Lift Report

The concept of the congress is characterized by an interesting mix of presentations on the work carried out with respect to the European Directives and Standards and the incorporation of the latest innovations. This international event is one of the highlights of the further education offer of the Heilbronn Technical Academy. It results from intensive contacts with the lift industry that have been established decades ago.

As managing director of the Technical Academy, Prof. Dr. Georg Clauss welcomed the guests and participants of the congress and thanked them for the vivid interest, displayed in this second international event of the lift industry. The purpose and objectives of the Heilbronn Technical Academy (TAH) were briefly outlined and reference was made to the specialist exhibition in the lobby, which accompanied the congress.

As representative of the Heilbronn University, its president Prof. Dr. Gerhard Peter welcomed the audience and introduced the university’s educational sys- tem (on the second day for time related reasons). Heilbronn is one of the largest universities of Baden-Württemberg with more than 6,500 students and 22 different degrees offered. An increase in the number of students by approx. 25 % is expected until 2012, a fact that presents a considerable challenge for the university.

Mayor Wilfried Hajek welcomed the guests and participants as official representative of the town of Heilbronn, making reference to the industrial import ance of the region with its international -ly renowned companies – apart from the benefits, which this region offers as the largest wine-growing district for red wines in Germany. One of the largest German inland harbours (rank 7 in Germany and before Stuttgart) and the mining in the nearby salt mine are proof for the diversity and activities of this town and its environs.

Luc Rivet – as representative of the ELA (European Lift Association) – welcomed the audience, making reference to the encouraging increase of the number of congress participants compared with the first event. The lift inventory – not only in Europe – requires constant modernisation and the ELA is involved in this subject in the respective specialist bodies. After a brief introduction of the working topics dealt with in the committees, the speaker wished the audience a successful conference on behalf of ELA.

As chairman of the event that he had planned, Dr. Gerhard Schiffner (STC Lift Consulting) also welcomed the audience, followed by an introduction to the topic of the congress. The changes experienced in the lift technology during the past years were enormous and the machine-room-less lift (MRL) has demonstrated its pioneer function in many respects. New lift systems with reduced space for headroom and pit as well as lifting platforms for persons with impaired mobility will have a significant impact on the lift market of the future.

Due to this reason, the focal topic of the conference was “innovation and new technologies for standard lifts”. The general framework specified by the European Directives and Standards is closely linked to technical innovations.

Dr. Gerhard Schiffner specifically thanked those presenters of the congress who provided an overview of the current activities in the lift industry. Further acknowledgement was addressed towards the European Lift Association ELA, the European Confederation of Organisation for Testing, Inspection, Certification and Prevention CEOC, the two German manufacturers’ associations VDMA and VFA as well as the Association of German Technical Inspection Services VdTÜV, who had made important contributions during the preparation of the congress.

Ian Fraser unfortunately had to cancel his participation on short notice, so that the first paper on the current new Machinery Directive and the modifications of the Lift Directive pertaining to it was presented by Dr. Gerhard Schiffner, thus opening the information lectures of the conference. The revision of the Machinery Directive that has been ongoing for quite some time now and the modification of the Lifts Directive pertaining to it could now finally be terminated. The new Machinery Directive 2006/42/EC entered into force on 29 June 2006. Its contents, however, will not be applicable and binding before their implementation into national law from 29 December 2009 on. A transition period is not provided for the time being. Important modifications over the previous version are that conformity assessment procedures have now also been introduced for partly completed machines and that a full quality assurance system was adopted to prove the conformity of machines.

The definitions for market surveillance were further specified and expanded and additional requirements regarding the contents and identification of the documentation established. Further responsibilities were defined for the Notified Bodies in addition to a review of the type examination certificates in intervals of 5 years to be carried out by the issuing notified body. Several technical modifications and clarifications were incorporated in Annex I in addition to an adjustment of the terminology to the relevant standards. It is particularly paragraph 6 that is significant for lifts, since it specifies the minimum requirements for lifts in accordance with the Machinery Directive. In connection with the modifications of the Lifts Directive realised at the same time, the borderline between these two directives will be clearly defined in the future. All lifts with an operating speed of up to 0,15 m/s will be subject to the Machinery Directive in the future and will have to meet its requirements. Other directives relevant for lifts and their consequences were also presented.

