Technical Field

The present invention relates to lift control panels.

The invention especially relates to a monoblock lift control unit that has been designed to be used in place of the existing lift panels, that does not have a control card or an integrated control unit apart from the motor driver that can work independently, that does not require an external cabinet, that is produced as a unit that is integrated into the body, and that carries out all the functions of a monoblock lift unit. It is a monoblock lift control unit that can fulfil all the functions of the existing lift control panels that take up a lot of space, that takes up less space, that can provide improvements to the production process, that requires less cabling, that is easier to install and connect, that provides additional advantages such as rapid troubleshooting.

State of the Art

A lift control panel is formed by the assembly of lift control units (motor driver, control card or lift integrated control unit) and other supporting units in an electrical cabinet on a mounting plate, by way of the electrical connection of protection and electrical equipment (fuse, contactor, relay, switch and button etc.) and the connection components (electric terminal, connector, ground bus), so as to produce a final product that is capable of controlling a lift. In addition, the control panel that is formed by the assemble of different units, is produced so as to not endanger life in accordance with the relevant security norms of lift manufacture and security rules. The production and installation of the present lift control panels is as follows:

Standard properties such as power values, motor type, number of stops that are necessary for the control panel are learned. The make, model, power and if relevant, the necessary additional/supporting card equipment (such as EMC filter or encoder card) of the motor driver is determined. The make, model, and if relevant, the necessary additional/supporting cards of the control card is determined. Equipment such as the power source, transformer(s), rectifier(s), fuses (circuit breakers), contactors, relays, control switches (breakers), buttons, electric terminals, sockets, and ground busses, are determined based on need according to type, number, current-potential, number of pole/contacts. An electrical connection schema (panel cabling), in which the detailed list of equipment and cable length and colours can be found, is prepared for the production of the control panel.

All units and equipment that are to be used in the assembly of the control panel are taken from the shelves on which they are located and gathered at the place where the panel layout plan is being carried out. The equipment is placed, and the most suitable layout plan is formed in accordance with any procedure that may be in application, or in accordance with the knowledge and experience of the personnel. During the process of forming the layout plan, the cable conduit (equipment used to enable the orderly and collective transfer of cables) and the DIN mounting rail (equipment used to mount the switch equipment) number and sizes are determined. The measurements of the formed mounting plate are determined according to the formed layout plan. Any such existing mounting plate is used or a mounting plate with the required measurements is procured.

By determining the measurements of the mounting plate, the measurements of the control panel cabinet in which the mounting plate is to be placed is also determined. Any such existing panel cabinet is used or a panel cabinet with the required measurements is procured.

The installation of each piece of equipment is carried out on the mounting plate in accordance with the prepared layout plan by way of the relevant methods. Switch equipment such as the fuse and contactor are installed on the DIN mounting rail. Therefore, the DIN mounting rail is first cut to size by the relevant cutting tool. Then, it is secured to the mounting plate in accordance with the prepared layout plan. Some equipment is secured directly on to the mounting plate with screws. For some equipment to be secured, rivet nuts need to be driven into the mounting plate at the relevant points. Some equipment requires raising spacers and/or assembly pedestals.

The product on the mounting plate that has had all the equipment installed is taken to the area in which cabling is to be carried out. All equipment is labelled in accordance with the electrical connection schema. Equipment such as electric terminals and sockets are labelled with their own special labelling methods and tools.

