DESCRIPTION Title of Invention: ELEVATOR CAR COMPONENT ASSEMBLY, CAR MANUFACTURING METHOD, AND ELEVATOR CAR
Technical Field
[0001] This invention relates to an elevator car component assembly, a car
manufacturing method and an elevator car, which are applied to the packaging and transportation of a car floor and a car ceiling, among members forming an elevator car.
Background Art
[0002] When a car floor unit and a car ceiling unit are packaged and
transported integrally, it is necessary to prevent damage to design surfaces of the car floor unit and car ceiling unit. In a conventional shipping mode, therefore, a wooden material is placed on top of the car floor unit in order to form a space above the car floor unit, the car ceiling unit is stacked on top of the car floor unit, and the resulting unit is loaded into a transportation container. In another well-known technique, a wooden stopper is provided in a horizontal direction in the transportation container to suppress horizontal direction movement of the stacked car floor unit and car ceiling unit inside the transportation container.
Summary of Invention Technical Problem
[0003] In this conventional shipping mode, however, the wooden material
is interposed between the car floor unit and the car ceiling unit, leading to an increase in the height of the packaged car floor unit and car ceiling unit and a corresponding increase in volume ratio when the packaged car floor unit and car ceiling unit are loaded into the transportation container. As a result, transportation costs increase.
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[0004] This invention has been designed to solve the problem described
above, and an object thereof is to obtain an elevator car component assembly, a car manufacturing method, and an elevator car with which a reduction in volume can be achieved when packaging a car floor unit and a car ceiling unit, thereby suppressing an increase in transportation costs.
Solution to Problem
[0005] An elevator car component assembly according to this invention
includes: a car floor unit that includes a car floor and a pair of side face mounting portions on which a pair of side face walls provided so as to oppose each other in a width direction of a car are respectively mounted, the side face mounting portions being provided to project in a height direction of the car from respective end portions of a car floor design surface of the car floor; and a car ceiling unit that includes an upper frame disposed at a distance from the car floor in the height direction of the car, and a ceiling provided on the upper frame such that a ceiling design surface opposes the car floor design surface, and fastened to the pair of side face walls, wherein, in a horizontal direction, a distance between the pair of side face mounting portions is set to be longer than a distance between respective end portions of the ceiling and shorter than a distance between respective end portions of the upper frame, a length of the pair of side face mounting portions is set to be greater than a length of the ceiling in a vertical direction, and when the car ceiling unit is stacked on top of the car floor unit for shipping, a lower surface of the upper frame contacts respective upper surfaces of the pair of side face mounting portions, the mutually opposing car floor design surface and ceiling design surface are disposed at a remove from each other, and the ceiling is housed in a nested condition between the pair of side face mounting portions.
[0006] Further, a car manufacturing method according to this invention
includes the steps of: transporting an elevator car component assembly fastened

by a connecting member into a hoistway in a condition where a car ceiling unit is stacked on top of a car floor unit, the car floor unit including a car floor and a pair of side face mounting portions on which a pair of side face walls provided so as to oppose each other in a width direction of a car are respectively mounted, the side face mounting portions being provided to project in a height direction of the car from respective end portions of a car floor design surface of the car floor, and the car ceiling unit including an upper frame disposed at a distance from the car floor in the height direction of the car, and a ceiling provided on the upper frame such that a ceiling design surface opposes the car floor design surface, and fastened to the pair of side face walls, and in a condition where a lower surface of the upper frame contacts respective upper surfaces of the pair of side face mounting portions, the mutually opposing car floor design surface and ceiling design surface are disposed at a remove from each other, and the ceiling is housed in a nested condition between the pair of side face mounting portions; causing the connecting member of the transported elevator car component assembly to project from a lower end portion of the car floor unit; adjusting the car floor unit horizontally using a horizontal adjustment jack mounted on a lower end portion of the connecting member projecting from the lower end portion of the car floor unit; lifting the car ceiling unit away from the horizontally adjusted car floor unit; and mounting columns between the lifted car ceiling unit and the car floor unit.
[0007] Furthermore, an elevator car according to this invention includes: a
car floor unit that includes a car floor and a pair of side face mounting portions on which a pair of side face walls provided so as to oppose each other in a width direction of a car are respectively mounted, the side face mounting portions being provided to project in a height direction of the car from respective end portions of a car floor design surface of the car floor; a car ceiling unit that includes an upper frame disposed at a distance from the car floor in the height direction of the car, and a ceiling provided on the upper frame such that a ceiling
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design surface opposes the car floor design surface, and fastened to the pair of side face walls; and a plurality of columns for connecting the car floor unit and the car ceiling unit together in the height direction of the car, wherein, in a horizontal direction, a distance between the pair of side face mounting portions is set to be longer than a distance between respective end portions of the ceiling and shorter than a distance between respective end portions of the upper frame, and a length of the pair of side face mounting portions is set to be greater than a length of the ceiling in a vertical direction.
