Door System Evolution

Keep it simple and reliable.

Most of the components of an elevator system, including door systems, have evolved over the decades to improve both cost and reliability. Door systems continue to be one of the highest proportions of total installed cost: material, labor for installation and service trouble calls. More attention is deserved.

History

In elevators’ early days, the opening and closing of doors was done with an arm, i.e., the bone/flesh/muscle and connective tissue of a human attendant moving a collapsible gate. While a few of these types of elevators are still in operation in North America, the design has evolved away from mechanical metal arms, linkages, motors/belts, etc. 

Hall door closers range from simple to complicated springs, arms, spirators and weighted closers, which have stood the test of time (gravity hasn’t failed). Material and engineering designs have evolved door panels to a “pan style” that will continue to meet UL fire test requirements.

Today

Many technological advances were made to simplify previous electromechanical elevator motion control systems: high-torque gearless permanent magnet (PM) motors, low cost/high performance VF drives, closed loop encoders and position devices, etc. These same technologies were scaled down to provide reliable high-performance door operation; closed-loop motor control replaces open-loop cams and resistors; and compact direct-drive motors with cogged drive belts replace multiple arms, bearings and linkage. Manufacturing improvements make it easy to install/replace/adjust designs.

Keep it Simple: Use Designs That Reduce Parts 

Reliability: “The only part that will never fail is the one you design out of the system.”

Costs that are eliminated:

• No part to manufacture/purchase nor provide spare parts inventory
• No installation during construction nor replacement when it fails or “wears out”   
• No time needed to maintain nor troubleshoot on a service call   
• Multiple examples that “keep it simple” and reliable:
• Linear direct drive operators mount easily and attach directly to hangers, eliminating the need for several bearings, arms and attachment points to the door panel. (Figure 1)
• Control board accessible with no proprietary tool to carry. Menus for setup/adjustment/troubleshooting that are intuitive, which means there is no need for a manual that people don’t read anyway.

• Unhanded parts: keep parts symmetrical, left- and right-hand parts can be unhanded with extra holes/bends.
• Gearless VF direct drive motors: no need for a gearcase. (Figure 2)
• Combine the “clutch,” car door interlock and the door restrictor into one assembly. (Figure 3)

• Bayonet-style interlock and gate switches with “wipe” have been field validated. (Figure 3 and 4) 
• Keep it simple to install/replace/adjust: Individual wearing parts should be individually replaceable without the need to remove others. The hardware should be accessible. Keyhole slots, cage nuts and welded nuts all help hold the nut that may be hard to access. These are factory preadjusted with field readjustment, if necessary, in multiple axes. (Figure 4)
• Eccentric hanger rollers to adjust to an imperfect world

These wins in cost, performance and reliability are welcome among all stakeholders in the industry:

• First, and most important, the end-customer building owner/manager enjoys high performance and low downtime.
• Manufacturers enjoy simplification.
• Installation/service contractors and mechanics enjoy simplification, reliability and reduced costs.

These cost reductions challenge the status quo currently in the marketplace.

About Level Up Elevator Components

Level Up Elevator Components Inc. was born in 2022 from a vision to revolutionize the elevator industry. Recognizing the need for greater product diversity, Level Up assembled a global team of experts to curate a unique collection of elevator components and solutions. Through two years of dedicated R&D, the company offers elevator companies a wider range of options to enhance their competitiveness. The company’s mission is to empower elevator companies to elevate their offerings and better serve their customers.

By providing innovative and high-quality products, Level Up aims to create a more dynamic and customer-centric industry. The company has locations in Vaughan, Ontario, Canada, and Connecticut and serves all of North America, providing geared and gearless machines and door systems including door operators and full landing door hardware, including interlocks, closers, tracks, hangers, headers, etc., that can be used with customer-preferred door panels and entrances. The company’s primary clients are elevator package providers and elevator installation contractors.