The present invention relates to an elevator system and a method of manufacturing a main cable for the elevator system, wherein a vertically-movable member is supported by a main cable made of a synthetic fiber rope, the rope being produced by tying in a bundle a plurality of strands made of twisted synthetic resin fibers.

A cable made of a synthetic fiber rope, the rope being produced from synthetic resin fiber such as that described in, e.g., Japanese Patent Application Laid-Open No. 267534/1995, has hitherto been known as a cable for supporting a vertically-movable member of an elevator system. In such a synthetic fiber rope made of strands of synthetic resin fibers, vacant spaces occupied by no wires arise among cross-sectional profiles of strands arranged adjacent to each other when viewed in cross section. These spaces pose a problem in terms of a synthetic fiber rope possessing required strength.

If the number of points of intimate contact between cross-sectional profiles of adjacent strands increases, flexion resistance in the synthetic fiber rope wound around a sheave increases. For this reason, there arises a problem of the life of the synthetic fiber rope being shortened by a temperature rise stemming from an increase in flexion resistance.

In the present invention, a vertically-movable member of an elevator system is supported by means of a main cable. The main cable is constituted of a synthetic fiber rope having wires made of synthetic resin fiber provided therein with a high filling factor when viewed in cross section. By virtue of the construction, the cross-sectional strength of the main cable per unit area can be increased, and the number of main cables used for supporting the vertically-movable member can be reduced. Further, equipment related to support of a main cable, such as a sheave, can be made compact.

The present invention relates to a main cable which is constituted by means of forming a strand so as to assume a sector-shaped cross-sectional profile, and arranging a plurality of strands into a circular pattern such that surfaces of a sector aligned with the radii of the included arc remain in contact with those of adjacent sectors. By means of this construction, wires made of synthetic resin fiber are provided in a strand with a high filling factor when viewed in cross section, and the cross-sectional strength of the main cable per unit area can be increased. The number of main cables used for supporting the vertically-movable member can be reduced. Equipment related to support of a main cable, such as a sheave, can also be made compact.

The present invention relates to a main cable constituted by means of collectively twisting a plurality of strands. The load shared by respective wires constituting a strand becomes uniform, thereby preventing occurrence of a drop in elastic modulus and strength and prolonging the life of the strand.

The present invention relates to a main cable constituted, by means of forming a strand from an inner-layer sleeve-shaped strand which is to constitute the cross-sectional center of a main cable and surroundings thereof and from an outer-layer sleeve-shaped strand which is to be disposed fittingly outside the inner-layer sleeve-shaped strand, and by means of making the outer-layer sleeve-shaped strand thinner than the inner-layer sleeve-shaped strand.

By means of this construction, wires made of synthetic resin fiber are provided in a strand with a high filling factor when viewed in cross section, and the cross-sectional strength of the main cable per unit area can be increased. The number of main cables used for supporting the vertically-movable element can be reduced. Equipment related to support of a main cable, such as a sheave, can also be made compact. The outer-layer sleeve-shaped strand is formed so as to become thinner than the inner-layer sleeve-shaped strand. As a result, the surface bending stress of the sleeve-shaped strands in respective layers when wound around a sheave can be made uniform, thereby elongating the life of the synthetic fiber rope.

The present invention relates to a main cable which is constituted by means of twisting wires and molding the thus-twisted wires with fiber adhesive resin material, thereby forming a sleeve-shaped strand. As a result, the load shared by respective wires constituting a sleeve-shaped strand becomes uniform, thereby preventing occurrence of a drop in elastic modulus and strength and prolonging the life of the strand.

The present invention relates to a main cable which is constituted into the cross-sectional profile of a flat rectangle, by means of arranging a plurality of strands side by side, each strand having a square cross-sectional profile. As a result, the diameter of a sheave around which the main cable is wound can be made smaller than that of a sheave around which a main cable having a circular cross-sectional profile is wound. Equipment related to support of a main cable, such as a sheave, can also be made compact.

The present invention also relates to a main cable constituted of strands, each strand being formed from an inner-layer strand which is to constitute a center of a rectangular cross section of the main cable in the direction of a shorter side, as well as from an outer-layer strand provided on either side of the inner-layer strand so as to face a long side of the rectangular cross section of the main cable. By means of this construction, the surface bending stress of the strands in respective layers when wound around a sheave can be made uniform, thereby elongating the life of the synthetic fiber rope.