Advantageous Effects of Invention
[0008] According to this invention, the ceiling can be housed in a nested
condition between the pair of side face mounting portions provided on the car floor, and the car floor design surface and ceiling design surface can be housed so as to oppose each other and at a distance from each other. As a result, it is possible to obtain an elevator car component assembly, a car manufacturing method, and an elevator car with which a reduction in volume can be achieved when packaging a car floor unit and a car ceiling unit, thereby suppressing an increase in transportation costs.
Brief Description of Drawings
[0009] Fig. 1 is a perspective view showing a structure of a car frame on
which a car ceiling unit and a car floor unit according to a first embodiment of this invention are mounted.
Fig. 2 is a perspective view showing the car floor unit of Fig. 1.
Fig. 3 is a perspective view showing the car ceiling unit of Fig. 1.
Fig. 4 is a perspective view showing a shipping mode of the car floor unit and the car ceiling unit according to this invention.
Fig. 5 is a front view showing a part of the shipping mode of the car floor unit and the car ceiling unit in Fig. 4 from the direction of an arrow V.
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Fig. 6 is a pattern diagram showing an operation for rotating a connecting member 180° using a fastening between the car floor unit and a first side of the connecting member as a central axis.
Description of Embodiments
[0010] First Embodiment
Fig. 1 is a perspective view showing a structure of a car frame on which a car ceiling unit and a car floor unit according to a first embodiment of this invention are mounted. Note that in the first embodiment, a direction of an arrow A in Fig. 1 denotes a width direction of a car, a direction of an arrow B in Fig. 1 denotes a depth direction of the car, and a direction of an arrow C in Fig. 1 denotes a height direction of the car.
[0011] As shown in Fig. 1, a pair of guide rails 1 are disposed in a
hoistway such that a distance is maintained therebetween. The pair of guide rails 1 are disposed to extend in the height direction of the car, or in other words a vertical direction. Further, the pair of guide rails 1 oppose each other in the width direction of the car.
[0012] A car frame 2 for forming the car is provided between the pair of
guide rails 1. The car frame 2 includes a car lower beam 3 provided horizontally between the pair of guide rails 1, a car floor unit 4 supported by the car lower beam 3, a plurality of columns 5 erected on the car floor unit 4 so as to extend in the height direction of the car, and a car ceiling unit 6 provided to extend over upper end portions of all of the columns 5.
[0013] Further, side walls, not shown in the drawing, are mounted on side
faces of the car, excluding a car doorway 7 side. A pair of side walls forming
respective side faces of the car and a side wall forming a back face of the car
when the car is seen in the depth direction of the car from the car doorway 7 will
be referred to hereafter as side face walls and a back face wall, respectively.
[0014] The car lower beam 3 is disposed to extend in the width direction
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of the car. A plurality of safety devices 30 are provided on the car lower beam
3.
[0015] The safety devices 30 are provided on respective end portions of
the car lower beam 3 in the width direction of the car. In other words, in Fig. 2,
two safety devices 30 are provided.
[0016] The respective safety devices 30 perform an operation to grip the
guide rails 1 when a control device determines that a movement speed of the car
through the hoistway, which is detected by a speed governor, exceeds a preset
speed. As a result of the gripping operation performed by the safety devices 30,
the car is stopped and held against the guide rails 1. Note that neither the speed
governor nor the control device is shown in the drawing.
[0017] Fig. 2 is a perspective view showing the car floor unit 4 of Fig. 1.
Note that Fig. 2 is obtained by rotating Fig. 1 such that an arrow A in Fig. 2
corresponds to the arrow A in Fig. 1 and an arrow B in Fig. 2 corresponds to the
arrow B in Fig. 1. As shown in Figs. 1 and 2, the car floor unit 4 includes a
pair of floor frame side beams 40 fixed onto the car lower beam 3, a car floor 41
disposed between the pair of floor frame side beams 40, and a plurality of wall
mounting plates 42 provided on the car floor 41.
[0018] The pair of floor frame side beams 40 are respectively disposed to
extend in the depth direction of the car. Each of the pair of floor frame side
beams 40 is provided with a lower portion guiding device 43 that includes a
guide shoe, and a plurality of column mounting portions 44 to which the
columns 5 are fixed. Note that the lower portion guiding devices 43 are not
shown in Fig. 2.
