Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B66—HOISTING; LIFTING; HAULING
  • B66B—ELEVATORS; ESCALATORS OR MOVING WALKWAYS
  • B66B31/00—Accessories for escalators, or moving walkways, e.g. for sterilising or cleaning

Definitions

• This disclosure relates to a sound collector installed in a passenger conveyor and its machine room.
• Patent Document 1 discloses an abnormality diagnosis system for a passenger conveyor.
• a fixed sound collection device is installed inside the machine room.
• the abnormality diagnosis system can diagnose abnormalities in the passenger conveyor based on the sounds collected by the fixed sound collection device.
• This disclosure has been made to solve the above-mentioned problems.
• the purpose of this disclosure is to provide a sound collector and passenger conveyor that can more reliably collect abnormal sounds generated during the operation of the passenger conveyor.
• the sound collector disclosed herein is a device installed inside the passenger conveyor's machinery room and includes a sound collection unit that detects ambient sounds, a fixed unit that is fixed to the floorboard support beam that supports the floorboard that covers the top of the passenger conveyor's machinery room, and an extension unit that extends from the fixed unit toward the passenger conveyor's driver and to which the sound collection unit is attached.
• the passenger conveyor comprises a truss that defines the passenger conveyor's machine room inside, a drive machine that drives the steps of the passenger conveyor, a floor panel that opens and closes an opening above the drive machine in the machine room, and a sound collector that is provided inside the machine room and collects sound;
• the truss supports a portion of the floor panel above the drive machine at its top surface and has a floor panel support beam with a through hole in its side extending downward from the top surface;
• the sound collector has a sound collection unit that detects ambient sound, a fixed unit fixed to the floor panel support beam at the through hole, and an extension unit that extends from the fixed unit toward the passenger conveyor's drive machine and has the sound collection unit attached.
• the sound collector is fixed to the floor support beam by a fixing portion. This makes it possible to more reliably collect abnormal sounds generated by the operation of the passenger conveyor.
• FIG. 1 is a schematic diagram of an escalator to which an inspection system according to a first embodiment is applied. 10 is an example of an interface screen displayed by the inspection system in the first embodiment.
• FIG. 1 is a perspective view of a main part of a machine room to which a sound collector is fixed in accordance with Embodiment 1.
• FIG. 1 is a top view of a machine room to which a sound collector is fixed in accordance with Embodiment 1.
• FIG. 2 is a transparent perspective view of the sound collector according to the first embodiment.
• FIG. 1 is a side view of a state in which the sound collector in the first embodiment is fixed.
• FIG. 2 is a diagram illustrating the configuration of an inspection device and a sound collector according to the first embodiment.
• FIG. 1 is a functional block diagram of an inspection system according to a first embodiment.
• 1 is a diagram showing an example of the transition of sound pressure of sound recorded by the inspection system of embodiment 1.
• FIG. 1 is a diagram showing an example of the transition of sound pressure of sound recorded by the inspection system of embodiment 1.
• FIG. 3 is a flowchart showing an outline of operations performed in the inspection system of the first embodiment. 3 is a flowchart showing an outline of operations performed in the inspection system of the first embodiment. 4 is a flowchart showing the operation of the inspection system in the first embodiment.
• FIG. 2 is a hardware configuration diagram of the inspection device according to the first embodiment.
• Fig. 1 is a schematic diagram of an escalator to which the inspection system according to the first embodiment is applied.
• Fig. 2 is an example of an interface screen displayed by the inspection system according to the first embodiment.
• Figure 1 shows an escalator 1, an example of a passenger conveyor.
• Escalator 1 is installed between the upper and lower floors of a building (not shown). Escalator 1 transports passengers between the upper and lower floors.
• Escalator 1 is equipped with a first entrance/exit 2a, a second entrance/exit 2b, a truss 3, and a machine room 4.
• the first platform 2a is located on an upper floor of the building.
• the second platform 2b is located on a lower floor of the building. Passengers use the escalator 1 by passing through the first platform 2a and the second platform 2b.
• a truss 3 spans between the first platform 2a and the second platform 2b. Although not shown in the figure, the truss 3 is made up of a number of beams assembled together.
• the truss 3 has a machine room 4 at its upper end, below the first platform 2a.
• the machine room 4 is a space surrounded by the beams of the truss 3 and an outer frame (not shown).
• the escalator 1 is equipped with a drive machine 5, a reducer 6, and a brake device 7 inside the machine room 4.
• the drive machine 5 is a motor that rotates a power shaft.
• the reducer 6 is equipped with an input shaft 6a, a drive shaft 6b, and a reduction mechanism 6c.
• a V-belt 8 is wound around the power shaft and input shaft 6a of the drive machine 5.
• the rotational driving force of the drive machine 5 input to the input shaft 6a via the V-belt 8 is output from the drive shaft 6b.
• the rotational speed and torque of the input rotational driving force are converted in the reduction mechanism 6c that connects the input shaft 6a and drive shaft 6b.
• the brake device 7 is connected to the drive shaft 6b.
• the brake device 7 can apply a braking force to the drive shaft 6b.
• the brake device 7 applies a braking force by clamping a braked object, such as a disc, which is connected to the drive shaft 6b so as to follow the drive shaft 6b, with a gripping body, such as a brake pad.
• operation the generation of braking force by the brake device 7
• release the brake device 7 not applying braking force by not clamping the braked object with a gripping body, etc.
• the escalator 1 further comprises a plurality of steps 9, step sprockets 10, a drive chain 11, a step chain 12, and a control panel 13.
• the plurality of steps 9 are all connected endlessly.
• the plurality of steps 9 are arranged between the first platform 2a and the second platform 2b.
• the steps 9 have a main rotation shaft.
• the main rotation shaft is guided by a guide rail arranged along the track of the steps 9. In this way, the steps 9 can move along the guide rail.
