Abstract:
The method of the present invention can be used to monitor and predict the condition of an automatic door of an elevator or more generally an automatic door in a building. In the method, the acceleration or velocity of the door is measured and a dynamic model of the door is created. Using the model, estimated values of acceleration or velocity of the door can be calculated as a function of unknown parameters. One of the unknown parameters is the frictional force acting on the door during movement. By utilizing the estimated acceleration or velocity as well as measured acceleration or velocity values, an error function is obtained, whose minimum value is found using an optimizer. The unknown parameters corresponding to the minimum value indicate the current condition of the door. On the basis of earlier measurement results, it is additionally possible to predict a point of time when a failure is likely to occur in the operation of the door. In addition to unknown force parameters, it is possible, using a genetic algorithm, to determine the operational condition of a door closing device as well.
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Notices, Deadlines & Correspondence
ELEVATOR DOOR MONITORING ARRANGEMENT
FIELD OF. THE INVENTION
The present invention relates to fault management of a
computer-controlled door either in an elevator system or in
another system containing the components in question.
BACKGROUND OF THE INVENTION
A mechanical system in normal operational condition
comprises a certain amount of frictional force due to
friction that resists movement. If the magnitudes of the
frictional forces in the system can be determined by
measuring or mathematically, this information can be
utilized as an indicator of the operational condition of
the system.
An elevator system contains numerous components that are
exposed to chafing and wear. The motion of the elevator car
causes wear of components, including e.g. the elevator
ropes and the guide rails of the elevator car. One of such
components is the elevator door, which moves automatically
on a horizontal rail. It is acted on by forces applied to
it from different directions, and both its upper and lower
edges are in contact with rails keeping the door movement
on its track. There is also a frictional force opposing the
motion of the automatic door. The operation of the door may
be disturbed when a sufficient amount of dirt is
accumulated on the door rail on the threshold of the
elevator car. Due to this physical obstruction, the force
opposing the motion of the door may grow to a magnitude
such that finally the door control system is no longer able
to open or close the door.
The magnitude of the frictional force can not be measured
directly. It is not possible to mount a separate "friction
meter" on the door. The magnitude of the friction resisting
the movement of the door has to be measured indirectly. It
is possible to create a model of the system to be examined,
in this case the elevator door, to study the forces applied
to the door. One of the forces appearing in the model is
the frictional force opposing the motion. Using the model,
it is possible to calculate desired parameters when the
magnitudes of the forces opening and closing the door are
known and the acceleration or velocity of the door is
measured. In this way, unknown parameters, such as
frictional force, can be solved. Thus, the matter at hand
is a problem of optimization and estimation of parameters.
For example, in an elevator system the door assembly
consists of a car door moving with the car and the landing
doors on different floors. A modern automatic elevator door
is opened and closed by means of a direct-current motor.
The torque produced by the direct-current motor is directly
proportional to the motor current. The energy of the motor
is transmitted to the door e.g. via a toothed belt and the
door moves on rollers. For reasons of safety, the landing
door alone is closed without a motor by means of a closing
device. The closing force of the closing device may be
produced by a closing weight or a helical spring. The motor
current and the corresponding torque are measured either
from the door control card or directly from a motor current
conductor. It is also possible to monitor a so-called tacho
pulse signal of the motor. The tacho signal is a square
wave whose frequency depends on the motor speed and
therefore the door speed.
The problem with prior-art solutions is that the frictional
force acting on the elevator door can not be measured
directly. This necessitates the use of an indirect method
of estimating the magnitude of the frictional force. The
magnitude of the frictional force is needed for an
estimation of the time to failure of the door or for
predicting a future time by which the operational condition
of the door will decline to a level consistent with a given
criterion.
OBJECT OF THE INVENTION
The object of the present invention is to detect the operational
condition of an electric automatic door used in an elevator system or
in some other system, by continuously monitoring the magnitude of the
frictional force opposing the motion of the door.