As chairman of the CEN/TC10, Pierre Bianchini (KONE Belgium) presented an overview of the work accomplished and currently handled by the committee, which was and is being realised in the course of the preparations and revisions made within the EN 81 family of standards. The most important work e.g. regarding the revision of EN 81-1/2 was explained and reference was made to the work performed in view of the pending regulations for the different types of lifts and their areas of application. The revision of EN 81-1/2 will make considerable efforts necessary in the years to come in order to allow for the adaptation of these internationally leading standards to the formal requirements of CEN as well as to the changing state-of-the-art of technology. The preparation of a first draft is planned until 2008. In this context, the opportunities of a possible harmonisation of the internationally applicable lift regulations in the regions Europe, North America and Japan are to be investigated and adjusted via the bodies of ISO/TC 178. The cooperation with representatives from Russia and China in the standardisation committees within CEN/TC 10 has already proven successful, and these countries should no longer be observers only in the long run.

Although the protection objectives and their technical realisation in the directives and standards are clear, their practical implementation by manufacturers and notified bodies often gives rise to questions regarding the interpretation of the text. These clarifications in the framework of recommendations for use is the main task of the horizontal coordination of notified bodies under the Lifts Directive (NB-L). As vice president of NB-L and technical manager of Lift Cert (UK), Malcolm Miles’ report focused on the work performed there. The make-up of the committees was outlined in an illustration and the fact pointed out that particularly the experience made by the NBs in practical inspection and testing was taken into account for this work, assistance for new developments was discussed and measures were recommended. These, however, must not conflict with the stipulations of the directives and must not additionally be interpreted as parallel regulations. The safety of workers performing maintenance and rescue operations, particularly on machine-room-less lifts, is currently an important topic of the ongoing discussions. A number of recommendations for use specify precise requirements with respect to the accessibility of components mounted in the hoistway, the availability and utilisation of special equipment for rescue operations, etc.

Dr. Harri Hakala (KONE Finland) was in a position to present a so to speak firsthand report on the topic of “10 years of MRL lifts” as someone directly involved and playing a crucial role in their development. After an in-depth analysis of the technical possibilities for lift systems equipped with linear drives and of the patent situation of the early Nineties, KONE continued pursuing low-profi le motors using the permanent magnet technology. After initial considerations relating to the accommodation of this motor within the counterweight and the investigation of other potential mounting locations, the known concept of the Monospace with the drive located in the area of the headroom was developed. The Monospace was first introduced on 14 March 1996 in a 450 kg variant. Meanwhile more than 150.000 installations that utilise this specific technology have been commissioned. The motor concept was also consistently further developed for installation in the machine room. Nowadays, motors for a nominal load of up to 5.000 kg and a nominal speed of up to 17 m/s with lifting heights of up to 400 m are feasible. The individual development steps were explained and the speaker gave an outlook towards future solutions. The Maxispace was introduced in the course of the further development of this motor, which allowed for an increase of the ratio between hoistway and car cross-section by omitting the counterweight so that the space required for the lift technology could be further reduced.

It is particularly the drive that is the essential element when it comes to investigating possibilities to reduce the size of components for MRL lifts. The decisive factor for the torque and thus the size of the drive is the traction sheave diameter which, however, is technically limited to minimum values for reasons of safety and service life. A substitute for the formerly used wire rope was found in the form of flat belts, which consequently resulted in smaller traction sheave diameters – while still adhering to the necessary D/d ratio. This specific OTIS solution was presented by Dr. Pascal Rebillard from OTIS France. The small diameter steel ropes are positioned next to one another, shielded by a plastic sheathing and forming a belt of about 30 mm width, which moreover offered a better coefficient of friction than steel. Traction sheave diameters of 80 to 100 mm instead of 400 to 575 mm have now become possible, with a diameter ratio of 40:1 still adhered to. The consequence was a distinct reduction of the motor torque, thus making the development of smaller drives possible, either via a transmission or in the form of a gearless direct drive. Initial problems with the centric running of the adjacent suspension belts and the generation of noise by the belt moving over the traction sheave have meanwhile been overcome and this specific technology has been in use for several years now. Worldwide more than 30,000 installations are in operation. The permanent surveillance of the individual ropes is carried out electronically, allowing for an early identification of the replacement state of wear of the suspension means.

The prEN 81-21 standard for new passenger and goods passenger lifts in existing buildings is an eagerly awaited standard that has been under discussion for many years. The draft standard will be submitted for approval towards the end of 2006, explained the head of the responsible standardisation group Giovanni Varisco (ECD Lift Italy). After carrying out 2 enquiries and discussing many partially quite controversial comments, the standard was again revised on the basis of a detailed risk assessment. The standard lists alternatives to EN 81-1/2 if the structural conditions in existing buildings do not permit the application of EN 81-1/2. Apart from the requirement for a separate hoistway for the counterweight and a reduced height of passages and machine rooms, the standard particularly focuses on requirements for temporary safety spaces realised by way of technical installations. The operation of movable stops and pre-triggered stopping gears to protect the safety spaces as well as the electrical safety system pertaining to them were explained in detail. Specific solutions for retractable balustrades and car aprons, which were equally presented, are also required on account of the reduced well dimensions. Since lift types with reduced well dimensions become increasingly popular also for new buildings and are willingly used by architects and planners, this standard is of essential importance. Even if the standard is limited to existing buildings, it will also be applied to new buildings. The final version of the standard is expected for 2007.