• the step sprocket 10 is mounted in the machine chamber 4.
• the drive chain 11 is endless. One end and the other end of the drive chain 11 are wound around the drive shaft 6b and a driven sprocket (not shown) mounted coaxially to the step sprocket 10, respectively.
• the step chain 12 is an endless chain.
• the step chain 12 connects multiple steps 9. A portion of the step chain 12 is wound around the step sprocket 10. In this state, a portion of the multiple steps 9 and a portion of the step chain 12 fold back from the top to the bottom of the step sprocket 10 along the circumference of the step sprocket 10.
• the control panel 13 is electrically connected to at least the drive machine 5 and the brake device 7.
• the control panel 13 may also be connected to the drive machine 5 via an inverter (not shown).
• the control panel 13 controls the overall operation of the escalator 1 by sending control signals to the drive machine 5 and the brake device 7.
• a command from the control panel 13 drives the drive unit 5, releasing the brake device 7.
• the rotational driving force generated by the drive unit 5 rotates the step sprocket 10 via the V-belt 8, the reducer 6, and the drive chain 11.
• the step chain 12 and the multiple steps 9 move in response to the rotation of the step sprocket 10.
• each of the multiple steps 9 moves along the guide rail.
• the upper step 9 moves along the passenger transport route.
• the upper step 9 turns back along the step sprocket 10 and moves downward as the lower step 9.
• the inspection system 100 comprises a first server 101, a second server 102, an individual terminal 103, a remote monitoring device 14, an inspection device 20, and a sound collector 30.
• the inspection system 100 may also include an escalator 1 as part of its configuration.
• at least one of the remote monitoring device 14, the inspection device 20, and the sound collector 30 may be considered to be a component of the passenger conveyor that is the escalator 1.
• the first server 101 and the second server 102 are provided in a building separate from the building in which the escalator 1 is installed.
• the first server 101 and the second server 102 may each be provided in a different building, or at least one of them may be implemented as a cloud server.
• the first server 101 and the second server 102 are owned by a company that maintains and manages the escalator 1.
• the first server 101 is a server that serves as an information center device and is accessed by a monitor who remotely monitors the escalator 1.
• the second server 102 is a server that is accessed from an individual terminal 103 by a worker who inspects, maintains, etc. the escalator 1 on-site.
• the remote monitoring device 14 is electrically connected to the control panel 13 in the machine room 4.
• the remote monitoring device 14 is capable of communicating with the first server 101 and the second server 102 via a public line.
• the remote monitoring device 14 obtains information about the operation of the escalator 1 from the control panel 13, and when specified conditions are met, transmits the information about the operation to the first server 101.
• the inspection device 20 is electrically connected to the remote monitoring device 14 in the machine room 4.
• the inspection device 20 can communicate with the first server 101 and the second server 102 via the remote monitoring device 14.
• the inspection device 20 is electrically connected to the control panel 13.
• the inspection device 20 may also be electrically connected to the drive machine 5 and the brake device 7.
• the sound collector 30 is provided inside the machine room 4 as one piece of inspection equipment.
• the sound collector 30 includes a microphone that can detect ambient sounds.
• the inspection system 100 may also include inspection equipment such as a camera installed on the escalator 1, a belt and chain deflection sensor, etc.
• the inspection equipment is electrically connected to the inspection device 20.
• the opening on the top of the machine room 4 is closed by a floor panel 15, which can be opened and closed. Users move on the floor panel 15, which serves as the landing plate for the first entrance/exit 2a. When inspecting the escalator 1, workers remove the floor panel 15 and inspect the drive mechanism 5 and other components through the opening.
• the inspection system 100 can replace part of the on-site inspection work performed by workers. Specifically, the inspection system 100 can replace the work of workers inspecting the escalator 1 for abnormalities by listening to sounds. Conventionally, when the floorboards 15 were blocking the machine room 4 and the steps 9 were moving, workers would listen to sounds coming from the machine room 4 to check for abnormalities in the V-belt 8, drive chain 11, brake device 7, etc.
• the inspection device 20 determines whether or not there is an abnormality based on the sound from inside the machine room 4 collected by the sound collector 30. If an abnormality is confirmed, the inspection device 20 notifies the first server 101 of the abnormality via the remote monitoring device 14. Furthermore, the inspection device 20 stores the collected sound as recorded information, regardless of whether or not there is an abnormality.
• a worker uses the individual terminal 103 to listen to the sounds stored in the inspection device 20.
• the individual terminal 103 accesses the second server 102 to specify the timing and send an inquiry notification to the inspection device 20.
• the inspection device 20 sends to the second server 102 sound information recorded at the timing included in the inquiry notification from the stored audio recording information.
• the worker can listen to the sounds and determine whether or not there is an abnormality in the equipment, in the same way as checking for abnormal sounds on site.
• FIG. 2 shows an example of an interface screen that is displayed on the individual terminal 103 by accessing the second server 102.
• the worker can listen to the recorded sound at the specified timing.
• the worker can check the image captured by the camera installed on the escalator 1 in area B2.
• FIG. Fig. 3 is a perspective view of the main parts of a machine room to which a sound collector is fixed in accordance with Embodiment 1.
• Fig. 4 is a top view of a machine room to which a sound collector in accordance with Embodiment 1 is fixed.
• Fig. 5 is a transparent perspective view of the sound collector in accordance with Embodiment 1.
• Fig. 6 is a side view of the sound collector in accordance with Embodiment 1 in a fixed state.
• the truss 3 includes a floor support beam 3a, an end beam 3b, and an end longitudinal beam 3c as part of the beams that make up the machine room 4.
• the floor support beam 3a is located at the top of the machine room 4, between the step sprocket 10 and the driver 5 on a horizontal projection plane.