BRIEF DESCRIPTION OF THE INVENTION
The method and system of the invention are disclosed in detail,
hereinafter:
Inventive embodiments are also presented in the description part of
the present application. The inventive content disclosed in the
application can also be defined in other ways than is done in the
claims below. The inventive content may also consist of several
separate inventions, especially if the invention is considered in the
light of explicit or implicit sub-tasks or in respect of advantages or
sets of advantages achieved. In this case, some of the attributes
contained in the claims below may be superfluous from the point of
view of separate inventive concepts. Within the framework of the
basic concept of the invention, features of different embodiments of
the invention can be applied in conjunction with other embodiments.
The method of the invention can be used for real-time examination of
the condition of an automatic door of an elevator or more generally
an automatic door in a building. In more precise terms, an automatic
door is a horizontally sliding door which is controlled by a motor
and whose closing movement may be assisted by a closing device. The
door is acted on by various forces, of which we are now
particularly interested in the magnitude of the frictional
force applied to the door. From the frictional force, it is
possible to deduce an acute maintenance need and in less
serious cases information regarding the frictional force
can be used at best to anticipate a future time at which
disturbances will most probably begin to appear in the
operation of the door. The operational condition of the
closing device of the door can be determined immediately.
In an embodiment of the method of the present invention,
the velocity of the automatic door is measured. This can be
accomplished by using the so-called tacho signal obtained
from the door motor. The tacho signal is a square wave in
which the space between pulses depends on the speed of the
motor and therefore on the door speed. The door speed can
be calculated from the tacho signal. An essential part of
the method is a dynamic model of the door. Some of the
parameters in the model are updated after each pure door
sequence. Pure door sequence means door opening and closing
operations wherein no re-openings occur during the closing
movement. The model includes the door and the closing
device and the forces applied to these parts, including the
frictional force. Using the model as an aid, the
acceleration of the door is estimated, and from this the
door speed as a function of time. The measured and the
estimated instantaneous speeds are compared to each other
and an error term is obtained. At each instant of time, the
error term is a function of three variables (mass of the
door, frictional force applied to the door, and force
resulting from inclination of the door) . Next, the sum of
the squares of the error terms is calculated, wherein each
square of an error term is weighted by a desired weighting
coefficient. For the so-called squared error term obtained
as a result, a minimum value is found, in which situation
the three model parameters being searched for are best in
keeping with reality. From the magnitude of the frictional
force thus obtained, the present state of the operational
condition of the door can be deduced.
In another embodiment of the method of the present
invention, the acceleration of the door is measured using
an acceleration sensor placed on the door. The method works
as above except that in this case the quantity estimated in
the dynamic model is acceleration. In the calculation of
the error term, the instantaneous acceleration estimated
from the model is subtracted from the instantaneous
measured acceleration. In this embodiment, too, the error
term is a function of the aforesaid three variables and the
further processing for determining these parameters
proceeds as in the example described above.
The input parameters needed for the dynamic model of the
door are door velocity, current of the motor driving the
door, torque coefficient of the motor, motor friction and
mass of door closing weight or force factor of closing
spring.
The calculation can be simplified by defining the mass of
the door as a constant among the variables. In this case,
the mass of the door is determined in connection with the
start-up or commissioning of the system by taking the mean
value from a desired number of door operations. The length
of the "teaching period" to be examined may be e.g. about
twenty door operations. Once the mass has been determined
as a mean value of the results of the teaching period, the
mass of the door is then set as a constant. After this, a
function of only two variables (the frictional force of the
door and the force caused by tilting of the door) is
processed in the optimization logic, so the processing
requires less calculation capacity and time than above. The
mass of the door can be defined as a constant because it
can be assumed that it will not change significantly in
normal operating conditions.
For immediate detection of a failure of the door closing
device, it is possible to use a genetic algorithm (GA). Via
the GA, both a correct door system model (with or without
closing device) and unknown forces relating to door
friction and tilt can be determined simultaneously. The
parameters of the dynamic model of the door are coded into
a chromosome of the genetic algorithm. In this connection,
unknown parameters relating to the operation of the closing
device, to the frictional force applied to the door and to
the force caused by the angle of tilt of the door are
genes, in other words, they together constitute a
chromosome. The chromosome quality function is a squared
error function, which can be regarded as an indicator of
the performance of the solution or phenotype represented by
the chromosome. With different gene values or alleles,
correspondingly different phenotypes are obtained, of which
the GA optimizer finally chooses, as a result of a search,
a phenotype giving the minimum value. The gene values
corresponding to this phenctype indicate the condition of
the door system at the instant of examination.