[0019] Each of the lower portion guiding devices 43 is fitted over a
projecting portion of the corresponding guide rail 1 so as to be capable of sliding
along the guide rail 1. Mounting positions in which the pair of floor frame side
beams 40 are mounted on the guide rails 1 with respect to the depth direction of
the car are determined by fitting the lower portion guiding devices 43 over the

projecting portions of the guide rails 1.
[0020] The column mounting portions 44 are provided on respective end
portions of each of the pair of floor frame side beams 40 in the depth direction of the car. In other words, in the first embodiment, two column mounting portions 44 are provided on each of the pair of floor frame side beams 40 such that a total of four column mounting portions 44 are provided. Each column mounting portion 44 includes a plate portion 44a having a substantially rectangular cross-section and an L-shaped plate portion 44b having a substantially L-shaped cross-section, the plate portion 44a and the L-shaped plate portion 44b being provided respectively on an upper portion and a lower portion of the column mounting portion 44 in the height direction of the car. The columns 5 are fixed along the L-shaped plate portions 44b of the respective column mounting portions 44 so as to extend vertically relative to the floor frame side beams 40 of the car floor unit 4 and side beams 600 of the car ceiling unit 6, to be described below.
[0021] The car floor 41 is mounted between the pair of floor frame side
beams 40. As a result, the car floor 41 is disposed horizontally such that the respective lower portion guiding devices 43 are fitted over the guide rails 1. A step 41b for mounting a threshold is provided on a part of the car floor 41 positioned in a lower portion of the car doorway 7.
[0022] The wall mounting plates 42 include a pair of side face mounting
portions 420 on which the pair of side face walls are mounted, and a back face mounting portion 421 on which the back face wall is mounted. The pair of side face mounting portions 420 are respectively mounted on the car floor 41 so as to project in the height direction of the car from a car floor design surface 41a of the car floor 41. Further, the side face mounting portions 420 are disposed to oppose each other in the width direction of the car. Furthermore, the side face mounting portions 420 are disposed so as to extend in the depth direction of the car.

[0023] The back face mounting portion 421 is mounted on respective car
depth direction end portions of the pair of floor frame side beams 40 and part of the car floor 41 where the step 41b is not provided. Further, the back face mounting portion 421 is disposed so as to extend in the width direction of the car. As a result, the wall mounting plates 42 are provided on all faces excluding the car doorway 7.
[0024] At this time, an upper end portion of the back face mounting
portion 421 is disposed, with respect to the height direction of the car, in either an identical position to respective upper end portions of the side face mounting portions 420 or a position that is closer to the car floor design surface 41a than the respective upper end portions of the side face mounting portions 420. In the first embodiment, the upper end portion of the back face mounting portion 421 is disposed in an identical position to the respective upper end portions of the side face mounting portions 420.
[0025] Respective lower end portions of the columns 5 are mounted on the
column mounting portions 44. In Fig. 1, the columns 5 are constituted by a pair of front columns 5a disposed in positions close to the car doorway 7, and a pair of rear columns 5b that are further removed from the car doorway 7 than the front columns 5a in the depth direction of the car.
[0026] Fig. 3 is a perspective view showing the car ceiling unit 6 of Fig. 1.
Note that Fig. 3 is obtained by rotating Fig. 1 such that an arrow A in Fig. 3 corresponds to the arrow A in Fig. 1 and an arrow B in Fig. 3 corresponds to the arrow B in Fig. 1. As shown in Figs. 1 and 3, the car ceiling unit 6 includes an upper frame 60 provided on the respective upper end portions of the columns 5, and a ceiling 61 provided on the upper frame 60.
[0027] The upper frame 60 includes the side beams 600 for connecting
respective end portions of the front columns 5a and rear columns 5b in the depth direction of the car, and a front beam 601, a rear beam 602, and an intermediate beam 603 for connecting the side beams 600 in the width direction of the car.
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[0028] The side beams 600 are fixed to the columns 5 so as to be parallel
to the floor frame side beams 40. Further, the side beams 600 have a substantially U-shaped cross-section, and are fixed to the columns 5 such that respective open portions thereof oppose each other.
[0029] An upper portion guiding device 62 that includes a guide shoe is
provided on each side beam 600. The upper portion guiding devices 62 are
configured similarly to the lower portion guiding devices 43, being fitted over
the projecting portions of the respective guide rails 1 so as to be capable of
sliding along the guide rails 1. In other words, positions in which the
respective side beams 600 are mounted on the guide rails 1 with respect to the
depth direction of the car are determined by fitting the upper portion guiding
devices 62 over the projecting portions of the guide rails 1.