• the longitudinal direction of the floor support beam 3a is horizontal and approximately parallel to the drive shaft of the driver 5.
• the floor support beam 3a has an upper surface S1 facing upward and a side surface S2 extending downward from the upper surface S1.
• the end beam 3b is a horizontal beam located at the top of the machine room 4, at the end of the machine room 4 opposite the step sprocket 10.
• the end longitudinal beam 3c is connected to the end of the end beam 3b and is a beam with a longitudinal direction that is vertical.
• the floor panel 15, not shown in FIG. 3, is supported by at least the upper surface S1 of the floor support beam 3a.
• the floorboard support beam 3a is a beam that is placed across the escalator 1 primarily for the purpose of supporting the floorboards 15, which bear the load.
• Different models of escalator 1 have different shapes for the machine room 4, and so the distance from the end beam 3b and end vertical beam 3c to the driver 5 often differs.
• the distance from the floorboard support beam 3a to the driver 5 does not vary significantly, regardless of the model.
• the sound collector 30 is fixed to the floor support beam 3a. Specifically, it is fixed with a bolt or the like to the side surface S2 of the floor support beam 3a facing the driver 5. A through hole H is drilled in the side surface S2 of the floor support beam 3a to allow the bolt to pass through.
• the sound collector 30 is located between the driver 5 and the folded portion of the step 9.
• the sound collector 30 is located closer to the driver 5 than the center of the step 9 in the width direction.
• the through hole H which is not shown in Figure 4, is opened closer to the driver 5 than the center of the floorboard support beam 3a in the longitudinal direction.
• the sound collector 30 comprises a sound collection unit 31 that detects sound, a fixing jig 32 that is fixed to the floorboard support beam 3a, and a mounting housing 33 that attaches the sound collection unit 31 to the fixing jig 32.
• the sound collection unit 31 comprises a microphone 31a, which is an element that detects ambient sound, and a sound collection board 31b.
• the sound collection board 31b outputs the sound detected by the microphone 31a as an electrical signal. Note that the sound collection board 31b may also have the function of converting the sound detected by the microphone 31a into recorded information.
• the fixing jig 32 is a jig that is formed by processing a single metal plate into a single unit.
• the fixing jig 32 has a fixing portion 34, an extension portion 35, and an upper protective portion 36.
• each component of the sound collector 30 will be explained based on the position in which the sound collector 30 is fixed to the floorboard support beam 3a.
• the fixing portion 34 is the part that is fixed to the floor board support beam 3a.
• One or more fixing holes 34a are drilled in the plate-shaped fixing portion 34.
• the fixing hole 34a is an oval hole where a small hole 34b and a large hole 34c are connected.
• the large hole 34c is located vertically below the small hole 34b and has a larger diameter than the small hole 34b.
• the diameter of the small hole 34b is large enough to allow the bolt that fixes the fixing portion 34 to the floor board support beam 3a to pass through.
• the diameter of the large hole 34c is large enough to allow the nut, washer, etc. fitted on the bolt that fixes the fixing portion 34 to the floor board support beam 3a to pass through.
• the extension portion 35 is plate-shaped and extends from a connection point 34d below the vertical center of the fixed portion 34.
• the connection point 34d is the lower end of the fixed portion 34 that is fixed to the floorboard support beam 3a.
• the extension portion 35 extends diagonally upward from the connection point 34d in the horizontal direction.
• the fixing jig 32 is such that a member extends horizontally or diagonally downward from the fixing portion 34, and the tip of the member extends diagonally upward, the member extending horizontally or diagonally downward can be considered to be the fixing portion 34. Even in this case, the extension portion 35 is the portion extending diagonally upward from the fixing portion 34.
• the upper protective portion 36 is a portion of the extension portion 35 that extends from a portion above the sound collection portion 31 so as to cover the upper part of the sound collection portion 31.
• the upper protective portion 36 is plate-shaped and extends from the upper end of the extension portion 35 approximately perpendicular to the extension portion 35.
• the mounting housing 33 attaches the sound collection unit 31 to the extension unit 35 as a mounting portion 37.
• the mounting housing 33 includes plates that form four of the six faces of a roughly cubic shape.
• the mounting housing 33 includes a mounting plate 38, a pair of side plates 39, and a lower plate 40.
• the sound collection unit 31 is attached to the mounting plate 38.
• a hole is drilled in the mounting plate 38 for attaching the sound collection board 31b.
• a sound collection hole is drilled in the mounting plate 38 at the position where the microphone 31a is located.
• the pair of side plates 39 are plates that face each other and extend perpendicularly from the mounting plate 38.
• a fixing plate 41 extends from each of the pair of side plates 39 at the end of the side plate 39 opposite the mounting plate 38.
• the fixing plate 41 extends in the opposite direction from the opposite side plate 39.
• the fixing plate 41 is fixed to the extension portion 35 with bolts or the like while making contact with the plate of the extension portion 35 at the contact surface. At this time, there is no gap between the fixing plate 41 and the extension portion 35.
• the mounting plate 38 and the upper protective portion 36 are in contact with no gaps.
• the side plate 39 and the upper protective portion 36 are in contact with no gaps.
• the lower plate 40 is a plate that extends from the lower end of the mounting plate 38 in the same direction as the side plates 39.
• the lower plate 40 extends from the mounting plate 38 in the direction in which the sound collection unit 31 is attached, and is located below the sound collection unit 31.
• the lower plate 40 is connected to each of the pair of side plates 39.
• a wire inlet 40a is formed in the lower plate 40.
• a storage space A is formed, surrounded by the mounting plate 38, which serves as the mounting housing 33, a pair of side plates 39, a lower plate 40, the extension portion 35, and the upper protective portion 36.
• the microphone 31a and sound collection board 31b which serve as the sound collector 31, are arranged inside the storage space A.
