cylinder is used.
In our project we just consider single-acting telescopic.
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3
5
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1. Reservoir
2. Filter
3,4. Pump
5. Relief valve
6. Pressure gauge
7. Distribution valve
8. Cylinder
9. Check valve
10. Flow regulating valve
b. Requirements
Load : 1500kg.
Fluid pressure: 6 Mpa
Single acting cylinder
Stroke length: 12m.
Stroke velocity: 1.5m/s
c. Length of the cylinder:
The system is used for 4-story building
Then the stroke length is: 3x4m=12m.
We use the telescopic cylinder with 6 stages, the length of each stage is 2m.
d. Diameter of the cylinder:
From the formula: F=A.P
10
F
P
15000
6106
2,5.10 3 m 2
D 2
4
A=
Then the inner diameter of the plunger(the smallest stage):
4A
4.2,5.10 3 m 2
3.14
D=
=
=0.056m
We also have:
- The thickness of the wall of the cylinder: t = 5mm (for all stages)
- The width of the shoulder of the cylinder: s = 5mm (for all stages)
- The width of slits between the wall of stages: b = 1mm
b=1mm
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e. Structure:
- The plunger:
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- The barrel:
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N=
(1)
Where:
N: pump capacity
0
: volumetric efficiency
=0.9
: mechanical efficiency
=0.96
P: working pressure P=6Mpa=60bar
F 15000
=
P 610 6
.Q
=0.0025
Then h=40mm
Diameter slit:
=0.1mm
= 0,4 bar.
Valve control:
To control the position of the sliding block, we use controlling top
(electromagnetic control)
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7. Reservoir :
a. Function:
- Holds excess hydraulic fluid to accommodate volume changes
from: cylinder extension and contraction, temperature driven
expansion and contraction, and leaks.
- Aid in separation of air from the fluid and also work as a heat
accumulator to cover losses in the system when peak power is
used.
- Maintain the temperature of fluid at allowable range.
b. Figure and dimension:
Figure: Deep and narrow are better than shallow and wide because the fluid
level could be higher and prevent it from whirling.
Dimension:
Vmin=3Q
c. Structure:
Baffle with the height about 2/3 the height of the fluid, with two functions:
- Prevent the return fluid from going directly to the pump.
- Prevent the fluid from splashing.
The lid of the reservoir has the vent with filter to prevent the dirts.
Choose water cooling:
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8. Filters
Filter the dirt and metal particles which continually produced by mechanical
components. They need to be removed along with other contaminants.
Unrefined filter and fine filter:
- Unrefined filter: Metal net filter purity 0,08-0,1 mm placed before the pump
- Fine filter: Paper filter, purity 4-5, placed after the pump.
Choose the filters with assisting valve that is closed at normal flow rate.
When the flow rate is too high or the filter is clogging, the valve is opened and
the fluid can go directly through the valve without filtering.
9. Pipes: Steel C45.
Depend on the height the system and disposition of reservoir, we can
determine the length of pipes.
Inner diameter of the pipe: d = 20 mm.
Flow rate : Q = 3.75 (l/s).
Pressure loss:
= 0,16 bar.
Steel C45:
= 400-500 MPa.
Allowable velocity of fluid: v = 5-6 m/s.
[Link]:
Fluid in hydraulic system is the energy transferring environment. It also
functions as lubricant and cooling. We chose SAE 10W-30.
180
990
- Working range:
C to
C
- Various additives to improve lubricity.
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B. Traction elevators
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1.
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+ Lifting structure
Installed in the engine wiring lift lifting generate traction and movement
of the counterweight.
Elevation mechanism includes the following components: pull cable parts
(pulleys), reduce speed box, electromagnetic brake and drive motor. All
parts are mounted on steel base. In the elevator often use two lifting
systems:
- Lifting with speed box
- Lifting without speed box
Lifting without speed boxes are often used in high speed lifts.
+ Electric cabinet: the circuit breaker panel assembly, fuses, switches and
intermediated relay.
Division speed limit part works in collaboration with brake insurance
cable to limit the speed movement of the lift
2. Equipment installed in machine cabinet
+ Lifting structure
Installed in the engine wiring lift lifting generate traction and movement
of the counterweight.
Elevation mechanism includes the following components: pull cable parts
(pulleys), reduce speed box, electromagnetic brake and drive motor. All
parts are mounted on steel base. In the elevator often use two lifting
systems:
- Lifting with speed box
- Lifting without speed box
Lifting without speed boxes are often used in high speed lifts.