The present invention relates to manufacture of a main cable. A main cable is formed through a method including steps for supplying fiber adhesive resin material, which thereafter is compressed by pressure rollers and molded by a molding die to form wires, constituting a strand from the wires, constituting the main cable from the strand. As a result, fiber adhesive resin material is applied in sufficient amount to the wires 6. Subsequently, the wires are pressed flat by the rollers, thereby removing internal air and producing a strand. By means of this construction, wires are provided in a strand with a high filling factor when viewed in cross section, and the cross-sectional strength of the main cable per unit area can be increased. The number of main cables used for supporting the vertically-movable member can be reduced, and equipment related to support of a main cable, such as a sheave, can be made compact.

• Fig. 1 is an elevation view conceptually showing a first preferable elevator system according to the invention;
• Fig. 2 is an enlarged cross-sectional view of a main cable shown in Fig. 1;
• Fig. 3 is an enlarged cross-sectional view of the main cable employed in a second preferable elevator system according to the invention;
• Fig. 4 is an enlarged cross-sectional view of the main cable employed in a fourth preferable elevator system according to the invention; and
• Fig. 5 is a view illustrating a method of manufacturing a main cable of a preferable elevator system according to the invention, conceptually showing a manufacturing apparatus.

In order to describe a first embodiment of the invention in more detail, the embodiment is described in by reference to the accompanying drawings . Referring to Figs. 1 and 2, a drive sheave of a hoisting machine installed in an elevated position within a hoistway of an elevator system; and 2 designates a main cable. Although details of the main cable will be described in detail later, the main cable is made of a synthetic fiber rope wound around the drive sheave 1, supports at one end a first vertically-movable member 3 constituting of a car, and supports at the other end a second vertically-movable member 4 constituting a counterweight.

Reference numeral 5 designates an inner-layer strand made of a plurality of twisted wires 6 consisting of synthetic resin fiber. A plurality of inner-layer strands 5 are twisted in a circular pattern when viewed in cross section, thereby forming core material of a synthetic fiber rope constituting the main cable 2.

Reference numeral 7 designates a filler strand of a synthetic fiber rope which has been twisted along with the inner-layer strand 5. The filler strand 7 is made of a plurality of twisted wires 6 and is interposed between outer peripheries of the inner-layer strands 5 which constitute a circular outer periphery of the core material.

Reference numeral 8 designates inner-layer cladding material of a synthetic fiber rope. The inner-layer cladding material is made of low-friction synthetic resin material reinforced by addition of reinforced fiber and is provided so as to surround the inner-layer strands 5 and the filler strands 7 when viewed in cross section.

Reference numeral 9 designates an outer-layer strand of a synthetic fiber rope. The outer-layer strand is made of a plurality of twisted wires 6 and is formed from a fiber adhesive resin material into the shape of a sector when viewed in cross section. A plurality of outer-layer strands 9 are twisted and arranged into a circular pattern such that surfaces of a sector aligned with the radii of the included arc remain in contact with those of adjacent sectors, thus forming an outer-layer section of a synthetic fiber rope constituting the main cable 2.

Reference numeral 10 designates outer-layer cladding material. The outer-layer cladding material 10 is made of flexible synthetic resin reinforced by addition of reinforced fiber. The outer-layer cladding material 10 is provided so as to surround the outer-layer strands 9 when viewed in cross section.

In relation to the elevator system that has been constructed in the manner as mentioned above, the cross-sectional profile of the outer-layer strand 9 formed from a plurality of wires 6, the wire being made of synthetic resin fiber, is made in the form of a sector. In relation to the cross section of the main cable 2 made of a synthetic fiber rope, a plurality of outer-layer strands 9 are twisted and arranged in such a pattern as shown in Fig. 2 such that surfaces of a sector aligned with the radii of the included arc remain in contact with those of adjacent sectors.

The wires 6 are provided in the outer-layer strand 9 with a high filling factor when viewed in the cross section of the synthetic fiber rope. Further, the inner-layer cladding material 8 and the outer-layer cladding material 10 are reinforced by addition of reinforced fiber. As a result, the cross-sectional strength of the main cable 2 per unit area can be increased. Consequently, the diameter of the main cable 2 supporting the vertically-movable member 3 or a like can be reduced, and the number of main cables can also be reduced, thereby curtailing manufacturing costs. Further, equipment related to support of the main cable 2, such as a sheave, can be made compact, thereby curtailing manufacturing costs.

In the embodiment shown in Figs. 1 and 2, if the wires 6 provided in strands, such as the inner-layer strands 5 or other strands, are arranged in parallel with the longitudinal direction of the main cable 2 without involvement of a twist intended for reducing elastic elongation under load, the load shared by the respective wires 6 becomes uneven, thereby reducing the strength of the wires. As a countermeasure for a drop in strength, since a synthetic fiber rope is employed, a twist angle of about 10° is imparted to the synthetic fiber rope, thereby suppressing a drop in elastic modulus and strength of a wire and elongating the life of the same.