The colour, type and section values are determined according to the requirements of use and power in accordance with the electrical connection schema. The relevant cables are carried to the area in which cabling is to be carried out on conveyance rollers or at the required lengths. The cabling is carried out on the mounting plate on which all equipment has been mounted in accordance with the electrical connection schema of the product. The required length of each cable is determined manually for each connection during the cabling process. The necessary length of the cables of correct type, colour and sections are cut. Cable end terminals are attached to each end of the cable by way of the relevant tools. The cable ends are attached to the relevant points in accordance with the electrical connection schema. The product that has been cabled is conveyed to the testing area. The product that is to be tested is attached to the panel test device that has been prepared for the test. The existing panel test devices are systems that have been produced in alignment with the need of the producers to simulate a lift to the extent that it is possible and that are operated manually. All functions are tested manually in accordance with any procedure that may be in application, or in accordance with the knowledge and experience of the personnel. If an error is detected during the test, the source is examined and when the source has been determined it is fixed and the test is continued. Error detection in complicated and large control panels that involve a lot of cables where cables are conveyed through cable conduits is a process that requires a great deal of knowledge, experience and time. The fact that the test procedure that is the only process in which the deficiencies and errors on the cabling can be determined, is carried out manually can lead to the tests being incomplete, to some deficits and to some errors being overlooked. After testing, the product on the mounting plate on which all equipment have been installed, is placed within the external control cabinet. It is then secured to the cabinet by way of the relevant process. The product in the form of the mounting plate achieves its final form as it is placed in the cabinet. The control panel cabinet is formed of a significant amount of plate and workmanship. The plates are cut and bent at the required measurements. These pieces are suitably joined and painted. Then the pieces are oven-dried and put together. The cover of the cabinet is attached to the main body by way of hinges. The number and type of hinges is determined in accordance with the measurements and the weight of the cabinet. When the hinges are being attached, the body of the cabinet and the pieces of the cover must be carefully aligned.

The direction that the cabinet is to open should allow for it to be comfortably opened in the area in which it is installed (towards the right or the left). Generally, the pieces are designed to enable the covers to be attached to open towards different directions. A locking mechanism is utilised to ensure that the covers can stay closed. Locking mechanisms can be designed in different forms to suit any needs (wall type, springed, latched type etc.). The covers require grounding as they are made of metal. As this is grounding for a piece that will be in constant use, the grounding needs to be a flexible, mechanically well-designed connection. Air vents are left on the sides of the cabinet and/or on the cover in the appropriate places, while taking into account the levels of protection of the relevant standards pertaining to protection from solid objects and external interference, and ventilation fans are used if necessary. The fact that products that are housed within their own boxes are housed within a cabinet makes it hard for the heat they generate when in operation to be distanced from the area and increases the need for ventilation.

As the panel cabinet and the cover are made of plate material that has been joined, there may not be a perfectly conforming mechanical fit. Therefore, to avert any shortfalls arising from mechanical incompatibility, a seal ring is attached to the inner side of the cover.

Lift control panels that are heavy with large volumes are carefully packed so as not to be scratched or adversely affected by blows as they are transported from the location at which they are produced to where they are to be installed. The panels are generally covered with a nylon (stretch or bubble) packing material and are placed into wooden cages protected by styrofoam, to be transported. Large panels are usually carried to the transport by way of transportation tools such as forklifts. Large volume, heavy lift control panels are not suitable for transportation with any type of vehicle. Vehicles suited to carrying large loads such as pickup trucks or lorries must be used.

Lift control panels are generally installed in the area called the lift motor room that is on the top floors of buildings. Therefore, a great deal of effort is expended when carrying the large volume and heavy lift control panels to the area in which they are to be installed. Installation holes on the back of the panels are used to secure the panels to the wall in the area in which they are to be used. For the large volume heavy panels to be secured to the wall, a great deal of effort is expended. The problems encountered in the current case are as follows: The need for an independent cabinet: The lift motor driver and control card or lift integrated control unit (devices in which the motor driver and the control card are in one unit) and other supporting control units must be in a separate box to enable them to be used (transportation, physical durability, attachment, painting, labelling etc.) independently as they are independent units. The fact that lift control units need to be housed independently results in an increase in production costs.

The problem of size: As the independent lift control units and other electrical materials that must be in individual boxes have not been designed to be physically compatible and to take up less space, they take up a great deal of space. This results in the size of the panel being increased to provide the necessary space to house the lift panel.

The problem of weight: The transportation costs of heavy lift panels are high due to the fact that they are large. It is not possible for one person to carry, assemble or disassemble them.