One of the advantages of the method according to the
present invention is that the information relating the
operation of the door can be saved. In this way, a data
base covering the operating history of the door is created,
on the basis of which it is possible to plan e.g. a
suitable date ior the next maintenance. From the operating
history, the present state of operation of the door can be
deduced directly, and even the probability of failure and
the need for maintenance at a future point of time can be
predicted.
LIST OF FIGURES
Fig. 1 presents a dynamic model of an automatic door
according to the present invention,
Fig. 2 represents a method according to the present
invention for determining the unknown parameters of the
model,
Fig. 3 represents another method according to the present
invention for determining the unknown parameters of the
model, and
Fig. 4 represents a third method according to the present
invention for determining the unknown parameters of the
model.
BRIEF DESCRIPTION OF THE INVENTION
To determine the frictional force acting on the door, a
dynamic model of the automatic door is created, wherein the
forces applied to the door are observed. The dynamic model
of the door is presented in Fig. 1. The basic law used here
is Newton's second law, whereby the force applied to an
object is obtained as the product of the mass and
acceleration of the object. Another basic law relating to
friction gives the magnitude of the frictional force
opposing the motion of an object as the product of the
coefficient of friction and the force (for an object
sliding on an even surface, the force of gravity) pressing
the object against the surface being examined. For the sake
of clarity, in the dynamic model all moving masses are
assumed to be concentrated on an individual mass point mdoor
10. Correspondingly, all frictional forces present in the
system, except for the friction of the motor, can be
combined into a single concentrated frictional force term
Fµ,door- A model of the dynamic operation of the door system
can be created using five different forces acting on it:
force of the motor, force caused by the closing weight or
spring, force caused by the angle of tilt of the door,
internal frictional force of the motor, and frictional
force caused by the door itself. The total mass of the
system consists of the concentrated mass of the door 10 and
the mass of a possible closing weight 11. All the moving
masses comprised in the door mechanics are concentrated in
the door mass 11. Fig. 1 shows the mass points and forces
in the system as well as the positive directions of
velocity and acceleration.
From the dynamic model and Newton's second law, an
expression for instantaneous acceleration adoor(t) of the
door 10 is obtained:
where Fmotor = B1 ■ 1motor(t) and Fcd(xd(t)) = mcd.g when the closing
device is a weight and Fcd(xd(t)) = kcd . (xd0 + xd(t)) when the
closing device is a spring. B1 is the motor torque
coefficient, Tmotor is the motor current, Fmotor is the force
caused by the motor, Ftilt is the horizontal component of
the force caused by the tilt of the door, FCd is the force
caused by the closing device, FµMotor is the internal
frictional force of the motor, FµDoor is the concentrated
frictional force acting on the door and caused by all the
sub-components, mdoor is the common concentrated mass
consisting of all the door masses and mcd is the mass of the
counterweight. If the closing device is a spring, then mcd =
0. As a closing weight is more commonly used as a closing
device, hereinafter we shall only deal with a closing
weight. However, this does not restrict the device of the
invention exclusively to a closing weight, but the closing
device may be a mechanism that gets its closing force from
a spring or some other arrangement.
When samples of the quantities to be measured on the door
are taken by means of the apparatus of the invention to
determine the friction, this means a transition from the
continuous-time world to discrete representation. In this
case, (1) is changed to the form
where instant t has been replaced by a sample taken at this
instant with the running number k.
Of the parameters of the dynamic model of the door, the
mass of the closing weight, the torque coefficient of the
motor and the internal frictional couple of the motor have
to be known beforehand. The mass of the closing weight can
be easily determined by weighing. The motor torque
coefficient and the internal frictional couple of the motor
can be determined by means of a dynamometer. Using a
dynamometer, the motor torque can be measured as a function
of motor current. The results obtained with different
current values form an approximately straight line T, the
equation for which is:
where T is motor torque. By linear regression, the unknown
quantities B1 and TµMotor can be determined as the slope of
the regression line and its point of intersection with the
y-axis.