• the fixed plate 41 extends from the side plate 39 to the side opposite the storage space A. The inside and outside of the storage space A are connected by a hole opened at the position of the microphone 31a and the wire inlet 40a.
• the microphone 31a when installed, the microphone 31a faces the driver 5. This makes it particularly easy to collect sounds around the driver 5. Furthermore, because an omnidirectional microphone element is selected, the microphone 31a can detect sounds generated inside the machine room 4 regardless of position.
• the upper end of the extension portion 35 is located below the upper surface S1 of the floorboard support beam 3a. In this case, the upper protective portion 36 is located below the upper surface S1, so the sound collector 30 does not come into contact with the floorboard 15 placed on it.
• the risk of the sound collection unit 31 being damaged by rainwater is reduced, and it also makes it easier for workers to work in the machine room 4. Specifically, when rainwater falls near the floorboard 15 of the escalator 1, and when a wet floorboard 15 is removed, there is a risk that rainwater will enter the machine room 4 along the floorboard support beams 3a, etc.
• the sound collector 30 is required to be configured so that the sound collection substrate 31b, etc. will not be damaged by this rainwater.
• the sound collection substrate 31b is surrounded by the storage space A, preventing rainwater from falling on it from above and on the sides. If the fixing plate 41 extended from the side plate 39 toward the storage space A, the holes used to secure the extension section 35 would connect to the storage space A. In this case, there is a risk that rainwater could enter the storage space A from above through the holes in the fixing plate 41. However, as shown in this embodiment, the fixing plate 41 extends on the side opposite the storage space A, thereby avoiding this risk. Furthermore, holes necessary to connect the storage space A to the outside, such as the holes corresponding to the line inlet 40a and microphone 31a, are positioned so that they face downward when the sound collector 30 is installed. Rainwater can enter from above or the sides, or from water droplets running downward. The upper part of the line inlet 40a is covered by the plate of the extension section 35, and the holes face downward, preventing rainwater from entering due to these factors.
• the extension portion 35 extends diagonally upward from the bottom of the fixed portion 34.
• the sound collection portion 31 is located at a height higher than the connection point 34d.
• Rainwater running down the floorboard support beam 3a can move downward along the fixed portion 34, but gravity prevents it from running above the connection point 34d and instead falls downward. Even if rainwater falls on the extension portion 35, it will run down the extension portion 35 to the connection point 34d and then fall downward.
• the upper protective portion 36 has a plate that is inclined downward. Therefore, even if rainwater falls on the upper protective portion 36, it will protect the sound collection portion 31 like a roof and fall downward.
• the fixing hole 34a is opened above the connection point 34d and the extension portion 35 extends from below the fixing hole 34a, workers can remove the sound collector 30 from above the sound collector 30 after opening the floorboard 15 to perform work on the machine room 4. This improves the workability of this work compared to removing the sound collector 30 from below or to the side. The same applies to the work of attaching the sound collector 30.
• FIGS. Fig. 7 is a diagram showing the equipment configuration of the inspection device and sound collector in embodiment 1.
• Fig. 8 is a functional block diagram of the inspection system in embodiment 1.
• Figs. 9 and 10 are diagrams showing an example of the transition of sound pressure of sound recorded by the inspection system in embodiment 1.
• Figs. 11 and 12 are flowcharts showing an overview of the operations performed by the inspection system in embodiment 1.
• the inspection device 20 is connected to the remote monitoring device 14 via a communications repeater.
• the inspection device 20 is connected to the sound collection board 31b of the sound collection unit 31.
• the inspection device 20 is connected to the control panel 13.
• a line that outputs a similar signal is input to the inspection device 20 in parallel with the signal line that outputs a control signal from the control panel 13 to the brake device 7.
• the brake-related control signal is input to the inspection device 20 at approximately the same time as it is input to the brake device 7.
• the inspection device 20 may also be connected in series between the control panel 13 and the brake device 7. In this case, brake-related control signals are input from the control panel 13 to the brake device 7 via the inspection device 20.
• the inspection device 20 has the following functions: a memory unit 21, a communication unit 22, a signal receiving unit 23, a recording unit 24, a recording control unit 25, an abnormality detection unit 26, a data processing unit 27, and a threshold creation unit 28.
• the memory unit 21 stores information related to various inspection results, including recorded information.
• the communication unit 22 communicates with the remote monitoring device 14. For example, in response to an inquiry notification from the second server 102, the communication unit 22 transmits recorded information stored in the memory unit 21 to the second server 102.
• the signal receiving unit 23 receives brake signals related to brake control output from the control panel 13.
• the recording unit 24 records the electrical signal representing the sound received from the sound collection board 31b. In other words, the recording unit 24 records the sound detected by the sound collector 30. As part of the recording process, the recording unit 24 creates recording information representing the sound and its progression over time.
• the recording control unit 25 controls the time when recording by the recording unit 24 starts and ends.
• the recording control unit 25 causes the recording unit 24 to start recording when the signal receiving unit 23 receives a brake signal.
• the recording control unit 25 causes the recording unit 24 to record for the start interval.
• the start interval includes the startup time from when the step 9 starts moving until it reaches a constant speed, and the constant speed time required to detect an abnormality in the constant speed state.
• the recording control unit 25 causes the recording unit 24 to record for the stop interval.
• the stop interval is set to the time from when the step 9 starts stopping until it stops during normal operation.
• the abnormality detection unit 26 monitors the sound recorded by the recording unit 24 and detects abnormalities based on the sound. Specifically, the abnormality detection unit 26 detects an abnormality when the sound pressure of the recorded sound exceeds a specified first or second threshold. The abnormality detection unit 26 changes the judgment threshold and target value depending on whether the current timing is startup time, constant speed time, or stop interval. Specifically, when monitoring abnormalities in sound recorded during startup time, the abnormality detection unit 26 detects an abnormality when the instantaneous value of the sound pressure of the recorded sound exceeds the first startup threshold or the second startup threshold. When monitoring abnormalities in sound recorded during constant speed time, the abnormality detection unit 26 detects an abnormality when the average value of the sound pressure of the recorded sound exceeds the first constant speed threshold or the second constant speed threshold.