[0030] The upper portion guiding devices 62 are disposed on the side
beams 600 such that virtual straight lines connecting the lower portion guiding devices 43 to the upper portion guiding devices 62 are parallel to the columns 5. Hence, when the lower portion guiding devices 43 and the upper portion guiding devices 62 are fitted over the guide rails 1, the columns 5 are disposed parallel to the guide rails 1, and the floor frame side beams 40 and side beams 600 are disposed perpendicular to the guide rails 1.
[0031] The guide rails 1 are disposed to extend in the vertical direction.
Therefore, when the lower portion guiding devices 43 and the upper portion guiding devices 62 are fitted thereto, a lengthwise direction of each of the columns 5 corresponds to the vertical direction, while respective lengthwise directions of the floor frame side beams 40 and the side beams 600 are horizontal.
[0032] The front beam 601 connects the end portions of the side beams
600 that are fixed to the upper end portions of the respective front columns 5a. In Fig. 1, the front beam 601 is a plate having a substantially L-shaped cross-section. A length of the front beam 601 in the height direction of the car

is set to be shorter than a length of the side beam 600. Further, a horizontal surface of the front beam 601, i.e. the surface of the L-shaped portion that extends in the horizontal direction, is mounted on the side beams 600 so as to be positioned higher than respective lower horizontal surfaces of the side beams 600.
[0033] The rear beam 602 connects the end portions of the side beams 600
that are fixed to the upper end portions of the respective rear columns 5b. The rear beam 602 is a member partially having a substantially L-shaped cross section, wherein one of the plates forming the L shape is disposed to extend in the vertical direction, or in other words the height direction of the car, and the other plate is disposed to extend in the horizontal direction. A horizontal surface of the rear beam 602, i.e. the surface of the L-shaped portion that extends in the horizontal direction, is mounted on the side beams 600 so as to be coplanar with the respective lower horizontal surfaces of the side beams 600 in the height direction of the car.
[0034] The intermediate beam 603 connects approximately intermediate
locations of the side beams 600. More specifically, the intermediate beam 603
is disposed in the width direction of the car on a straight line connecting the
respective upper portion guiding devices 62. In Fig. 3, the intermediate beam
603 is a member having a substantially U-shaped cross-section, and is fixed to
the side beams 600 such that an open portion thereof is oriented upward.
[0035] The ceiling 61 is disposed between the pair of side beams 600.
Further, the ceiling 61 includes a ceiling main body 610, and a ceiling mounting portion 611 surrounding the periphery of the ceiling main body 610. In Fig. 1, when the ceiling 61 is seen from the height direction of the car, the ceiling main body 610 takes the form of a rectangular plate, and forms a single plate ceiling in which a lower face and an upper face thereof in the height direction of the car serve respectively as a ceiling design surface 610a and a lid surface. Note that the ceiling design surface 610a is shown in Fig. 5, to be described below.
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[0036] The ceiling mounting portion 611 is provided to project upward in
the height direction of the car from the periphery of the ceiling main body 610. Further, the ceiling mounting portion 611 includes a vertical surface portion 611a that projects in the height direction of the car from a peripheral edge portion of the ceiling main body 610, and a horizontal surface portion 611b that projects away from the ceiling main body 610 in the horizontal direction from an upper end portion of the vertical surface portion 611a.
[0037] Accordingly, the ceiling mounting portion 611 has a substantially
L-shaped cross-section. Note that the vertical surface portion 611a and the horizontal surface portion 611b are shown in Fig. 4, to be described below. Further, in the first embodiment, the ceiling main body 610 and the ceiling mounting portion 611 are formed from a single cross-shaped plate, the ceiling mounting portion 611 being formed by bending the peripheral edge portion of the part that is to become the ceiling main body 610.
[0038] The vertical surface portion 611a, excluding the vertical surface
portion 611a on the car doorway 7 side, forms a fastening portion that is
fastened to the upper end portions of the pair of side face walls and the upper
end portion of the back face wall. At this time, the vertical .surface portion
611a is fastened to the respective design surface sides of the pair of side face
walls and the back face wall. Further, the vertical surface portion 611a on the
car doorway 7 side forms a fastening portion that is fastened to a door stop post,
a door pocket post, a modesty panel, or the like, not shown in the drawings.
[0039] The horizontal surface portion 611b is fixed after being placed on
the horizontal surface of the L-shaped portion of the rear beam 602 and the horizontal surfaces of the side beams 600 that are oriented downward in the height direction of the car. The ceiling 61 is thus mounted on the upper frame 60.