In order to describe a second embodiment of the present invention in more detail, the second embodiment is described by reference to the accompanying drawings. An elevator system is constructed so as to be identical with that described in connection with the embodiment shown in Figs. 1 and 2, except for an element shown in Fig. 3.

Referring to Fig. 3, reference numeral 11 designates a core material strand. The core material is formed by means of twisting a plurality of wires 6 made of synthetic resin fiber and forms a core material of a synthetic resin rope constituting the main cable 2.

Reference numeral 12 designates an inner-layer sleeve-shaped strand. The inner-layer sleeve-shaped strand is formed by means of twisting a plurality of wires 6 made of synthetic resin fiber. The inner-layer sleeve-shaped strand 12 is arranged so as to fit the outer periphery of the core material strand 11 when viewed in cross section.

Reference numeral 13 designates an outer-layer sleeve-shaped strand. The outer-layer sleeve-shaped strand is formed by means of twisting a plurality of wires 6 made of synthetic resin fiber. The inner-layer sleeve-shaped strand 12 is arranged so as to fit the outer periphery of the inner-layer sleeve-shaped strand 12 when viewed in cross section.

Reference numeral 14 designates a sleeve-shaped surface strand. The sleeve-shaped surface strand 14 is formed by means of twisting a plurality of wires 6 made of synthetic resin fiber and is arranged so as to fit around the outer periphery of the outer-layer sleeve-shaped strand 13 when viewed in cross section.

In the elevator system that has been constructed in the manner as mentioned above, the main cable 2 made of the synthetic fiber rope is constructed by means of stacking sleeve-shaped strands, such as the inner-layer sleeve-shaped strand 12, into a multilayer when viewed in cross section. Thus, the wires 6 are arranged with a high filling factor when viewed in cross section of the synthetic fiber rope. Even the embodiment shown in Fig. 3 yields the same working operation as that yielded in the embodiment shown in Figs. 1 and 2, although its detailed explanation is omitted.

In the embodiment shown in Fig. 3, the sleeve-shaped multilayered stands are not fixed to each other and are arranged slidable so as to cause relative displacement, so as to prevent occurrence of an increase in flexion resistance in the main cable 2 wound around the sheave.

Adjacent sleeve-shaped strands are manufactured from resin materials which greatly differ in fusing temperature. As a result, there can be prevented occurrence of an anomalous state attributable to a temperature rise due to flexion resistance of the main cable 2.

In relation to the sleeve-shaped strands, the sleeve of the outer-layer strand is formed so as to become thinner than that of the inner-layer strand. As a result, the surface bending stress of the sleeve-shaped strands in respective layers can be made uniform, thereby elongating the life of the synthetic fiber rope.

A third embodiment of the present invention is described as follows. When all the wires 6 constituting the inner-layer strands 5 or other strands are placed in parallel with the main cable 2 without involvement of a twist intended for diminishing the elastic elongation under the load of the main cable 2, the load shared by the respective wires 6 becomes uneven, thereby reducing the strength of the wires. As a countermeasure for a drop in strength, since a synthetic fiber rope is employed, a twist angle of about 10° is imparted to the synthetic fiber rope, thereby suppressing a drop in elastic modulus and strength of a wire and elongating life of the same.

In order to describe a fourth embodiment of the present invention in more detail, the fourth embodiment is described by reference to the accompanying drawings. An elevator system is constructed so as to be identical with that described in connection with the embodiment shown in Figs. 1 and 2, except for an element shown in Fig. 4.

Referring to Fig. 4, reference numeral 15 designates a main cable having a flat cross-sectional profile. The main cable is made of a synthetic fiber rope wound around the drive sheave 1 to be described in detail later. The main cable supports at one end the vertically-movable member 3 and at the other end the second vertically-movable member 4.

Reference numeral 16 designates a strand. A plurality of strands are arranged side by side within a cross section of the main cable 15, thereby constituting a rectangular cross section of the main cable 15. Reference numeral 17 designates an inner-layer strand. The inner-layer strand 17 is formed by means of twisting a plurality of wires 6 made of synthetic resin fiber. The inner-layer strands 17 constitutes a center section of each strand 16 in the direction of a short side of the rectangular cross section of the main cable 15.

Reference numeral 18 designates an outer-layer strand. The outer-layer strand 18 is formed by means of twisting a plurality of wires 6 made of synthetic resin fiber. The outer-layer strand 18 is disposed on either side of the inner-layer strand 17 and in line with a long side of the rectangular cross section of the main cable 15.