It is particularly the realising of the requirements of prEN 81-21, which makes components necessary that fully meet the stipulations and enable a safe operation. The selection of such facilities for the creation of refuges was presented by Wolfgang Adldinger (Wittur AG Germany). The prerequisites for the application of components to create safety spaces were explained in his paper on the basis of installations realised for different areas of application. WITTUR offers as a solution movable stops which may either be installed stationary in the lift pit or in the headroom, but also directly on the car or the counterweight. The automatically engaging stops are activated by switches at the unlocking devices of the lift doors. Signalling facilities in the safety spaces are used to inform any personnel present in the safety space about the safe position of the stops. The speaker is convinced that automatically activated and electrically monitored devices should definitely be the solutions of choice. The facilities are classified according to load categories and approved for installations of up to a rated load of 6,000 kg and an operating speed of up to 1,5 m/s. In the future, the safety of the maintenance and inspection personnel may further be enhanced by an additional video-supported status monitoring system for this certified safety equipment.

The evening between the two conference days startet with an exceptional opportunity: A tour of a state-of-the-art production facility of the automotive industry, which set off at the AUDI Forum in Neckarsulm – a very special highlight. The participants were welcomed in the futuristic AUDI FORUM after a short bus tour to Neckarsulm, where they were given the opportunity to take a closer look at and even get inside the successful motorsports automobiles and latest models of the AUDI model range. After an introductory video on the history of the plant and the AUDI brand, a factory tour was organised. The participants were equipped with headphones and split into three groups, one German and two English speaking. The considerable size of the plant required the participants of the tour to board a factory bus several times and the impression obtained in the factory halls would have been that of a hospital rather than that of a metalworking shop, hadn’t there been the noise level produced by the processing machines and robots. It was particularly the technical solution and processing of light alloy in combination with steel or cast steel components that provided informative details. High-strength and clearly defi ned bonded joints help to overcome the cathodic problems, which normally occur if two different metals are joined. Food for thought also for applications in the lift industry. The strenuous factory tour was terminated by a superb dinner in an excellent atmosphere, where wines from the region were served. Special thanks were extended to the hosts and organizers of the evening.

The first presenter of the second day was Andreas Hunziker (Bucher Hydraulics Switzerland), who spoke about the topic “hydraulic lifts – fit for the future”. It is a known fact that the market situation for hydraulic lifts has become increasingly difficult during the past decade as a consequence of the introduction of MRL rope lifts. The more than 7,000 employees of Bucher Hydraulics not only manufacture products for the lift industry, but also benefit from the experience potential of other industries. State-of-the-art valve technology was used to live up to the market requirements regarding ride quality. With hydraulic lifts, the location of the machine room had never been a major problem, the reason why it was possible to follow the trend for MRL versions without the need for making specific efforts. The speed control of the pump motor resulted in an essential improvement of the noise behaviour and furthermore helped to considerably reduce the energy input. Further solutions with pressure accumulators and a partial compensation of the dead loads made hydraulic lifts highly competitive for many applications. A high share of the existing hydraulic lifts call for modernisation measures to be adopted, a fact that constitutes a considerable market potential. The respective modernisation kits contribute to keeping the financial burden on the operators on an acceptable level and thus promote and accelerate the implementation of state-of-the-art safety stipulations.

The increasing utilisation of MRL lift installations primarily affected the electric motor industry. The trend was and unambiguously is towards gearless drives, since the spatial advantage offered by this solution is also beneficial when it comes to a modernisation of the installation. Roland Hoppenstedt (Ziehl-Abegg AG Germany) reminded the audience of the fact that Ziehl-Abegg had already promoted the development of gearless drives ever since 1990. The basis was the principle of a linear motor, a principle that was again explained and outlined as the basis for further development. In the search for practicable solutions, the essential parameters were traction sheave diameter, patent situation and arrangement of the drive in the hoistway. This included the taking into consideration of installation (weight) and accessibility (maintenance and service). It was also important to investigate and consider the market situation vis-à-vis hydraulic drives. The principle of the external rotor motor was also explained and the respective solution adopted was presented. The areas of application were outlined and the fact was explained that the decision taken in view of the selection of a flat or long external rotor variant usually depends on the spatial situation encountered on site. The utilisation of small rope diameters allows for a reduction of the traction sheave diameter and thus of the torques, which ultimately results in smaller drives in general. The different model lines offered are capable of covering all possible demands and the further development focuses on supplying controls adapted to the motor as a complete package solution rather than just supplying the drive alone.