From the motor torque, the force acting on the door can be
obtained by taking into account the power transmission
mechanisms of the door system. In an example, the motor
shaft carries a belt pulley of radius r, and a toothed belt
running around the pulley moves the door leaves. In this
case, the force moving the door leaves is easily obtained
as Fmot0r = T/r.
On the other hand, from the model it is possible to
determine the unknown parameters, which in this connection
are door mass, frictional force caused by tilt and
frictional force acting on the door. Of these, the last
mentioned parameter is the object of interest in a
preferred embodiment of the present invention.
A method according to the present invention for determining
unknown parameters is presented in Fig. 2. The motion of
the elevator door 20 is controlled by a control logic 26,
from which a command to open or close the door is received.
The door is driven by a direct-current motor, which is
connected to a door control card. From this card, the motor
current and a so-called tacho signal can be measured
directly. The tacho signal is obtained from the motor's
tacho generator, which detects the mechanical speed of
rotation of the motor. In this embodiment, the tacho signal
is typically a signal having the shape of a square wave.
The frequency and pulse spacing of the square wave are
directly proportional to the speed of the door motor and
the velocity of the door. Between two successive pulses,
the door always moves through the same sub-distance dx.
The signals received from the control card and the commands
given by the control logic are passed to a functional block
21 which takes care of collection and pre-processing, of
information. In this block, the door motion data is
filtered to remove from it those door opening operations
during which the door has to be re-opened in the midst of
the closing movement because of an obstacle, typically a
passenger in the path of the door. During the period dt
between to tacho pulses, the door moves through a constant
sub-distance dx. In block 21, it is now possible to
calculate the velocity vd of the door at each instant k of
time:
The pre-processing block also calculates weighting
coefficients for later calculation of an error term. By-
using weighting coefficients, desired error terms can be
weighted more than others. In the pre-processing block 21,
all the information relating to door opening and closing
operations is combined for further processing.
The next step in the method is processing of the dynamic
model 22 of the door. The model was described above and
illustrated in Fig. 1. As stated above, the input
parameters fed into the model are motor torque coefficient,
frictional couple of the motor, mass of door closing
weight, motor current, period of time dt and velocity vd of
the door. In the model, the acceleration of the door is
estimated as a function of four variables as follows.
where ΣFk(.) is the sum of the forces acting on the door at
instant k. From the estimated acceleration of the door, the
velocity of the door can be estimated as follows:
where vd,0 is the velocity of the door at instant t=0.
In the next step, the estimated velocity of the door and
the door velocity calculated in the pre-processing block
are passed into a differential block 23. The estimated
instantaneous velocity is subtracted from the measured
instantaneous velocity, producing an error term ek as a
result. The error term ek is a function of the three
variables md, Fµ and Ftilt. By applying weighting
coefficients Wi, a so-called squared error term E can now
be calculated in block 24:
In the next step in the block diagram of the method of the
present invention, the squared error term E is transferred
to an optimizer 25. The function of the optimizer is to
minimize the function (7) of the three variables. When the
minimum value is found, the variable parameters
corresponding to this have been estimated for the mass of
the door, the frictional force opposing the motion of the
door and the force caused by the tilt of the door.
In the examples illustrated in Fig. 2-4 and in the model in
Fig. 1, it is possible to define one or more of the force
parameters in the model as constants if it is desired to
simplify the model and the calculation under certain
assumptions.
Fig. 3 presents another example of the method of the
invention for detecting a failure of an automatic door. The
operation in this example is very close to the method
presented in Fig. 2. The control logic 36 of the elevator
system issues an opening or closing command to the door. In
the case of elevators in which no motor tacho signal is
available, the motion of the elevator door must be observed
by other methods. One method is to mount on a door leaf 30
an acceleration sensor to monitor the acceleration of the
door. The measured acceleration ad is passed to a block 31
for collection and pre-processing of information. As in the
above-described block 21, the door motion data is filtered
to remove from it those door opening operations during
which the door has to be re-opened in the midst of the
closing movement because of an obstacle in the path of the
door. After this, the velocity vd of the door is calculated
in block 31 from the following basic formula:
where Vd,0 is the initial velocity of the door at instant
t=0. In other respects, the pre-processing block 31 works
like the pre-processing block 21 in Fig. 2. The signals
between block 31 and the dynamic model 32 of the door are
consistent with the method of Fig. 2 with the difference
that the error term E is calculated from acceleration
values instead of velocities.