+ Electric cabinet: the circuit breaker panel assembly, fuses, switches and
intermediated relay.
Division speed limit part works in collaboration with brake insurance
cable to limit the speed movement of the lift
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a)
With speed box; b) Without speed box
1. Drive motor 2. Electromagnetic brake, 3. Speed box 4. Pull the
cable part
3. Cabin and other related equipment
Cabin is part of the elevator load bearing structure. Cabin must have the
ability to disassemble it into small parts. About structure, cabin consists
of 2 parts: bearing structures (the frame cabin) and the wall covering,
ceiling and floor form frame. Over the frame cabin is the guide block,
cabin suspension system and brake handles insurance, the system shut
down and open structure. In addition, the elevator cabin seats must meet
the information requirements wind, temperature and light.
4. Cab suspension
Because cabin and counterweight are suspended by many separate strands
so it requires a suspension to ensure that the separate strands improve the
same. In tension case, tensile strength cable will be overloaded even
without tension, cable pulley grooves will slide on a very dangerous
friction. In addition, due to fiber tension so slack fiber cable on the pulley
grooves are worn friction will not same. So that why the suspension
system must be equipped with electric contact of the safety circuit
breaker to stop the elevator when a in the excess cable slack to allow the
ladder to prevent disasters. At this time the elevator can only work when
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adjusting tension of the cable as the other. The cabin suspension with
beams installed on the frame will stand in the cabin bearing system.
5. Guide rails
Guide rails were installed along the ladder to lead well and for
instructions for cabin moves along well. Guide rails will ensure the cabin
always located in the well and will not be moved horizontal during
movement. Additionally guide rails also have the stiffness enough for the
weight of the cabin and the passengers rest on cabin. The guide rails have
bars so when the load brake they will make the insurance (in case of
broken cable or cabin goes down at a rate higher than the value allowed).
6. Counterweight
Counterweight is the part played a key role in balancing system of the
elevator. For the elevators height is not large, people choose
counterweight so that its weight equals the weight of cabin plus some
weight of its passenger. When the elevators weight increase, the weight
of the lifting cable and power cable is considerable so people use chain to
compensate the weight of the lifting cables
Counter weight can be determined by the formula:
m=C + eQ
In that
C: Weight cabin
Q: The nominal load of the elevator
e: Coefficient balance
If the weight of the counterweight balance perfectly equal with the cabin
and payload weight lifting (e = 1) then when raise or lower cabin with
fully loaded, the engine's lifting is to overcome friction and inertia force,
but the cabin does not load the engine must overcome more resistance is
equal to the nominal lifting capacity Q to lower cabin (or lift
counterweight). So for that reason people choose counterweight to
balance e coefficients so that the force needed to lift the cabin filled with
passengers will lower the cabin at no load.
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II.
Electronic design
1. Concept
1.
2.
3.
2. Definition
2.1Operational specification
On each floor there are up and down call buttons for the elevators.
Depending on which way, the user presses one of the call buttons. Once
in the elevator the user chooses his destination by pressing the
appropriate button inside the card. The elevator moves to the desired floor
and the user disembarks.
Because this project have the human-to-product interface, it is necessary
to have a clear display module to inform the passengers the position of
the elevator so that they can use elevator more efficiently. The operational
specification of display module list as following:
The buttons are lighten up by green LEDs when they are pressed.
The 7 segment LED indicate the position when the car reaches each
floors.
The arrows (also using LEDs) indicate the direction of the car.
The floor sensors send signal to the controller that the car has reached the
exact position to stop.
The coming sensor send signal to the controller that the car should reduce
speed and ready to stop.
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4. Two power circuits to control the main motor and the motor that drives
the door.
The speed of two motors will be control by pulse width modulation
(PWM)
2.2Basic Block Diagrams
The ATMegal6 was chosen for the prototype development. The Mega16
is pin-for-pin compatible with the smaller-memory model ATMega8535 as
well as with the larger-memory model ATMega32. This allows some
freedom during the design phase. The option of increasing the memory
model may be needed, since we do not know exactly how much code space
is required in either unit. At the end of the project, and after the features have
ceased to creep, if the code would fit into a potentially less expensive
component with a smaller memory size, that choice is available as well.
3. Hardware Design
3.1AVR Microprocessor
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3.2Power Supply
The supply power of the implemented circuit need to have a
capability of maintaining be a steady voltage level despite vary current
demands and input voltage variations. For this purpose, we use IC 7805
LM 7805 is used very simple with input pin will be the (9-24V),
common leg for ground, which is connected mass, the output pin is 5V to
feed the circuit.