The demographic development requires the lift industry to consider the different technical solutions that are available for vertical transport – which are also affordable for the people concerned to allow them to stay in their familiar environment as long as possible. In a block of topics, Ulf W. Thorn (Cibes Lift Sweden), Marco Marcetti (Vimec Italy) and Carlo Beletti (IGV Italy) explained the efforts taken on the standards side and underlined the demand for lifting platforms with the respective practical experience from the field, particularly that made in Sweden. In this respect, lifting platforms should definitely not be used as a substitute for conventional lifts, a fact that not only results from the technical restrictions of these lifts according to the Machinery Directive, which makes their utilization more diffi cult and limits it. The essential aspect is a maximum operating speed of 0,15 m/s as well as the hold-to- run control, which inevitably results in a practical limitation of the travelling height. The utilisation of lifting platforms is thus rather recommended for privately used buildings or for buildings with only a limited number of floors, where disabled users may be instructed accordingly or transported with the support of an assistant. This means that platform lifts are primarily used where a conventional lift would not be installed on account of the specific situation encountered in the building or for reasons of costs. The results of the standardisation work carried out so far regarding prEN 81-41 were outlined and the differences vis-à-vis EN 81- 1/2 were pointed out. In order to explain the recommended operating conditions, examples of installations realised were shown. In his paper, Ulf W. Thorn also briefly presented the European Association for Lifting Platforms and Stair Lifts EPSA, an association formed by the manufacturers of such lifts.

As chairman of ISO/TC 178, Philippe Lamalle (OTIS France) reported about their current work and further tasks and objectives on an international level. The structure of ISO and its working groups was explained and the staff make-up outlined. In addition to the standards already prepared, the drafts currently being discussed were also mentioned and briefly commented. For quite some time now, efforts have been made to compare the internationally existing safety standards and to review them regarding a possible harmonisation. The currently “leading” standards globally used are EN 81 (Europe), A17.1/B44 (USA/Canada) and JIS (Japan), with EN 81 having reached a coverage of more than 80 % for new installations. The globalisation of the markets makes a standardisation of the requirements for lifts in view of safety and of the processes for conformity assessment necessary. For this purpose a project for a global harmonisation was established several years ago, in the context of which ISO/TS 22 559-11) for global safety requirements has already been published. Additional parts of this standards compendium for global safety parameters and global conformity assessment procedures will follow in the years to come. With this, the basic elements exist that allow for the introduction of a similar system as the Lifts Directive also in other countries outside of Europe to thus make a quicker introduction of innovations in the markets possible. The leading standards worldwide will be furthermore adapted in the scope of these activities. The vision of a globally harmonised lift standard could thus be realised some day in the future with this preparatory work already carried out.

The highly interesting final presentation of Gerhard Thumm (ThyssenKrupp Elevator Germany) described a new technology for the lift industry and was capable of again captivating the audience. Programmable electronic systems in safety-relevant lift applications were the topic presented and fi rst-hand information was provided on the systematic approach. Safety is the key issue no. 1 in the lift industry and this is naturally reflected in the requirements on the components specified in the standards. The application of software based solutions for electrical safety systems, switches and circuits was now also introduced for lifts as an alternative to electrical safety systems in the form of amendment A1 of the EN 81-1/2 standards published in the middle of this year. The fundamentals of this technology were outlined together with elements for the realisation of PESSRAL solutions. This technology not only allows for the replacement of conventional electrical safety systems, but solutions that up to now have been purely mechanical may be replaced as well. One example for this is the overspeed governor, the monitoring function of which may also be realised reliably with the help of sensors and electronic circuitry. A safety system for avoiding collisions was developed on the basis of PESSRAL – meanwhile already realised in several real life applications – in the TWIN lift system, where two cars travel up and down on top of one another in one and the same well. This allowed for the replacement of the mechanical safety system used in the first generation of the TWIN, which would have encountered problems at higher nominal speeds in view of the minimum safety distances to be adhered to. The safety system and its function together with the measures provided for realizing the highest safety level were explained.

In his closing remarks, Gerhard Schiffner thanked the audience for its attention and the vivid discussions and the speakers for their interesting contributions and the wealth of information presented. The next European Lift Congress is scheduled for the autumn of 2008 and will be published in lift magazines in due time.

Gerhard Schiffner closed the conference wishing the participants a safe and pleasant journey home.