• the abnormality detection unit 26 may use the time average value over a specified unit time as the average value of the sound pressure, or the time average value over the entire constant speed time. For example, the abnormality detection unit 26 may start monitoring for abnormalities in the sound recorded during the startup time, and then start monitoring for abnormalities in the sound recorded during the constant speed time after the startup time. When monitoring for abnormalities in the sound recorded during the stop interval, the abnormality detection unit 26 detects an abnormality when the instantaneous value of the sound pressure of the recorded sound exceeds the first stop threshold or the second stop threshold.
• the second startup threshold, second constant speed threshold, and second stop threshold are each set in advance as specified upper limits.
• the anomaly detection unit 26 detects an anomaly, it notifies the first server 101 via the remote monitoring device 14 that the anomaly has been detected. If the anomaly detection unit 26 detects an anomaly, it may also notify the second server 102 via the remote monitoring device 14 that the anomaly has been detected.
• the data processing unit 27 compresses the recording information to reduce the data volume and stores it in the storage unit 21. At this time, the data processing unit 27 adds information indicating the recording timing, such as the current date and time, to the recording information.
• the information indicating the recording timing may also include information indicating the brake signal that was the starting point for recording.
• the threshold creation unit 28 creates at least one of the first activation threshold, first constant speed threshold, and first stop threshold based on the sound pressure of the sound contained in the recording information stored in the memory unit 21, and updates the thresholds.
• the threshold creation unit 28 creates a threshold from the recording information for the most recent reference period calculated from the current time.
• the reference period is set to any period, such as 10 days. For example, the threshold creation unit 28 creates a threshold once a day.
• the threshold creation unit 28 calculates the average sound pressure value at each activation time for multiple pieces of recording information from the most recent reference period.
• the threshold creation unit 28 calculates the interquartile range of the average sound pressure values.
• the interquartile range is the range that indicates the bottom 25% to 75% of the multiple sound pressure values.
• the threshold creation unit 28 then creates a value that is 1.5 times the upper limit of the interquartile range as the first activation threshold.
• the threshold creation unit 28 may create the first constant speed threshold and the first stop threshold by applying the same calculations as above to constant speed recording or stop interval recording.
• the start time and stop interval are calculated from the characteristics of the passenger conveyor when it starts and stops. At this time, the time is set so that recording does not continue for longer than necessary, in order to reduce communication volume when sending data to the second server 102. Specifically, the start time is set to within 2 seconds. The constant speed time is set to within 8 seconds. The stop interval is set to within 2 seconds.
• Figure 9 is a graph showing the time progression of the sound pressure of the sound recorded in the machine room 4 when the escalator 1 starts up and enters normal operation.
• the vertical axis represents sound pressure [dB], and the horizontal axis represents time [s (seconds)].
• step 9 starts up, it is accelerated to a constant speed within a range that does not exceed a specified acceleration. For example, if the constant speed of step 9 is 40 [m/min], step 9 will reach the constant speed within 2 seconds after the brake device 7 is released.
• possible causes of abnormal noise during startup include damage to the bearings of the drive unit 5, abnormal gear meshing in the reducer 6, deterioration of the V-belt 8, and poor meshing due to deflection or stretching of the drive chain 11. If any of these causes occur, a loud noise may be generated at least momentarily during startup. In this case, by comparing the noise with the first startup threshold or second startup threshold, the inspection device 20 and the operator can discover the abnormality.
• possible causes of abnormal noise during constant speed operation include damage to the bearings of the drive unit 5, abnormal gear meshing in the reducer 6, and poor meshing due to bending or stretching of the drive chain 11. If such causes occur, the noise generated during constant speed operation may steadily increase in accordance with the rotation cycle of the bearings, etc. If a recording of around 8 seconds is made, even if such causes occur, the inspection device 20 and the operator will be able to discover the abnormality by comparing it with the first constant speed threshold or second constant speed threshold.
• an abnormal noise may occur each time step 9 passes.
• the average value during constant speed time may be larger than normal.
• Figure 10 is a graph showing the time progression of the sound pressure of the sound recorded in the machine room 4 when the escalator 1 stops from normal operation.
• the vertical axis is sound pressure [dB]
• the horizontal axis is time [s (seconds)].
• possible causes of abnormal noise during stopping intervals include faulty linings in the brake device 7, poor tension in the V-belt 8, etc. If such causes occur, squealing will occur from the affected area when the vehicle stops, and a loud noise may occur, at least momentarily.
• step 9 the vehicle decelerates to a stop within a range that does not exceed the specified deceleration. For example, when decelerating at a normal deceleration rate of 0.75 m/ s2 , it takes approximately 0.9 seconds to stop from a constant speed (40 m/min). In Figure 10, deceleration begins around 27 seconds, and step 9 stops around 28 seconds. For example, when decelerating at a slower deceleration rate of 0.55 m/ s2 using a mechanical slow stop, it takes approximately 1.2 seconds to stop from a constant speed (40 m/min). In this way, if recording is performed at a stop interval of approximately 2 seconds, abnormal noise during stopping can be detected.
• Figure 11 shows an overview of the operation of the escalator 1 when it is started and the operation of the inspection system 100 at that time.
• the flowchart in Figure 11 begins when the caretaker operating the escalator 1 turns on the start key for the escalator 1. For safety reasons, the caretaker usually checks that there are no people around the escalator 1 before turning on the start key. At the start of the flowchart, the brake device 7 is activated.