Workmanship is time consuming and costly: Establishing electrical connections between independent units takes a lot of time. Therefore, workmanship costs are high. As pre-prepared cable groups are not used and as all connections are established separately, workmanship is time consuming and costly.

The complexity and high cost of cabling: Due to the large size, the length of the connection cables increase, and the cost of cabling is high. As there are several independent units, there are multiple connection points.

High error rate: The fact that there are multiple pieces and connections results in a high error rate. The difficulty of troubleshooting: The fact that there are multiple pieces and connections makes troubleshooting difficult in the event of an error. The problem of conformity with safety norms: The conjoining of units procured from different producers and the errors encountered in the electrical connections between units and the technical incompatibility of the units creates the possibility of a security gap.

The necessity to have experienced and technically qualified staff: The firm that is conjoining units procured from independent producers has to employ personnel with complete knowledge of the units that are being conjoined and who have sufficient technical knowledge in accordance with the relevant safety norms so as to prevent a technical risk. This technical personnel or team carry out the necessary work to prevent a safety or technical violation (checks for conformity with standards, technical calculations etc.).

The full, automatic testing of panels: Once the control panel has been produced, the testing is a difficult procedure. Most manufacturers connect their panels to panel test devices that they assemble and follow the testing procedure for a certain amount of time and test manually. The fact that the panel cannot be tested as a whole and be automatically tested like a device results in human errors being overlooked.

The need for storage space: The volume of storage space required for the storage of large panels is high.

The fact that inventory can’t be kept: Due to the fact that large lift control panels take up a lot of space, manufacturers prefer to not produce panels to keep in inventory.

Delays in panel order times: Because producers do not keep panels in stock and do not have them ready to sell means that they only fulfil orders after a delay for production.

Working with different suppliers: The time necessary for repairs may be extensive in the event of an error in the control panel that has been produced by procuring independent parts due to the fact that the owner of the lift has to contact the producer of the lift control panel and producers of the control units separately.

The fact that cables of different electrical properties pass side by side through the cable conduit: Cable conduits are used to ensure that cables are conveyed in an orderly fashion in control panels. Cables with high voltage switching that produce electrical noise and digital cables that operate on low voltage that are sensitive to electrical noise passing through the same cable conduit is not a desirable situation. Even though in practice this situation is avoided, the fact that there are a large number of connections results in this method being used. This lowers the panel’s protection from electrical noise, results in hard to detect errors and lowers the device’s working life.

The lack of panel connection schemas: Producers of lift control panels produce the panels in accordance with the published sample electrical connection schemas of the lift control units they are using. As the materials used in each panel may be different, each panel has to have a unique connection schema. Panel producers pass these along with the panel to those who are installing the panels. For lifts that are in use for long periods of time, these schemas become unusable or lost. For these panels that are not produced serially, if the schema for the panel is not accessible, repairing faults becomes difficult and the duration of the repairs is extended.

The fact that various electrical and mechanical equipment is used in the production of the panels: As no preparation is carried out for the installation of the materials beforehand, the use of tools such as drills, rivet nut machines, rail and cable cutting tools is required at every stage of installation. As no preparation is carried out regarding the cable connections, a beforehand, a collet tightening tools must be used at every stage of cabling. In application number TR 201 1/08242 for a utility model for an integrated lift control device relates to an integrated lift control device that has reduced the complicated lift control system to a single device, that minimises the connection error rate and that aligns the lift to the floor (saves) in the event of a power cut. Due to the modular structure of the integrated lift control device, installation is easier, a faster response is given to any signal that is received, and large savings are made regarding materials and workmanship. However, the solution provided only constitutes one portion of the lift control panel.

It is not a solution for problems encountered within the installed lift control panels. A different solution to replace the lift control panel use is required.

Description of the Purposes of the Invention

The purpose of the invention that is based on the state of the art is to develop a monoblock lift control unit that negates the negative situations in the existing structures. An additional purpose of the invention is to provide a solution that resolves the problems encountered in lift control panels and carries out all functions in a smaller volume.

