A leading elevator OEM has enjoyed market-leading success with their low
rise elevator line as well as with their line of elevators for high-rise buildings.
However, customers began calling for a flexible elevator solution to meet
the needs of the growing global mid-rise, mixed-use building market. The
definition of a mid-rise building can differ significantly depending on local
and surrounding buildings. For example, a mid-rise building in Madison,
Wisconsin might be 4-11 floors, while a mid-rise structure in Chicago could
have 40-50 floors.
The construction boom of mid-rise buildings can be attributed to several
factors. Developers are more apt to build “short” because it requires less
capital and the time to get permits approved is reduced considerably,
especially in developing countries.
In response to the growing demand, the elevator OEM began developing
a new elevator design that was adaptable for a variety of mid-rise buildings
including apartments, hotels, offices and shopping centers. To ensure global
acceptance, the new flexible elevator was designed to meet building codes
around the world.
Due to their reputation as a market leader in elevator braking systems,
Warner Electric was asked to design an innovative braking solution for the
new elevator. Warner engineers worked closely with the OEM’s engineering
team as the elevator design evolved.
UNIQUE ENGINEERED BRAKING SOLUTION
The challenging gearless motor elevator application
required dynamic torque <160% of normal static torque, noise <54 dBA and very high energy, up to 57kJ. The braking system had three functions: ascending car overspeed protection, unintended car movement protection and maintaining car position in parking mode.
Warner Electric engineers developed a solution that
had low wear but high energy, noise dampening with
low torque impact combined with torque stability and
precision. To meet the criteria, two modified ERS VAR15
electrically-released brakes with fixed magnets and a
floating friction disc were designed. The highly modular,
compact units allowed the configured system to fit within
the customers tight footprint. Units are microswitch
equipped, EC 95/16 certified and provide EN81-1
The brakes were subjected to a full array of lengthy
testing including energy, life cycle, climatic, aging and
destruction tests. Pre-packaged brake assemblies are
delivered to the customer with ready-to-mount paired
magnets and burnished discs.
COMMITMENT TO QUALITY MANUFACTURING
Warner Electric has recently invested in new,
state-of-the-art manufacturing technology while
optimizing their elevator brake manufacturing workflow
for improved quality and efficiency.
Manufacturing upgrades include a new production
line divided into two new work cells. The primary work
cell allows for semi-automatized assembly utilizing
conveyors. Components and brakes are traceable via bar
codes. Visio software is used for component presence
and profile detection. A slaved system has also been
incorporated for screwdrivers, di-electrical tests,etc.
A new, multi-station robotized cell is also incorporated
into the production process to provide friction disc
burnishing, static torque adjustment, electrical
adjustment, dynamic torque measuring, and component
crimping to secure the adjustment. All production
parameters are stored in a custom software program
developed exclusively for Warner Electric. The program
provides traceability for future analysis and continuous
The new production enhancements to the Warner
Electric plant in Angers, France will allow Warner to more
effectively meet the anticipated demand for the new
elevator brake from Europe, Asia Pacific, and