• step S001 the control panel 13 sends a command signal to the drive unit 5 to start it up and increase its torque.
• the drive unit 5 increases its torque based on the signal.
• the braking force of the brake device 7 keeps the step 9 stationary.
• step S002 the control panel 13 determines whether the brake release condition has been met.
• the release condition may be met when a specified time has elapsed since a command signal to increase torque was sent, or when the torque generated by the drive machine 5 exceeds a specified value. Setting the release condition prevents the step 9 from behaving unexpectedly due to its own weight after the brake device 7 is released. The operation of step S002 is repeated until the release condition is met in step S002.
• step S003 the control panel 13 sends a brake release signal to the brake device 7 and the inspection device 20.
• step S004 the signal receiving unit 23 of the inspection device 20 receives the brake release signal.
• step S005 the recording control unit 25 causes the recording unit 24 to start recording.
• the recording unit 24 starts recording.
• step S006 the brake device 7 releases the brakes based on the release brake signal, reducing the braking force to zero.
• step S007 the anomaly detection unit 26 monitors the recorded sound for any abnormalities during the start interval. If the anomaly detection unit 26 detects an abnormality, it notifies the first server 101 of this. Also, in step S007, the anomaly detection unit 26 changes the criteria for judgment depending on the startup time and constant speed time.
• step S008 the recording control unit 25 determines whether the start interval has elapsed. If the start interval has not elapsed in step S008, the operations from step S007 onwards are repeated.
• step S009 the recording control unit 25 causes the recording unit 24 to end recording.
• step S010 the data processing unit 27 stores the recording information created by the recording unit 24 in the memory unit 21, associating it with the date and time and the timing of startup. Note that the timing of startup may also be associated with information indicating that the recording was made in response to a brake release signal.
• Figure 12 shows an overview of the operations performed when the escalator 1 stops from normal operation, and the operations of the inspection system 100 at that time.
• the flowchart in Figure 12 begins when the manager who stops the escalator 1 turns off the start key for the escalator 1. For safety reasons, the manager will usually check that there are no people around the escalator 1 before turning off the start key. At the start of the flowchart, the brake device 7 is open.
• step S101 the control panel 13 sends an activation brake signal to the brake device 7 and the inspection device 20.
• step S102 the signal receiving unit 23 of the inspection device 20 receives the brake activation signal.
• step S103 the recording control unit 25 causes the recording unit 24 to start recording.
• the recording unit 24 starts recording.
• step S104 the brake device 7 activates the brakes based on the release brake signal to generate braking force.
• step S105 the abnormality detection unit 26 monitors the sound during the stop interval. If the abnormality detection unit 26 detects an abnormality, it notifies the first server 101 of this.
• step S106 the recording control unit 25 determines whether the stop interval has elapsed. If the stop interval has not elapsed in step S106, the operations from step S105 onwards are repeated.
• step S107 the recording control unit 25 causes the recording unit 24 to end recording.
• step S108 the data processing unit 27 stores the recording information created by the recording unit 24 in the memory unit 21, associating it with the date and time and the timing of the stop.
• the timing of the stop may also be associated with information indicating that the recording was made in response to an actuated brake signal.
• FIG. 13 is a flowchart showing the operation of the inspection system according to the first embodiment.
• the flowchart in Figure 13 begins, for example, when a worker creates a monthly report for escalator 1. The worker performs the creation work by accessing the first server 101 and the second server 102 using the individual terminal 103.
• step S201 the worker checks whether any abnormalities have been reported in the past month based on the information stored in the first server 101. If a report indicating that an abnormality has been detected has been received from the inspection device 20, the first server 101 stores information indicating that such a report has been received. If no such report has been received, the worker determines that no abnormalities have been confirmed.
• step S202 the second server 102 sends an inquiry notification to the inspection device 20, transmitting the latest recorded information.
• the timing specified in the inquiry notification is the most recent date and time.
• the second server 102 may also send an inquiry notification to the inspection device 20 specifying the most recent date and time as the timing at any trigger other than step S202.
• step S203 the communication unit 22 of the inspection device 20 transmits the recorded information to the second server 102 at the timing specified in the inquiry notification.
• step S204 the worker operates the interface screen, listens to the transmitted recorded information, and determines whether or not there are any abnormalities.
• step S205 If in step S205 the worker determines that it is necessary to listen to the recorded information at another timing, the operation of step S206 is performed.
• step S206 the second server 102 sends an inquiry notification including the timing specified by the worker to the inspection device 20. Thereafter, the operations from step S203 onwards are repeated.
• step S205 If in step S205 the worker determines that there is no need to listen to the recorded information at a different time, in step S207 the worker creates a report. The operation of the flowchart then ends.
• the sound collector 30 includes a sound collection section 31, a fixed section 34, and an extension section 35.
• the escalator 1 may also include the sound collector 30.
• the fixed section 34 is fixed to the floor support beam 3a.
• the inventor attached a sound pressure meter to the floor support beam 3a, the end beam 3b, and the end vertical beam 3c, and compared the sound pressure measurements. The results showed that the sound pressure level varied depending on the installation location. Based on the results of this comparative experiment, the distance from the driver 5 to the end beam 3b or the end vertical beam 3c varies depending on the model of passenger conveyor, which may result in a wide range of measured values. Meanwhile, for maintenance reasons, the floor support beam 3a is typically located near moving equipment such as the driver 5, regardless of the model. Because the fixed section 34 is fixed to the floor support beam 3a, the sound collector 30 can more reliably collect abnormal sounds generated by the operation of the passenger conveyor.
• the extension portion 35 extends horizontally upward from the connection point 34d on the lower side of the fixed portion 34.