An additional purpose of the invention is to develop a simplified monoblock control unit that can be installed faster.

An additional purpose of the invention is to develop a new solution that takes up less space, that is easier to carry, that is not heavy, that can be installed rapidly, that can be stocked, and that negates supply problems.

An additional purpose of the invention is to not necessitate the use of cable conduits as it utilises pre-prepared cable groups due to the fact that it needs less cabling.

An additional purpose of the invention is to take up less space due to the fact that the components forming the monoblock lift control unit being designed to be physically compatible and to take up less space. Therefore, the space required to produce, store, transport, and install the product is reduced. An additional purpose of the invention is to reduce the error rate and facilitate troubleshooting in the event of an error, due to the reduction in the number of parts and connections, and the use of pre-prepared cable groups.

An additional purpose of the invention is to remove the problem of certification as the developed device is a monoblock product that can be inspected by an authorised institution and that can be certified with a type examination certificate and a certificate regarding conformity with safety rules.

An additional purpose of the invention is to negate the need for a large number of electrical and mechanical equipment during production due to the fact the all installation and cabling requirements being pre-prepared for the monoblock lift control unit.

An additional purpose of the invention is to negate the connections between units, due to the fact that all external connections from the lift’s surrounding units being made to a single unit. Therefore, the complexity of connection is resolved. An additional purpose of the invention is to complete all procedures, including the material placement, cabling, testing and packing, in a much shorter time.

An additional purpose of the invention is to enable the easy solution of problems by providing the required connection schema with ease due to the fact that the products are of the same type and that there are no special alterations made on a product basis.

A monoblock control unit, housed in single box, that is transportable by hand, has been developed that fulfils all functions required for lift control to achieve the aforementioned purposes.

Description of the Figures Figure-1 ; An illustration of the general view of the inner part of the invention in a representation of use.

Figure-2; An illustration of the general view of the invention in a representation of use.

Figure-3; An illustration of the general view of the inner part of the invention in a representation of use in the state of the art.

Figure-4; An illustration of the general view of the empty inner part of the invention in a representation of use in the state of the art.

Reference Numbers

Detailed Description of the Invention

As seen in Figure-3 and Figure-4 that illustrate the state of the art, the lift control panel cabinet (1 ) has a large volume and is ungainly. The cabinet cover (4) is located on the cabinet body (3). Inside, it contains the lift motor driver and additional card/materials (5), lift control card and additional card/materials (6), power sources (7), manual control switches/buttons (8), electrical equipment (9), electrical connections (10) in the form of electrical terminals, connection cards, connector/sockets and grounding busses, and cable conduits (1 1 ) that are mounted on the mounting plate (2). It is opened by way of the cabinet cover lock (12) and the cabinet cover hinge (13).

It has been developed as a monoblock solution that can carry out all lift control functions, that can be produced as a unit in a single body (21 ) without the independent lift motor driver and additional card/materials (5) and lift control card and additional card/materials (6) that are used in the state of the art and without the need for an external cabinet.

This monoblock body (21 ) houses the necessary motor driver unit (14), control card unit (15), electrical equipment (9) (protective devices such as the fuse, switch components such as contactor, relay, breaker/switch and button, electrical connections (10) (connection components such as electric terminal, connector, grounding bus), power sources (7) such as the transformer and/or SMPS, transformer, rectifier, motor brake control component (22), and does not require external use of these parts.

The control units that comprise the monoblock lift control unit (20) cannot operate independently and cannot be used in conjunction with other independent units for the purposes of lift control. The parts comprising the monoblock lift control unit (20), can only be used for the purposes of lift control when completely and correctly assembled.

All components forming the monoblock lift control unit (20) are predetermined and each unit is standard material used in each product. The parts cannot be changed. The installation places and methods are predetermined and cannot be changed. The parts are assembled following predetermined procedures. The obtained technical solutions are as follows:

The monoblock lift control unit (20) has been developed that fulfils all necessary functions for lift control in a single box shaped body (21 ). The components comprising the monoblock lift control unit (20) take up less space as they have been designed to be physically compatible and not take up space. Therefore, the area needed for the production, storage, transportation and installation of the product is decreased at all stages. As it has been designed to be lighter, the transportation costs are also lower. It is possible for one person to carry, install or disassemble.

