ELEVATOR (LIFT) MANUFACTURING PLANT
[EIRI/EDPR/4634] J.C.: 2851XL
An elevator system is a vertical transport vehicle that efficiently moves people or goods between floors of a building. They are generally powered by electric motors. The most popular elevator is the rope elevator. In the rope elevator, the car is raised and lowered by transaction with steel rope. Elevators also have electromagnetic brakes that engage, when the car comes to a stop. The electromagnetic actually keeps the brakes in the open position. Instead of closing them with the design, the brakes will automatically clamp shut if the elevator loses power. Elevators also have automatic braking systems near the top and the bottom of the elevator shaft. Many modern elevators are controlled by a computer. The computers job is to process all of the relevant information about the elevator and turn the motor correct amount to move the elevator car in correct position.
In order to do this the computer needs to know at least three things those are where people want to go where each floor is where the elevator car is Finding out where people want to go is very easy. The buttons in the elevator car and the buttons in each floor are all wired to the computer, when anyone presses these buttons, the computer logs this request.
COST ESTIMATION
Plant Capacity 1100 Nos./Year
Land & Building (8000 sq.mt.) Rs. 1.07 Cr
Plant & Machinery Rs. 3.94 Cr
Working Capital for 2 Months Rs. 8.31 Cr
Total Capital Investment Rs. 13.63 Cr
Rate of Return 25%
Break Even Point 53%
CONTENTS
INTRODUCTION
IN ORDER TO DO THIS THE COMPUTER NEEDS TO KNOW AT LEAST THREE THINGS THOSE ARE:
HISTORY OF ELEVATOR
FIG. 1.1 (STANDARD ELEVATOR)
FIG. 1.2 (ELEVATORS IN HOSPITAL)
ELEVATOR SYSTEM OVERVIEW
DESCRIPTION
METHODOLOGY:
ELEVATOR TECHNOLOGY-
TYPES OF ELEVATOR CONTROL SYSTEMS:
SINGLE AUTOMATIC OPERATION:
SELECTIVE COLLECTIVE OPERATION:
GROUP AUTOMATIC OPERATION:
HYDRAULIC ELEVATORS OPERATION-
FIG. 2.1 HYDRAULIC LIFT
THE CABLE SYSTEM-
GEARED VERSUS GEARLESS ELEVATORS
FIG. 2.2 DETAILED VIEW OF ERECTION
ELEVATOR SAFETY MECHANISM:
THE ROPE SYSTEM:
SPEED GOVERNOR:
ELECTROMAGNETIC BRAKES:
SEQUENTIAL LOGIC CIRCUITS:
COMPONENTS OF ELEVATOR
ELEVATOR FABRICATION:
FIG. 3.1 HOSITWAY OF A 6 STORYED BUILDING
MARKET POSITION
INDIA ELEVATOR MARKET OVERVIEW:
INDIA ELEVATOR MARKET KEY PLAYERS
DESIGN SPECIFICATIONS:
CAR HEIGHT AND OVERHEAD CLEARANCE:
PLATFORM CONFIGURATION:
NUMBER OF STOPS:
FIG. 3.2 MODERN DAY MOTOR
TYPES OF MATERIALS USED AND IT’S PROPERTIES:
ELEVATOR CAR: STAINLESS STEEL/3CR12
GUIDE RAILS/HAND RAILS: STEEL E235B
SUSPENDING ROPES: UNALLOYED CARBON STEEL (CARBON 0.4-0.8 %)
CONTROLLING METHODS
FIG. 4.1 MANUAL PUSHBUTTON ELEVATOR CONTROLS
FIG. 4.2 OTIS 1920’S CONTROLLER
GENERAL CONTROLS
A TYPICAL MODERN PASSENGER ELEVATOR WILL HAVE:
FIG.4.3 TYPICAL FRIEGHT ELEVATOR CONTROL
SOME ELEVATORS MAY HAVE ONE OR MORE OF THE FOLLOWING:
FIG. 4.4 DUAL DOOR OPEN AND CLOSE DOOR BUTTONS
FIG. 4.5 SIGNAL BUTTON
EXTERNAL CONTROLS
FIG. 4.6 AN EXTERNAL CONTROL PANEL
THE ELEVATOR ALGORITHM
RELAY LOGIC ELEVATOR
CONTROLLER
THE PRIMARY FUNCTION OF THE ELEVATOR CONTROLLER
YPES OF ELEVATOR CONTROLLERS:
1- RELAY BASED CONTROLLER (ELECTROMECHANICAL SWITCHING)
FIG.4.7 RELAY BASED CONTROLLER (ELECTROMECHANICAL SWITCHING)
SOLID-STATE LOGIC TECHNOLOGY
FIG.4.8 SOLID-STATE LOGIC TECHNOLOGY
PLC CONTROLLER (COMPUTER BASED TECHNOLOGY)
FIG.4.9 PLC CONTROLLER (COMPUTER BASED TECHNOLOGY)
COMPUTER BASED CONTROLLERS ARE SUITABLE FOR THE FOLLOWING:
ELEVATOR CONTROL SYSTEM SEQUENCE DIAGRAMS
1- FROM THE POINT OF VIEW OF AN INDIVIDUAL USER:
DISCRETE CONTROL AND COMMUNICATION INTERFACES IN ELEVATOR CONTROL SYSTEM:
UNDER THIS TITLE, (5) COMPONENTS AS FOLLOWS:
CAR OPERATING PANEL COP
FIG.4.12 OPERATING PANEL
CAR OPERATING PANEL-
FIG.4.13 CAR OPERATING PANEL COP BUTTONS
A- DOOR-CLOSE-BUTTON
B- DOOR-OPEN-BUTTON
C- ALARM BUTTON
D- FAN BUTTON
E- OVERLOAD INDICATOR
F- CAR POSITION INDICATOR/DIRECTION INDICATOR
G- FIREMAN BUTTON
H- FLOORS BUTTON
I- INSTRUCTION PLATE
FIG.4.15 CONTROLLER CABINET
COMMUNICATIONS INTERFACE
A- STANDARD PHONE
FIG.4.16 STANDARD PHONE
B- HANDS FREE ADA PHONE
FIG.4.17 HANDS FREE ADA PHONE
SUPERVISORY CONTROL PANEL
FIG.4.18 SUPERVISORY CONTROL PANEL
SPECIAL OPERATING MODES FOR ELEVATOR CONTROL SYSTEM
1- ANTI-CRIME PROTECTION (ACP)
2- UP PEAK (MIT)
3- DOWN PEAK
SABBATH SERVICE (SHO)
FIG.4.20 SABBATH SERVICE
4- INDEPENDENT SERVICE (ISC)
5- INSPECTION SERVICE (INS)
6- FIRE SERVICE MODE (EFS)
7- MEDICAL EMERGENCY/'CODE BLUE' SERVICE (EHS)
8- EMERGENCY POWER OPERATION (EPO)
CONTROL ROOM ELECTROMECHANICAL REQUIREMENTS
ELEVATOR MODERNIZATION
FIG.5.1 AN ELEVATOR TEST TOWER
USES OF ELEVATORS
BRIEF DESCRIPTION OF PROJECT & PRODUCT
ABOUT THE LIFT AND THEIR COMPONENTS
1) LIFT COMPONENTS
PLAN AND SECTION OF A PASSENGER ELEVATOR
I) HOIST WAY OR SHAFT
II) MACHINE ROOM
III) LIFT PIT
IV) OVERHEADS
V) COUNTERWEIGHT
VI) GUIDE RAILS
VII) BUFFERS
2) CLASSIFICATION
I) DRUM TYPE
II) TRACTION TYPE
GEARLESS TRACTION ELECTRIC ELEVATORS
GEARED TRACTION ELEVATORS
TYPES OF COMMERCIAL LIFTS AND THEIR USES
1. TRACTION LIFTS
2. GOODS LIFTS
3. LOW PIT LIFTS
4. FREIGHT ELEVATORS:
5. DUMBWAITER ELEVATOR:
MANUAL ELEVATOR DOOR:
AUTOMATIC DOORS:
MS THREE FOLD TELESCOPIC ELEVATOR DOOR
STAINLESS STEEL AUTO ELEVATOR DOOR
GLASS ELEVATOR DOOR
COLLAPSIBLE ELEVATOR DOOR
IMPERFORATE ELEVATOR DOOR
IMPERFORATE ELEVATOR DOOR
G. P. BRACKET
DOOR LOCK
GUIDE SHOE
SAFETY BLOCK
SPRING BUFFERS
ELEVATOR COUNTER WEIGHT
ELEVATOR RETIRING CAM
ELEVATOR DOOR HEADERS
ELEVATOR GUIDE RAILS
ELEVATOR INSPECTION BOXES
PASSENGER ELEVATORS
PASSENGER ELEVATORS MAIN FEATURES
PASSENGER ELEVATORS - SAMPLE DRAWING
HOME ELEVATOR
EXPLAINING ELEVATOR COMPONENTS
ELEVATOR RAILS
CABIN
SPEED GOVERNORS
ELEVATOR SHAFT AND BUFFERS
DOORS
SAFETY DEVICE
SAFETY SYSTEMS IN ELEVATORS
OVER SPEED GOVERNOR
DOOR SENSORS
DOOR & DOOR LOCK
OVERLOAD SENSOR
AUTOMATIC RESCUE DEVICE
BUFFER SPRINGS
INTERCOM
OVER TRAVEL PROTECTION
MACHINERY AND EQUIPMENT
PILLAR/VERTICAL DRILL MACHINE
CUT OFF SAW MACHINE
GRINDING MACHINE
MANUAL DRILL MACHINE
GENERAL TOOL KIT
GLASS CUTTER
PRODUCTION PROCESS FLOW
BRIEF DESCRIPTION OF THE PROCESS FLOW IS AS FOLLOWS:
PROCUREMENT OF RAW MATERIALS
CUTTING
DRILLING AND SCREW FITTING
GRINDING
GLASS FITTING
QUALITY CHECK
PACKAGING
DELIVERY AND PAYMENT
ELEVATOR MANUFACTURERS
ELIVATORS PARTS MANUFACTURERS
D.G. SET
LABORATORY TESTING EQUIPMENTS
ADDRESSES OF RELEVANT GOVERNMENT OFFICES
ADDRESSES OF FINANCIAL INSTITUTIONS
LOCATION OF SITE
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
DEPRECIATION:
FIXED ASSETS:
WORKING CAPITAL:
BREAK-EVEN POINT:
OTHER FIXED EXPENSES:
MARGIN MONEY:
TERM LOANS:
TOTAL LOAD:
LAND AREA/MAN POWER RATIO:
UTILITIES
POWER
WORKING
TOTAL MANPOWER AND PAYROLL
UTILITIES
PRODUCTS PHOTOGRTAPH
PLANT LAYOUT
ORGANIZATION CHART
LIST OF DOCUMENTS REQUIRED TO GET FOR LICENSES
DOCUMENTS:
OTHER LICENSES REQUIRED FOR THE SETUP:
PROJECT IMPLEMENTATION SCHEDULE
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