• the sound collection portion 31 is located above the connection point 34d. Therefore, even if rainwater flows down from the floorboard support beam 3a and the fixed portion 34, the rainwater will fall at the connection point 34d due to gravity. This prevents rainwater from entering the sound collection portion 31 via this path. As a result, the soundness of the sound collector 30 can be improved when it is installed.
• the sound collector 31 also includes a microphone 31a and a sound collection substrate 31b.
• the sound collector 30 is primarily required to detect abnormal sounds generated by the drive unit 5, reducer 6, brake device 7, V-belt 8, and drive chain 11.
• the microphone 31a is attached facing the drive unit 5. This allows the microphone 31a to more reliably collect abnormal sounds.
• the fixing part 34 has a fixing hole 34a which is a potbelly hole. Because the sound collector 30 is attached to the floorboard support beam 3a, it can be removed so as not to get in the way of maintenance work in the machine room 4. Because the fixing hole 34a is a potbelly hole, it can be removed via the large hole 34c, making the work easier, and can be firmly fixed by fastening it with a bolt or the like via the small hole 34b.
• the sound collector 30 also includes an upper protective portion 36. This prevents rainwater from hitting the sound collector 31 even if it falls from above.
• the fixed portion 34, extension portion 35, and upper protective portion 36 are molded integrally. This makes it easy to manufacture the sound collector 30.
• the sound collector 30 also has an attachment section 37.
• the attachment section 37 which is a mounting housing 33, has an attachment plate 38, a pair of side plates 39, and a lower plate 40.
• the sound collection section 31 is placed in storage space A, which is surrounded by the attachment section 37, the upper protective section 36, and the extension section 35. This prevents the sound collection section 31 from coming into contact with rainwater and causing damage.
• a wire inlet 40a is provided in the lower plate 40.
• the storage space A requires a hole through which a signal line, which is a line drawn from the sound collection board 31b and transmits sound collected by the sound collection section 31 to the outside, can pass.
• the power line supplied to the sound collection board 31b also passes through the wire inlet 40a.
• a fixing plate 41 is provided on each of the pair of side plates 39.
• the fixing plate 41 extends to the side opposite the storage space A and is fixed to the extension portion 35. Therefore, the structure for attaching the mounting portion 37 can prevent rainwater from entering the storage space A.
• the sound collector 31 is located between the driver 5 and the folded portion of the step 9 on the horizontal projection plane. Therefore, the sound collector 30 can collect the sound of the driver 5 as well as the sound of the step 9 moving.
• the inspection system 100 also includes an inspection device 20.
• the inspection device 20 includes a recording unit 24 and a recording control unit 25.
• the recording control unit 25 causes the recording unit 24 to record for a start interval after the escalator 1, which serves as a passenger conveyor, begins its startup operation.
• the start interval includes the startup time from when the brake device 7 begins its release operation until the steps 9 reach a constant speed.
• the start interval and startup time are the times during normal operation.
• the inspection system 100 can collect sounds during normal operation.
• the escalator 1 is started only after it has been confirmed that there are no disturbing passengers nearby. Therefore, the inspection system 100 and the inspection device 20 can easily collect sounds from the passenger conveyor in situations with few disturbances.
• the recording control unit 25 causes the recording unit 24 to record for the stop interval after the escalator 1, which is the passenger conveyor, begins to stop.
• the stop interval is the time during normal operation.
• the inspection system 100 can collect sounds during normal operation.
• the escalator 1 is stopped only after it has been confirmed that there are no passengers nearby who could cause disturbances. Therefore, the inspection system 100 and the inspection device 20 can easily collect sounds from the passenger conveyor in situations with few disturbances.
• the inspection device 20 also includes a signal receiving unit 23.
• the recording control unit 25 causes the recording unit 24 to start recording when the signal receiving unit 23 receives a brake release signal or a brake activation signal.
• the sounds collected by the inspection device 20 are the sounds made when a part of the equipment, such as the drive machine 5, is actually rotating or moving. If recording were to start based on a signal that operates the drive machine 5 at startup, it would be impossible to capture the sounds made when the equipment is actually moving until the startup conditions are met.
• the inspection device 20 can record reliably and with sufficient timing. Furthermore, by starting recording when a brake activation signal is received, the inspection device 20 can start recording just before the brake device 7 generates braking force.
• the start time is set to within 2 seconds.
• the constant speed time is set to within 8 seconds.
• the stop interval is set to within 2 seconds. While these times are longer than the target start or stop operation time, they are not too long, but are necessary and sufficient to detect abnormalities. This makes it possible to save storage capacity for saving recorded information and communication capacity for transmitting recorded information.
• the inspection system 100 also includes a sound collector 30 and a server.
• the server includes at least one of a first server 101 and a second server 102.
• the inspection device 20 further includes a memory unit 21 and a communication unit 22.
• the server sends an inquiry notification specifying a timing to the inspection device 20.
• the inspection device 20 sends recorded information at the specified timing to the server. Therefore, the inspection system 100 allows workers in remote locations to listen to recorded information at any timing. As a result, inspections can be performed by workers using sound without having to go to the site.
• the inspection device 20 also includes an abnormality detection unit 26.
• the abnormality detection unit 26 detects an abnormality and issues an alert if the sound pressure of the recorded sound exceeds a threshold. For example, the alert is sent to a server. Therefore, if an abnormality is detected, the inspection device 20 can notify the outside world.
• the company that maintains the passenger conveyor can immediately learn of the detected abnormality or signs of an abnormality. As a result, a prompt response can be made, improving the accuracy of passenger conveyor maintenance.
• the inspection device 20 also includes a threshold creation unit 28.
• the threshold creation unit 28 creates new thresholds from the audio recording information for the most recent reference period. This allows the inspection system 100 to flexibly respond to conditions that gradually change over time, enabling it to detect abnormalities.
• the fixing jig 32 does not have to be integrally molded as long as it has the functions of the fixing portion 34, extension portion 35, and upper protective portion 36.