[0040] Here, in the width direction of the car, or in other words the
horizontal direction, a distance (a distance D in Fig. 3) between respective end
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portions of the ceiling 61 is set to be shorter than a distance (a distance E in Fig,
2) between the side face mounting portions 420 of the car floor 41. In other
words, the distance D and the distance E have a relationship of distance D <
distance E. Note that the distance E is preferably set at a length obtained by
adding twice the car width direction length of the side face wall to the distance
D.
[0041] Further, in the width direction of the car, or in other words the
horizontal direction, a distance (a distance F in Fig. 3) between respective end
portions of the upper frame 60 is set to be longer than the distance (the distance
E in Fig. 2) between the side face mounting portions 420 of the car floor 41. In
other words, the distance E and the distance F have a relationship of distance E
< distance F.
[0042] Furthermore, in the height direction of the car, or in other words the
vertical direction, a length (a length G in Fig. 3) of the vertical surface portion
611a of the ceiling mounting portion 611 is set to be shorter than a length (a
length H in Fig. 2) of the side face mounting portion 420 of the car floor 41. In
other words, the length G and the length H have a relationship of length G <
length H.
[0043] Next, a shipping mode of the car floor unit 4 and the car ceiling
unit 6, or in other words an elevator car component assembly, will be described.
Fig. 4 is a perspective view showing a shipping mode of the car floor unit 4 and
the car ceiling unit 6 according to this invention. Further, Fig. 5 is a front view
showing a part of the shipping mode of the car floor unit 4 and the car ceiling
unit 6 in Fig. 4 from the direction of an arrow V.
[0044] As shown in Figs. 4 and 5, in the elevator car component assembly,
the car ceiling unit 6 is stacked directly on top of the car floor unit 4 such that
the car floor design surface 41a of the car floor unit 4 and the ceihng design
surface 610a of the car ceiling unit 6 oppose each other.
[0045] Here, the distance D between the respective ends portions of the
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ceiling 61 is set to be shorter than the distance E between the side face mounting
portions 420, and therefore the ceiling 61 is housed in a space surrounded by the
side face mounting portions 420 and the back face mounting portion 421.
[0046] Further, the distance F between the upper frame 60 is set to be
longer than the distance E between the side face mounting portions 420, and therefore the lower surfaces of the side beams 600 in the height direction of the car respectively contact upper surfaces of the side face mounting portions 420. In other words, the upper frame 60 is placed on respective upper end portions of the side face mounting portions 420 and the back face mounting portion 421. At this time, the length G of the ceiling mounting portion 611 is set to be shorter than the length H of the side face mounting portion 420, and therefore the mutually opposing ceiling design surface 610a and car floor design surface 41a are removed from each other.
[0047] In other words, the ceiling 61 of the ceiling unit 6 nests in the part
of the car floor unit 4 that is surrounded by the side face mounting portions 420
and the back face mounting portion 421. Therefore, even when the car floor
unit 4 and the car ceiling unit 6 are stacked directly, damage to the ceiling design
surface 610a and the car floor design surface 41a can be prevented.
[0048] Further, a plurality of connecting members 8 are provided to
maintain the car floor unit 4 and the car ceiling unit 6 in a stacked condition. Each connecting member 8 takes the form of a plate having a substantially L-shaped cross-section. A plurality of mounting holes 80 (three in Fig. 4) are provided in a first side 8a of the L shape of the connecting member 8 that is fastened to the car floor unit 4 and the car ceiling unit 6 so as to extend in a lengthwise direction of the connecting member 8.
[0049] The mounting holes 80 are provided in positions corresponding
respectively to mounting holes (component mounting holes) provided in the car floor unit 4 and the car ceiling unit 6 for the columns 5. Note that at least two mounting holes 80 are preferably provided, namely one in a position
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corresponding to a column 5 mounting hole provided in the side beam 600 and one in a position corresponding to a column 5 mounting hole provided in the floor frame side beam 40. Here, the column mounting portion 44 is provided in the position of the column 5 mounting hole provided in the floor frame side beam 40.
[0050] Each connecting member 8 can fasten the car floor unit 4 to the car
ceiling unit 6 by tightening bolts passed respectively through the column 5 mounting hole provided in the side beam 600, the column 5 mounting hole provided in the floor frame side beam 40, and the mounting hole 80 from the connecting member 8 side.
[0051] In the first embodiment, the connecting members 8 are provided in
positions corresponding to the mounting positions of all of the columns 5, and therefore four connecting members 8 are provided. By employing the connecting members 8 to fasten the car floor unit 4 and the car ceiling unit 6 to each other in a stacked condition using the mounting holes for the columns 5 in this manner, an integrated shipping mode can be realized.