Reference numeral 19 designates outer-layer cladding material. The outer-layer cladding material 19 is formed from flexible synthetic resin material which has been reinforced by addition of reinforced fiber. The outer-layer cladding materials 19 surrounds the strands 16 disposed side by side when viewed in cross section, thereby constituting a surface of the main cable 15 in the direction of cross section.

In the elevator system having been constructed in the manner as mentioned above, when viewed in cross section, the main cable 2 made of a synthetic fiber rope is constructed such that strands, such as inner-layer strands 17, are stacked in layers within the strand 16. By virtue of this construction, the wires 6 are provided with a high filling factor when viewed in cross section of the synthetic fiber rope. Even the embodiment shown in Fig. 4 yields the same working operation as that yielded in the embodiment shown in Figs. 1 and 2, although its detailed explanation is omitted.

In the embodiment shown in Fig. 4, strands within the strands 16 are not fixed to each other and are arranged to be slidable so as to cause relative displacement, so that there can be prevented occurrence of an increase in flexion resistance in the main cable 2 wound around the sheave.

Adjacent strands within the strands 16 are manufactured from resin materials which greatly differ in fusing temperature. As a result, there can be prevented occurrence of an anomalous state attributable to a temperature rise due to flexion resistance of the main cable 2.

In relation to strands within the strands 16, the outer-layer strand 18 is formed so as to become thinner than the inner-layer strand 17. As a result, the surface bending stress of the strands can be made uniform, thereby elongating the life of the synthetic fiber rope.

Since the cross-sectional profile of the main cable 2 is formed into the shape of a flat rectangle, the diameter of a sheave around which the main cable 2 is wound can be made smaller than that of a sheave around which a main cable having a circular cross-sectional profile is wound. As a result, the life of the main cable 2 can be elongated, and equipment relevant to suspension of the main cable 2, such as a sheave, can be made compact, thereby curtailing manufacturing costs.

The number of strands 16 arranged side by side, the number of outer-layer strands 18 stacked in layers in each strand 16, and the size of each strand 16 in the longitudinal direction of the rectangular cross section of the main cable 15 of the strand 16 are set, as required. Thereby, the required strength of the main cable 2 and the required bend radius of the main cable 2 can be readily satisfied.

In order to describe in more detail an embodiment of a method of manufacturing a main cable of an elevator system according to the present invention, the embodiment will be described by reference to the accompanying drawings. Referring to Fig. 5, reference numeral 20 designates a heating/thermal-insulating device; and 21 designates feeders disposed on one side of the heating/thermal-insulating device 20. The feeders 21 supply fiber adhesive resin material or synthetic resin material for the outer-layer cladding material 10.

Reference numeral 22 designates a molding die disposed on the other side of the heating/thermal-insulating device 20 so as to oppose the feeders 21. Reference numeral 23 designates pressure rollers interposed between the feeders 21 provided in the heating/thermal-insulating device 20 and the molding die 22.

Reference numeral 24 designates a cooler disposed adjacent to the heating/thermal-insulating device 20. A chilled water feeder 25 is provided at a position in the cooler 24 opposing the molding die 22. Chilled water 26 is reserved in the cooler 24.

Reference numeral 27 designates strand core material to be supplied to the molding die 22; 28 designates wires corresponding to the previously-described wire 6. The wires 6 are supplied to the molding die 22 via the feeders 21 and the pressure rollers 23.

In the apparatus for manufacturing a main cable for an elevator system, which apparatus has been constructed in the manner as mentioned above, the strand core material 27 and the wires 6 are supplied to the molding die 22 via the feeders 21 for supplying fiber adhesive resin material and the pressure rollers 23.

As a result, fiber adhesive resin material is applied in sufficient amount to the strand core material 27 and the wires 6. Subsequently, the wires 6 are pressed flat by the rollers 23, thereby removing internal air. As a result, the wires 6 are provided in the inner-layer strand 17 with a high filling factor when viewed in cross section. Consequently, the inner-layer strand 17 manufactured by the apparatus for manufacturing a main cable for use in the elevator system shown in Fig. 5 yields the same working operation as that yielded in the embodiment shown in Figs. 1 and 2, although its detailed explanation is omitted.

As has been described, in relation to the elevator system according to the present invention, the main cable is constituted of a synthetic fiber rope having wires made of synthetic resin fiber provided therein with a high filling factor when viewed in cross section. Hence, the cross-sectional strength of the main cable per unit area can be increased, and the resultant main cable is useful as a cable to be wound around a drive sheave for supporting a vertically-movable member. Further, the present invention enables a reduction in the diameter of a main cable and the number of main cables to be used and is suitable for making equipment related to support of a main cable, such as a sheave, compact.