Also we will use the power supply of the PC to generate the 12V sources
from the 220V AC
3.3Button
Because ATmega16 has a limited number of pins and this system
requires quite many buttons to operate, we use each of three pins to
take the input of each group of buttons. Here we use matrix 3x8 like
the following figure
3.4Floor sensors
Use the same matrix as buttons
3.5Display module
To display the position of the car, we use 7 segment LED, to light
up background of the pressed buttons, we use green LED. To control
all of these LED, we use IC 74HC595
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the storage register appears at the output whenever the output enable
input (OE) is LOW.
4. Software Design
Build and Test Prototype Hardware
4.1. Display function using 74HC595
void display (unsigned char x, unsigned char y, unsigned char z, unsigned
char w)
{
Int i,j,k,l,t1,t2,t3,t4;
for(i=0;i<8;i++)
{
t1=x;
t1=t1&0x80;
if(t1==0x80)
DATA=1;
else
DATA=0;
x*=2;
SCK=0;
SCK=1;
}
for(j=0;j<8;j++)
{
t2=y;
t2=t2&0x80;
if(t2==0x80)
DATA=1;
else
DATA=0;
y*=2;
SCK=0;
SCK=1;
}
for(k=0;k<8;k++)
{
t3=z;
t3=t3&0x80;
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if(t3==0x80)
DATA=1;
else
DATA=0;
z*=2;
SCK=0;
SCK=1;
}
for(l=0;l<8;l++)
{
t4=w;
t4=t4&0x80;
if(t4==0x80)
DATA=1;
else
DATA=0;
w*=2;
SCK=0;
SCK=1;
}
SCL=0;
SCL=1;
}
4.2Display button LED
void scan(){
switch(button)
{
case 1:
button_led |=0x01;
break;
case 2:
button_led |=0x02;
break;
case 3:
button_led |=0x04;
break;
case 4:
button_led |=0x08;
break;
case 5:
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button_led |=0x10;
break;
case 6:
button_led |=0x20;
break;
}
switch(call_up)
{
case 1:
up_led |=0x01; break;
case 2:
up_led |=0x02; break;
case 3:
up_led |=0x04; break;
case 4:
up_led |=0x08; break;
case 5:
up_led |=0x10; break;
}
switch(call_down)
{
case 1:
down_led |=0x01; break;
case 2:
down_led |=0x02; break;
case 3:
down_led |=0x04; break;
case 4:
down_led |=0x08; break;
case 5:
down_led |=0x10; break;
}
switch(floor_sensor)
{
case 1:
seg_led=1; break;
case 2:
seg_led=2; break;
case 3:
seg_led=3; break;
case 4:
seg_led=4; break;
case 5:
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seg_led=5; break;
case 6:
seg_led=6; break;
} }
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void door()
{ do{
PORTD.5=0;
PORTD.6=1;
}while(PINC.6!=0);
PORTD.5=0;
PORTD.6=0;
delay_ms(2000);
do{
PORTD.5=1;
PORTD.6=0;
}while(PINC.7!=0);
PORTD.5=0;
PORTD.6=0; }
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void go(char d)
{
do{
PORTD.3=1;
PORTD.4=0;
}
while(d!=((PINC>>3)&0x07));
PORTD.3=0;
PORTD.4=0;
button_led &=~(button_led);
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}
4.5. Test Program
void main()
{
DDRA = 0x00;
PORTA = 0x00;
DDRB = 0x00;
PORTB = 0x00;
DDRC = 0x00;
PORTC = 0xC0;
DDRD = 0xFF;
PORTD = 0x00;
while(1)
{
button = PINA&0x07;
call_up = (PINA>>3)&0x07;
call_down = (PINA>>6)|((PINB<<2)&0x04);
floor_sensor = (PINC>>3)&0x07;
coming_sensor = PINC&0x07;
scan();
display(code[seg_led],down_led,up_led,button_led);
if(button == 1){
dest_floor = 1;
go_up(dest_floor);
door();
}
else if(button == 2){
dest_floor = 2;
go_up(dest_floor);
door();
}
else if(button == 3){
dest_floor = 3;
go_up(dest_floor);
door();
}
else if(button == 4){
dest_floor = 4;
go_up(dest_floor);
door();
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}
else if(button == 5){
dest_floor = 5;
go_up(dest_floor);
door();
}
else if(button == 6){
dest_floor = 6;
go_up(dest_floor);
door();
} }}
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