[0052] Here, as shown in Fig. 4, a length of the connecting member 8 in
the height direction of the car is set to be shorter than a length between the separated end portions of the car floor unit 4 and the car ceiling unit 6 in the shipping mode.
[0053] Note that the number of connecting members 8 is not limited to
four, and as long as the car floor unit 4 and the car ceiling unit 6 can be
maintained in the stacked condition, one to three, or five or more, connecting
members 8 may be used. Further, the component mounting holes are used as
the mounting holes for the columns 5, but any holes capable of connecting the
car floor unit 4 and the car ceiling unit 6 in the height direction of the car, such
as mounting holes for the guiding devices 43, 62, for example, may be used.
[0054] Further, a horizontal adjustment jack portion 9 for ensuring that the
car floor unit 4 is horizontal when assembling the car is mounted on a second
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side 8b of the L shape of each connecting member 8.
[0055] The horizontal adjustment jack portion 9 includes a tubular portion
90 provided on the second side 8b of the connecting member 8 so as to extend in the lengthwise direction of the connecting member 8, and a bolt portion 91 that can be inserted into and withdrawn from the tubular portion 90. In the first embodiment, as shown in Fig. 5, the tubular portion 90 is provided on a ceiling unit 6 side end portion of the second side 8b of the connecting member 8 when the car floor unit 4 and the car ceiling unit 6 are fastened by the connecting member 8. Further, although not shown in the drawing, a bolt hole is provided in the interior of the tubular portion 90.
[0056] The bolt portion 91 includes a jack main body (not shown) that can
be inserted into and withdrawn from the tubular portion 90 by being rotating relative to the bolt hole in the tubular portion 90, and a bolt head portion 91a. The bolt portion 91 can adjust a distance between the bolt head portion 91a and the tubular portion 90 by adjusting a condition in which the jack main body is inserted into the tubular portion 90.
[0057] In Fig. 5, the bolt head portion 91a is positioned so as not to project
from the ceiling unit 6 side end portion of the second side 8b of the connecting member 8 when the car floor unit 4 and the car ceiling unit 6 are fastened by the connecting member 8.
[0058] Next, a car manufacturing method for assembling the car floor unit
4 and the car ceiling unit 6 in the shipping mode within a hoistway so as to form a car will be described. First, the car floor unit 4 and the car ceiling unit 6 in the integrated shipping mode are transported into the hoistway. Car forming members other than the car floor unit 4 and the car ceiling unit 6 are also transported at this time.
[0059] Next, after loosening the fastening between the car ceiling unit 6
and the first side 8a of each connecting member 8, the car floor unit 4 is lifted using a lifting tool or the like. At this time, the car ceiling unit 6 remains
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stacked on top of the car floor unit 4.
[0060] After lifting the car floor unit 4, each connecting member 8 is
rotated 180° using a fastening portion between the car floor unit 4 and the first side 8a of the connecting member 8 as a central axis. Fig. 6 is a pattern diagram showing an operation for rotating the connecting member 8 180° using the fastening portion between the car floor unit 4 and the first side 8a of the connecting member 8 as a central axis.
[0061] The connecting member 8 is rotated in a direction indicated by an
arrow K in Fig. 6. The reason for this is that when the car floor unit 4 and the car ceiling unit 6 are fastened by the connecting member 8, a car ceiling unit 6 side end portion of the L-shaped plate portion 44b contacts an end portion of the first side 8a of the connecting member 8 that is removed from the car ceiling unit 6.
[0062] When the connecting member 8 is rotated 180°, the horizontal
adjustment jack portion 9 shifts from being oriented upward to being oriented downward. In this condition, the car floor unit 4 and the car ceiling unit 6 are placed on either a hoistway pit surface or a floor beam temporary placement frame, not shown in the drawing, that is placed temporarily on the hoistway pit surface. In this condition, the position of the bolt portion 91 is adjusted so that the car floor unit 4 is horizontal. In other words, the bolt portion 91 is capable of extending from and retreating into a lower end portion of the connecting member 8 in the vertical direction.
[0063] Next, the car is installed in the hoistway by lifting the car ceiling
unit 6 and mounting car forming members such as the columns 5, the side face walls, and the back face wall between the car floor unit 4 and the car ceiling unit 6. As a result, manufacture of the car is completed.
[0064] In the elevator car component assembly according to the first
embodiment, as described above, the car floor unit and the car ceiling unit are configured such that when the car ceiling unit is stacked directly on top of the
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car floor unit, the car floor design surface and the ceiling design surface oppose each other.