In the model 32, an estimated door acceleration is
calculated from equation (5). This information is fed
directly into a differential block 33, where the measured
acceleration, which in this case is obtained from the
sensor, and the estimated acceleration obtained from the
model are subtracted from each other. This produces an
error term e, which is a three-variable function of the
same type as in the example in Fig. 2. The error is squared
with desired weightings in block 34 in the way described
above. Correspondingly, optimizer 35 works in the same way
as optimizer 25. As a result, the same three unknown
parameters are obtained as above.
In an embodiment of the model, the three unknown parameters
of the model are determined once in conjunction with the
start-up of the system. To ensure the accuracy of the
parameters, several door operations are needed for each
floor. A suitable estimate for the number of door
operations is at least ten. When the system is subsequently
in its operating condition, the previously defined model of
the system is in use and this makes it possible to compare
the existing model to recently collected new information
about the motion of the door. After the comparison it is
possible to conclude e.g. whether the frictional force Fµ
has changed significantly. A clearly increased friction
between the door and the door rail is quickly detected from
the error terms ek, i.e. from the residuals of the model.
The residuals of the model can be e.g. analyzed
statistically. It is possible to evaluate e.g. the mean
value, variance, distortions of distribution, and number of
peaks. The error term can also be analyzed in respect of
frequency range. By these methods of analysis, it is
possible to determine characteristics typical of different
failure situations. For example, an increase of the
friction opposing the motion of the door will appear as a
deviation of the mean value of the residuals from zero. For
an analysis of failure type from the statistical quantities
or the frequency range signal it is naturally required that
failure types can be clearly distinguished from each other
and from an error-free operating condition by examining the
amplitudes and frequencies of the spectrum components. This
may be difficult.
In another embodiment of the model, an analysis of the
operational condition of the door can preferably be
performed each time the door is closed or opened. The
method in this case is one of continuous detection. The
processing and analysis of the collected information have
to be carried out within the period of time between two
door operations. In the case of an elevator, this
processing period should be of the order of max. 15
seconds, which is the time needed by the elevator in a
driving cycle between two successive floors. Of course it
is not absolutely necessary to include every door operation
in the analysis. Therefore, it does not matter if the
analysis of one door operation should take more time than
about 15 seconds as stated above. In this case the
efficiency of fault diagnosis is naturally impaired. Even
if not every door operation is included in the analysis, it
is still important to count the number of all floor-
specific door operations. This is an essential item of
information when in the event of a failure the average
useful life of the door is to be determined.
The analysis performed by the optimizer can be simplified
by assuming the door mass to be constant. Anyway, the door
mass has to be defined in connection with the start-up of
the system. In practice, the model is given a constant door
mass value which is determined e.g. as an average of the
mass values obtained from the first 20 door operations at
each floor. After this "teaching period", the function of
the optimizer is to find values for two unknown parameters,
the friction opposing the motion of the door and the force
caused by the tilt of the door. The amount of computing
work is now reduced and the search for parameters becomes
easier. After the teaching period, the method in this
example of the present invention works like the method
presented in Fig. 3, with the difference that ma is now a
fixed constant parameter and that both ek and E are
functions of two parameters.
A typical door failure situation is for example a fault
occurring in the bearing of a roller guiding the door,
preventing smooth sliding of the door on the roller. In
such a situation, the frictional force Fµ of the door
mechanism increases either abruptly or slowly with time,
depending on the nature of the failure. One possibility is
to determine from this information the need and time for
maintenance.