The connections in the monoblock lift control unit (20) are pre-prepared cable groups with suitable types, sections, colours and lengths, with the necessary end connections and labelling preparations having been made. Therefore, the time required for the workmanship and the cost is reduced.

The connection cables are shorter, and the cabling cost is reduced due to the fact that the sizes are small and the fact that the components have been designed to conform with each other.

The error rate during connection is reduced and troubleshooting is made easier due to the fact that there is a reduced number of components, that there are less connections and the fact that pre-prepared cable groups are used.

Because the device is a monoblock product, it is examined by the authorised institution and its adherence to safety rules is documented with a type examination certificate. As there is no later conjoining or arrangement involved, there is no doubt as to the adherence of each product to the product safety norms.

Because the device is a monoblock product, it is subjected to electromagnetic conformity tests (EMC) as a whole by the testing authority, and this is documented. As there is no later conjoining or arrangement involved, there is no doubt as to the electromagnetic compatibility of each product.

As all components and production stages are predetermined according to the relevant standards and technical calculations, there is no need to employ experienced personnel with sufficient technical skills during production.

The testing of the monoblock unit as a whole, that is produced in the same types, is carried out automatically by a device; in the parts of the test that must be carried out manually, the personnel are directed by the test unit. This ensures a complete testing and prevents human errors to be overlooked.

As the monoblock lift control unit (20) is serially produced like a device, it can be kept in stock and the delivery of the product can be met without delay from the products in the inventory.

The monoblock lift control unit (20) is procured as a whole from a single manufacturer. If necessary, lift owners contact a single manufacturer. Therefore, they easily receive assistance from product installation, fixing problems is easier and the durations are shortened.

As there is not as much need for cables and as pre-prepared cable groups are used there is no need for cable conduits (1 1 ). Therefore, the cost of the product is lowered, the size is reduced, the cables are easily distinguished during troubleshooting and the passing of cables that negatively affect each other within the conduit has been prevented.

As the monoblock control unit (20) is produced in the same types, and as there are no special alterations made on a product basis, the electrical connection schemas of the products are identical. When connection schemas are no longer usable or when they are lost, the product’s connection schema is easily obtained from the manufacturer. As all the installation and cabling requirements of the product are pre-prepared, there is no need for multiple electrical and mechanical equipment during production (rivet nut machine, rail and cable cutting tool, collet tightening tool etc.).

As all external connections are made to a single unit there are no connections between different units. Therefore, the complexity of connection is negated.

All stages of material placement, cabling, testing and packaging of the monoblock lift control unit (20) take approximately 90 minutes. This constitutes an improvement by a factor of four on the 6-hour duration of the control panels of the same specifications that are produced in the state of the art.

The operation and installation of the monoblock lift control unit (20) can be summarised as follows:

The components comprising the monoblock lift control unit (20) are standard materials used in all products. All installation and connection preparations for assembly have been carried out. The mounting plate (2) in the form of sheet metal on which the unit and the materials are mounted are supplied ready for installation with the installation holes already drilled.

The motor driver unit (14), is placed and secured in the prepared area on the mounting plate (2).

The power source (7), transformer, rectifier and motor brake control components (22) are placed and secured in the prepared area on the mounting plate (2). The bundle of cables with some having pre-prepared electric terminals and some having open collets, are placed on the mounting plate (2). The trivets used to raise the materials on the mounting plate (2) are placed and secured in the prepared area on the mounting plate (2). DIN mounting rails are placed and secured on the trivets in the prepared area on the mounting plate (2). Electrical equipment (9), electrical connections (10) are placed on the DIN mounting rail.

The trivets used to raise the materials on the mounting plate (2) are placed and secured in the prepared area on the mounting plate (2). The control card unit (15) is secured onto the relevant metal trivets.