[0065] At this time, in the horizontal direction, the distance between the
pair of side face mounting portions that are provided on the car floor in order to
mount the side face walls of the car thereto is set to be longer than the distance
between the respective end portions of the ceiling. Further, in the horizontal
direction, the distance between the upper frame of the car ceiling unit is set to be
longer than the distance between the pair of side face mounting portions.
Furthermore, the length of the pair of side face mounting portions is set to be
greater than the length of the ceiling in the vertical direction.
[0066] By providing this configuration, the ceiling nests between the pair
of side face mounting portions, and a gap is provided between the mutually opposing car floor design surface and ceiling design surface. As a result, the car floor unit and the car ceiling unit can be stacked directly and integrated without interposing a wooden material between the car floor unit and the car ceiling unit.
[0067] Further, since the car ceiling unit can be stacked directly on top of
the car floor unit, an increase in the height of the packaged car floor unit and car
ceiling unit can be suppressed. As a result, the volume of the stacked and
packaged car floor unit and car ceiling unit can be reduced.
[0068] In a conventional car floor unit and car ceiling unit, it is necessary
to form a wooden stopper in accordance with the size of a transportation
container to prevent the stacked car floor unit and car ceiling unit from moving
horizontally. Hence, the cost of the stopper leads to a cost increase, and the
weight of the stopper leads to an increase in transportation cost.
[0069] Therefore, in the elevator car component assembly according to the
first embodiment, the car floor unit and the car ceiling unit are maintained in a stacked condition by the connecting members. Hence, when the car floor unit and the car ceiling unit are stacked, the connecting members prevent the car
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ceiling unit from moving relative to the car floor unit. Accordingly, the need to
provide a wooden stopper formed in accordance with the size of the
transportation container in the container can be eliminated, and as a result, a cost
increase caused by providing the stopper can be suppressed.
[0070] Furthermore, the size of the connecting member is set such that the
connecting member does not project in the vertical direction from the respective end portions of the stacked car floor unit and car ceiling unit that are furthest removed from each other, and therefore the connecting member is lighter than a wooden stopper formed in accordance with the size of the transportation container. As a result, an increase in transportation cost due to the weight of the packaging material can be suppressed.
[0071] Moreover, mounting holes are provided in the connecting member
in positions corresponding to existing mounting holes provided in the car floor unit and the car ceiling unit for other components when the car ceiling unit is stacked on top of the car floor unit. Hence, there is no need to provide separate connecting member mounting holes in the car floor unit and the car ceiling unit, and as a result, an increase in the manufacturing cost of the car floor unit and the car ceiling unit can also be suppressed.
[0072] Furthermore, the horizontal adjustment jack portion is provided on
the connecting member so that the car floor unit can be adjusted horizontally when transported into the hoistway. As a result, labor expended by an operator to cany a horizontal adjustment jig to the installation site and prepare the horizontal adjustment jig can be eliminated.
[0073] Note that in the first embodiment described above, the horizontal
adjustment jack portion 9 is configured to include the tubular portion 90 and the bolt portion 91. However, the horizontal adjustment jack portion 9 is not limited to this configuration, and any member capable of adjusting the distance below the lower end portion of the connecting member 8 when the connecting member 8 is rotated 180° using the fastening portion between the car floor unit 4
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and the first side 8a of the connecting member 8 as a central axis may be employed.
[0074] Further, in the first embodiment described above, the horizontal
adjustment jack portion 9 is provided on the ceiling unit 6 side end portion of the second side 8b of the connecting member 8 when the car floor unit 4 and the car ceiling unit 6 are fastened by the connecting member 8. However, the horizontal adjustment jack portion 9 is not limited to this mounting position, and may be mounted detachably in any desired position of the connecting member 8. To adjust the car floor unit 4 horizontally at this time, the horizontal adjustment jack portion 9 is temporarily detached from the connecting member 8, and then mounted on the lower end portion of the connecting member 8 again once the connecting member 8 has been rotated 180°.
[0075] Furthermore, the horizontal adjustment jack portion 9 may be
provided on the car floor unit 4 side end portion of the second side 8b of the connecting member 8 when the car floor unit 4 and the car ceiling unit 6 are fastened by the connecting member 8. To adjust the car floor unit 4 horizontally at this time, the connecting member 8 is temporarily detached from the car floor unit 4 and the car ceiling unit 6, and then mounted on the car floor unit 4 again so that the horizontal adjustment jack portion 9 is positioned on the lower end portion thereof.