Anothex possible type of fault is a failure of the door
closing device. Such a fault may arise e.g. when the
closing weight has been removed in connection with
maintenance and the serviceman has forgotten to mount it
again. A failure may be due to the wire cable of the
closing weight being broken. Such a fault appears as a
sudden and large increase in the force Ftilt caused by the
tilt of the door. It can be inferred that such a large tilt
of the door is not due to a real tilt but to a
disappearance of the closing force. In this connection
there arises a need to automate the process of inferring
the operational condition of the closing device by a
suitable method. Genetic algorithms can be utilized for
this purpose. Using these algorithms, it is possible to
determine both the right door model (in which a closing
device is either included or not) and the unknown forces
FµDoor and Ftilt. While searching for the forces of friction
and tilt, the genetic optimizer simultaneously finds the
system model that produces the smallest force of tilt.
Genetic algorithms are based on the principle of creating
an artificial evolution by using the computing logic of a
processor. The question at issue is how to obtain as
advantageous a final result ("phenotype") as possible by
varying the properties of a "population". In the process of
variation, the genetic operations used are "selection",
"hybridization" and "mutation". The strongest members of
the population "make it", and the properties of these ones
are passed on to the next generations. In an example of the
method of the present invention, the population is a number
of model parameter vectors. In this connection, one
parameter vector corresponds to one chromosome. Each
chromosome has genes. Each gene in this connection
corresponds to one of the model parameters to be estimated,
which now are operation of the closing device, frictional
force of the door, and force of tilt of the door. These
three genes together can be called a phenotype. The
operation of the genetic algorithm is such that first a
population is created with gene values selected at random.
For each chromosome in the population, an "efficiency" or a
quality value is calculated, which in this example is the
above-described squared error term computed from the
dynamic model of the door. In the genetic algorithm, the
search proceeds generation by generation. From each
generation, the most efficient chromosomes, i.e. the ones
that give the lowest squared error term value, are selected
and included in the next generation. From the best
alternatives after this selection, the next generation is
created via hybridization and mutation. As a result of the
genetic operations, a new kind of population is obtained in
which the genotype of the chromosomes differs from the
earlier population either completely or only in some of the
genes. For the new generation, an efficiency, i.e. squared
error terms are calculated, and a chromosome having the
best efficiency is again obtained as a result. After this,
the sequence of numbers of the squared error terms is
checked to see if it converges and if a sufficient number
of generations have been processed to guarantee
convergence. As a final result, the genes of the best
individual in the last generation reveal the magnitudes of
the unknown forces and the operational condition of the
closing device.
The operation of the above-described genetic algorithm can
be combined with both of diagrams 2 and 3. Diagram 4
represents the operating principle by way of example when
the genetic algorithm is combined with diagram 2. In the
automatic door 40, the current of the door motor and the
tacho pulse signal of the motor are measured. In the pre-
processing block 41, the door velocity is calculated, and
the result is passed to the differential block 43 and to
the model 42 of the door. In this example the door mass is
assumed to be constant. In the model, the door velocity is
estimated and likewise passed to the differential block 43.
A squared error term calculator 44 and a so-called GA
optimizer 45 form a loop, whose operation was described
above in connection with the description of the genetic
algorithm. The information about the genes is transferred
from the GA optimizer 45 to the error calculator 44 and
correspondingly the efficiency value, i.e. the squared
error term E is passed from the error calculator 44 to the
GA optimizer 45. As a final result of the search, the
optimizer gives parameters CD, FµDoor and Ftilt. CD means the
operational condition of the closing device, where e.g. the
value one may represent error-free operation of the closing
device and zero a failure of the closing device. These
three parameters are returned back to the model, so the
model takes the performance of the closing device
immediately into account. Thus, in addition to the force
parameters, the model that best describes the system is
found immediately. The door opening and closing commands
come from the door control system 46. The dynamic model of
the door is now
where the term CD is one when the closing device is in
operation, and CD is zero when the closing device does not
work. In order that the genetic algorithm should be able to
find the system model that produces the smallest tilt
angle, the force of tilt Ftilt is also included in the error
function
where K is a scaling coefficient, G is the sequential
number of the generation in the genetic algorithm and G1 is
a limit value for generation G after which the force of
tilt is no longer included in the error function (10). The
result of this arrangement is that in the early stage of
the search, when G