• the function of the recording unit 24 may also be provided on the sound collection board 31b.
• the recording control unit 25 controls the timing at which the sound collection board 31b records sound.
• inspection system 100 of this first embodiment can also be applied to passenger conveyors other than escalators.
• FIG. 14 is a hardware configuration diagram of the inspection device according to the first embodiment.
• Each function of the inspection device 20 can be realized by a processing circuit.
• the processing circuit includes at least one processor 1000a and at least one memory 1000b.
• the processing circuit includes at least one dedicated hardware 2000.
• each function of the inspection device 20 is realized by software, firmware, or a combination of software and firmware. At least one of the software and firmware is written as a program. At least one of the software and firmware is stored in at least one memory 1000b.
• the at least one processor 1000a realizes each function of the inspection device 20 by reading and executing the program stored in the at least one memory 1000b.
• the at least one processor 1000a is also called a central processing unit, processing unit, arithmetic unit, microprocessor, microcomputer, or DSP.
• the at least one memory 1000b is a non-volatile or volatile semiconductor memory such as RAM, ROM, flash memory, EPROM, or EEPROM, a magnetic disk, a flexible disk, an optical disk, a compact disk, a minidisk, a DVD, etc.
• the processing circuit includes at least one dedicated hardware 2000
• the processing circuit is realized, for example, as a single circuit, a composite circuit, a programmed processor, a parallel programmed processor, an ASIC, an FPGA, or a combination thereof.
• each function of the inspection device 20 is realized individually by a processing circuit.
• each function of the inspection device 20 is realized collectively by a processing circuit.
• the functions of the inspection device 20 may be implemented by dedicated hardware 2000, with the remaining functions implemented by software or firmware.
• the functions of the memory unit 21 may be implemented by a processing circuit as dedicated hardware 2000, and functions other than those of the memory unit 21 may be implemented by at least one processor 1000a reading and executing a program stored in at least one memory 1000b.
• the processing circuit realizes each function of the inspection device 20 using hardware 2000, software, firmware, or a combination of these.
• the functions of the sound collection board 31b, control panel 13, first server 101, and second server 102 may also be realized by processing circuits equivalent to the processing circuits that realize the functions of the inspection device 20. Furthermore, the functions of the first server 101 and the second server 102 may be provided in the second server 102 and the first server 101, respectively.
• Appendix 1 An apparatus installed inside a passenger conveyor machine room, A sound collection unit that detects surrounding sounds; a fixed portion fixed to a floor board support beam that supports a floor board that closes an upper portion of a machine room of the passenger conveyor; an extension portion that extends from the fixed portion toward a driving machine of the passenger conveyor and to which the sound collecting portion is attached; A hearing aid equipped with: (Appendix 2) The fixing portion is fixed to a side portion of the floor board support beam that extends downward from an upper surface portion that supports the floor board, the extension portion extends upward in the horizontal direction from a connection point below the center of the fixed portion, The sound collection unit is attached to the extension unit so as to be positioned above the connection point.
• Attachment 1 The hearing aid described in claim 1.
• the sound collection unit is a microphone having an element for detecting sound; a sound collection board to which the microphone is attached and which outputs the sound detected by the microphone as an electrical signal; Including, The microphone is attached facing the driver.
• Attachment 2. A hearing aid according to claim 2. (Appendix 4)
• the fixing portion is a pothole formed above the connection point, and is a fixing hole through which a bolt passed through the floor board support beam can pass. 4.
• the sound collector according to any one of Supplementary Note 2 to Supplementary Note 4, further comprising: (Appendix 6)
• the connection point is a lower end of the fixed portion fixed to the floor board support beam, the upper protective portion extends from an upper end of the extension portion,
• the fixing portion, the extension portion, and the upper protection portion are integrally molded. 6.
• the mounting portion is a mounting plate to which the sound collecting unit is attached; a pair of side plates extending from the mounting plate in a direction in which the sound collecting unit is attached, facing each other, and each fixed to the extension portion; a lower plate extending from the mounting plate below the sound collection unit in a direction in which the sound collection unit is attached and connected to each of the pair of side plates; and the sound collection unit is disposed in a storage space surrounded by the upper protective unit, the extension unit, the mounting plate, the pair of side plates, and the lower plate,
• the lower plate is provided with a wire inlet through which a signal line drawn from the sound collecting unit passes.
• Each of the pair of side plates has a fixing plate extending from an end opposite to the mounting plate toward the opposite side to the storage space, The fixing plate is fixed to the extension portion while being in contact with the extension portion.
• the hearing aid described in appendix 7. (Appendix 9) the sound collection unit is located between the driving machine and a turning portion of a step of the passenger conveyor on a horizontal projection plane; 9. The hearing aid according to any one of claims 1 to 8.
• a truss that configures a passenger conveyor machine room inside; a driving machine for driving the steps of the passenger conveyor; a floor plate that opens and closes an opening above the driving machine in the machine room; a sound collector provided inside the machine room for collecting sound; Equipped with the truss has a floor panel support beam that supports a part of the floor panel at an upper surface portion above the driving machine and has a through hole in a side surface portion that extends downward from the upper surface portion,
• the sound collector is A sound collection unit that detects surrounding sounds; a fixing portion fixed to the floor board support beam in the through hole; an extension portion that extends from the fixed portion toward the driving machine of the passenger conveyor and to which the sound collecting portion is attached; It had Passenger conveyor.
• the through hole is opened closer to the driver than the central portion of the floor board support beam. 11.
• the sound collector disclosed herein can be used to inspect escalators.

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• 2024
  • 2024-02-29 WO PCT/JP2024/007509 patent/WO2025182002A1/ja active Pending
  • 2024-02-29 JP JP2024513851A patent/JP7498879B1/ja active Active

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