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CLAIMS [Claim 1] An elevator car component assembly comprising:
a car floor unit that includes a car floor and a pair of side face mounting portions on which a pair of side face walls provided so as to oppose each other in a width direction of a car are respectively mounted, the side face mounting portions being provided to project in a height direction of the car from respective end portions of a car floor design surface of the car floor; and
a car ceiling unit that includes an upper frame disposed at a distance from the car floor in the height direction of the car, and a ceiling provided on the upper frame such that a ceiling design surface opposes the car floor design surface, and fastened to the pair of side face walls,
wherein, in a horizontal direction, a distance between the pair of side face mounting portions is set to be longer than a distance between respective end portions of the ceiling and shorter than a distance between respective end portions of the upper frame,
a length of the pair of side face mounting portions is set to be greater than a length of the ceiling in a vertical direction, and
when the car ceiling unit is stacked on top of the car floor unit for shipping, a lower surface of the upper frame contacts respective upper surfaces of the pair of side face mounting portions, the mutually opposing car floor design surface and ceiling design surface are disposed at a remove from each other, and the ceiling is housed in a nested condition between the pair of side face mounting portions.
[Claim 2] The elevator car component assembly according to claim 1, further comprising a connecting member which, when the car floor unit and the car ceiling unit are housed in the nested condition for shipping, fastens an end portion of the car floor unit in the width direction and an end portion of the car ceiling unit in the width direction together in the height direction,
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wherein mounting holes are provided in the connecting member in positions corresponding to component mounting holes provided respectively in the end portion of the car floor unit in the width direction and the end portion of the car ceiling unit in the width direction, and
the component mounting holes are appropriated to fasten the car floor unit and the car ceiling unit together.
[Claim 3] The elevator car component assembly according to claim 2, further comprising a horizontal adjustment jack portion that is provided on the connecting member, includes a jack main body capable of extending from and retreating into one end portion of the connecting member in the vertical direction, and is capable of adjusting the car floor unit horizontally when the car floor unit and the car ceiling unit are transported into a hoistway.
[Claim 4] The elevator car component assembly according to claim 3, wherein the horizontal adjustment jack portion is provided on an end portion of the connecting member on the car ceiling unit side when the car ceiling unit is stacked on top of the car floor unit, and
when the connecting member is rotated using a fastening portion between the connecting member and the car floor unit as a central axis in a condition where a fastening portion between the car ceiling unit and the connecting member has been released and the fastening portion between the car floor unit and the connecting member has been loosened, the horizontal adjustment jack portion moves below the car floor unit.
[Claim 5] The elevator car component assembly according to claim 3, wherein the horizontal adjustment jack portion is provided detachably in a desired position of the connecting member, and
the horizontal adjustment jack portion is mounted on a lower end portion
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of the connecting member when the connecting member is mounted on the car floor unit such that the lower end portion of the connecting member projects downward from the car floor unit.
[Claim 6] A car manufacturing method employing the elevator car component assembly according to claim 3, comprising the steps of:
forming the elevator car component assembly for shipping, by stacking the car ceiling unit on top of the car floor unit so that a lower surface of the upper frame contacts respective upper surfaces of the pair of side face mounting portions and the mutually opposing car floor design surface and ceiling design surface are disposed at a remove from each other, thereby realizing the nested condition, and then fastening an end portion of the car floor unit in the width direction and an end portion of the car ceiling unit in the width direction together in the height direction using the connecting member;
transporting the formed elevator car component assembly into the hoistway;
detaching the connecting member of the transported elevator car component assembly from the end portion of the car ceiling unit in the width direction and re-fastening the connecting member so that a lower end portion of the connecting member projects downward from a lower end portion of the car floor unit;
adjusting the car floor unit horizontally using the horizontal adjustment jack mounted on the lower end portion of the connecting member projecting from the lower end portion of the car floor unit;
lifting the car ceiling unit away from the horizontally adjusted car floor unit; and
mounting columns between the lifted car ceiling unit and the car floor unit.
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[Claim 7] An elevator car comprising:
a car floor unit that includes a car floor and a pair of side face mounting portions on which a pair of side face walls provided so as to oppose each other in a width direction of a car are respectively mounted, the side face mounting portions being provided to project in a height direction of the car from respective end portions of a car floor design surface of the car floor;
a car ceiling unit that includes an upper frame disposed at a distance from the car floor in the height direction of the car, and a ceiling provided on the upper frame such that a ceiling design surface opposes the car floor design surface, and fastened to the pair of side face walls; and
a plurality of columns for connecting the car floor unit and the car ceiling unit together in the height direction of the car,
wherein, in a horizontal direction, a distance between the pair of side face mounting portions is set to be longer than a distance between respective end portions of the ceiling and shorter than a distance between respective end portions of the upper frame, and
a length of the pair of side face mounting portions is set to be greater than a length of the ceiling in a vertical direction.