According to the present invention, a main cable is constituted by means of forming a strand so as to assume a sector-shaped cross-sectional profile, and arranging a plurality of strands into a circular pattern such that surfaces of a sector aligned with the radii of the included arc remain in contact with those of adjacent sectors, thus forming a synthetic fiber rope. By means of this construction, wires made of synthetic resin fiber are provided in a strand with a high filling factor when viewed in cross section, and the cross-sectional strength of the main cable per unit area can be increased. The resultant main cable is useful as a cable to be wound around a drive sheave for supporting a vertically-movable member. Further, the present invention enables a reduction in the diameter of a main cable and the number of main cables to be used and is suitable for making equipment related to support of a main cable, such as a sheave, compact.

The present invention relates to a main cable constituted by means of collectively twisting a plurality of strands. The load shared by respective wires constituting a strand becomes uniform, thereby preventing occurrence of a drop in elastic modulus and strength and prolonging the life of the strand. The resultant stand is useful for a main cable to be wound around a drive sheave for supporting a vertically-movable member.

According to the present invention, a strand is constituted of an inner-layer sleeve-shaped strand which is to constitute the cross-sectional center of a main cable and surroundings thereof, as well as of an outer-layer sleeve-shaped strand which is to be disposed fittingly outside the inner-layer sleeve-shaped strand. The outer-layer sleeve-shaped strand is made thinner than the inner-layer sleeve-shaped strand, thus constituting a main cable.

By means of this construction, wires made of synthetic resin fiber are provided in a strand with a high filling factor when viewed in cross section, and the cross-sectional strength of the main cable per unit area can be increased. The resultant main cable is useful as a cable to be wound around a drive sheave for supporting a vertically-movable member. Further, the present invention enables a reduction in the diameter of a main cable and the number of main cables to be used and is suitable for making equipment related to support of a main cable, such as a sheave, compact.

The outer-layer sleeve-shaped strand is formed so as to become thinner than the inner-layer sleeve-shaped strand. As a result, the surface bending stress of the sleeve-shaped strands in respective layers when wound around a sheave can be made uniform, thereby elongating the life of the synthetic fiber rope.

The present invention relates to a main cable which is constituted by means of twisting wires and molding the thus-twisted wires with fiber adhesive resin material thereby forming a sleeve-shaped strand. As a result, the load shared by respective wires constituting a sleeve-shaped strand becomes uniform, thereby preventing occurrence of a drop in elastic modulus and strength and prolonging the life of the strand. The resultant stand is useful for a main cable to be wound around a drive sheave for supporting a vertically-movable member.

The present invention relates to a main cable which is constituted into the cross-sectional profile of a flat rectangle, by means of arranging a plurality of strands side by side, each strand having a square cross-sectional profile. As a result, the diameter of a sheave around which the main cable is wound can be made smaller than that of a sheave around which a main cable having a circular cross-sectional profile is wound. The resultant main cable is useful as a cable to be wound around a drive sheave for supporting a vertically-movable member. Further, the present invention enables a reduction in the diameter of a main cable and the number of main cables to be used and is suitable for making equipment related to support of a main cable, such as a sheave, compact.

The present invention also relates to a main cable constituted of strands, each strand being formed from an inner-layer strand which is to constitute a center of a rectangular cross section of the main cable in the direction of a shorter side, as well as from an outer-layer strand provided on either side of the inner-layer strand so as to face a long side of the rectangular cross section of the main cable. By means of this construction, the surface bending stress of the sleeve-shaped strands in respective layers when wound around a sheave can be made uniform, thereby elongating the life of the synthetic fiber rope. The resultant main cable is useful as a cable to be wound around a drive sheave for supporting a vertically-movable member.

The present invention relates to manufacture of a main cable. A main cable is formed through a method including steps for supplying fiber adhesive resin material, which thereafter is compressed the wires by pressure rollers and molded by a molding die to form wires, constituting a strand from the wires, constituting the main cable from the strand. As a result, fiber adhesive resin material is sufficiently applied to the wires 6. Subsequently, the wires are pressed flat by the rollers, thereby removing internal air and producing a strand.

By means of this construction, wires are provided in a strand with a high filling factor when viewed in cross section, and the cross-sectional strength of the main cable per unit area can be increased. The resultant main cable is useful as a cable to be wound around a drive sheave for supporting a vertically-movable member. Further, the present invention enables a reduction in the diameter of a main cable and the number of main cables to be used and is suitable for making equipment related to support of a main cable, such as a sheave, compact.