The manual control components (16) on the metal plate, the switches and buttons are secured onto the relevant metal trivets. The electrical connections (10) in the form of electrical terminals, connection cards, connector/sockets and grounding busses are secured on the metal trivets and partially on the mounting plate (2).

The open-ended cables from among the bundle of cables are connected to the relevant points and the ones with electrical terminals are attached to the relevant places. The surrounding plates (17) that comprise the edges of the body (21 ) of the device are placed and secured on the sides of the mounting plate (2).

The cover (18) of the body (21 ) of the device is secured to the surrounding plates (17) of the device. The opening and closing component (19) on the cover (18) enables the cover (18) to be opened and closed.

The product that has been assembled is conveyed to the testing band for testing and connected to the testing unit. The testing of the unit is mostly carried out automatically; in the parts of the test that must be carried out manually, the personnel are directed by the test unit. If an error is detected during testing, the relevant error is shown to the personnel on the test unit screen. The faulty product is taken onto the repairing band and the relevant error is fixed. The tested product is placed in its box and packed, and therefore, is in its final form. Due to the fact that the monoblock lift control unit (20) has a smaller volume and is lighter, it is easier to carry in all stages from production to its installation in the lift.

The invention relates to lift control panel cabinets (1 ) in the form of cabinets, containing the lift motor driver and additional card/materials (5), lift control card and additional card/materials (6), power sources (7), manual control switches/buttons (8), electrical equipment (9), electrical connections (10) in the form of electrical terminals, connection cards, connector/sockets and grounding busses, and cable conduits (1 1 ) that are mounted on the mounting plate (2), characterised by; comprising a body (21 ) that is used in place of a lift control panel cabinet (1 ), that forms a monoblock lift control unit (20) that is portable by hand, that can carry out the functions necessary for a lift with a smaller volume, that can be installed easily with lesser installation errors, that is produced as a unit without the need for independent lift motor driver additional card/materials (6) and a cabinet, that fulfils all lift control functions, that contains the motor driver unit (14), control card unit (15), electrical equipment (9) power sources (7) such as transformers and/or SMPS, and that operates without the need for these components to be used externally, that negates the used of cable conduits (1 1 ) due to the face that is uses much less cabling and pre-prepared cable groups, that contains all components within.

It comprises pre-prepared cable groups with suitable type, colour, sections and lengths with the necessary connection and labelling preparations having been made, having been designed so that the sizes are small and the pieces are compatible to reduce the time required for the workmanship and to reduce the cost of cabling due to the shortening of the connection cables. It comprises power sources (7), electrical equipment (9), electrical connections (10) in the form of electrical terminals, connection cards, connector/sockets and grounding busses within the monoblock body (21 ) that negates the complexity of connection as all external connections from external lift units are made to a single location.

There is a cover (18) that can be locked and unlocked on the box shaped body (21 ).

It comprises electrical connections (10) in the form of fuses and protective devices, switch components such as contactors, relays, breaker/switches and buttons, electrical equipment (9) in the form of electrical terminals, connection cards, connector/sockets and grounding busses where all lift connections are made to one location. The body (21 ) comprises a transformer, rectifier, motor brake control component (22) that have been designed as a whole.

It comprises a motor driver unit (14) that is placed in the prepared area on the mounting plate (2), a power source (7), a transformer, rectifier, motor brake control component (22) that have been placed in the prepared location, trivets used to raise the materials on the mounting plate (2), a control card unit (15) placed in the prepared area, manual control components (16) of switches and buttons installed on the relevant trivets on the secured metal plate, electrical equipment (9) in the form of electrical terminals, connection cards, connector/socket and grounding busses that are partially secured on the mounting plate (2) and secured on metal trivets, the surrounding plates (17) that form the sides of the body (21 ) of the device that is placed on the sides of the mounting plate (2), the cover (18) of the body (21 ) of the device that is attached to the surrounding plates (17) of the device, and the opening and closing component (19) on the cover (18).