Elevator braking device, powerhead and methods

1. A brake system for use with a rotating cable drum around which a cable operably coupled to an elevator car of an elevator is wound, comprising:

a brake rotor operably attachable to the cable drum to rotate with cable drum;

a brake caliper assembly including:

a brake member for selectively engaging with the brake rotor;

a brake member actuation lever having a first position in which the brake rotor is free to move relative to the brake member and a second position in which the brake member is biased into engagement with the brake rotor and the brake rotor is prevented from moving relative to the brake member under the weight of the elevator car and any rated load;

a biasing member acting on the brake member actuation lever biasing the brake member actuation lever from the first position towards the second position;

a speed sensing arrangement for sensing a rotational speed of the cable drum;

a latch arrangement having a first orientation maintaining the brake member actuation lever in the first position and a second orientation releasing the brake member actuation lever such that the brake member actuation lever can transition from the first position to the second position, the latch arrangement transitioning from the first orientation to the second orientation when the speed sensing arrangement senses that the rotational speed of the cable drum is at least a predetermined rotational speed; and

wherein:

the brake member actuation lever and latch arrangement includes a catch arrangement therebetween, the catch arrangement including:

a projection member;

a projection member holder including a first cavity holding the projection member; and

a second cavity provided by the brake member actuation lever sized to receive the projection member therein;

in the first orientation, the projection member extends into the first and second cavities inhibiting motion of the brake member actuation lever from the first position to the second position;

in the second orientation, the projection member is removed from the second cavity and the brake member actuation lever is permitted to transition from the first position to the second position.

2. The brake system of claim 1 , wherein an actuator is coupled to the latch arrangement to drive the latch arrangement from the first orientation to the second orientation when the predetermined rotational speed is sensed.

3. The brake system of claim 2 , wherein the speed sensing arrangement includes an encoder arrangement including a plurality of marks formed on the brake rotor and a sensor for sensing motion of the marks on the brake rotor to determine the rotational speed of the cable drum.

4. The brake system of claim 2 , wherein the catch arrangement includes a blocking member having a blocking position in which the blocking member maintains the projection member in the first and second cavities in the first orientation and that is moveable relative to the projection member holder to an unblocking position in which the projection member is unblocked and the projection member is allowed to be removed from the second cavity in the second orientation.

5. The brake system of claim 4 , wherein the projection member and second cavity have a cooperating interface that is configured such that when the blocking member unblocks the projection member the spring force provided by the biasing member acting on the brake member actuation lever biasing the brake member actuation lever from the first position towards the second position drives the projection member out of the second cavity to release the brake member actuation lever to transition from the first position to the second position.

6. The brake system of claim 5 , wherein the cooperating interface is provided by cooperating tapers provided by the projection member and second cavity.

7. The brake system of claim 5 , wherein the cooperating interface is provided, at least in part, by the projection member having a curved surface.

8. The brake system of claim 5 , wherein the cooperating interface is provided, at least in part, by the projection member being spherical.

9. The brake system of claim 4 , wherein the blocking member is driven from the blocking position to the unblocking position by the actuator.

10. The brake system of claim 9 , further comprising a pivoting linkage between the blocking member and the actuator such that linear motion of the actuator along a first axis is converted into linear motion of the blocking member along a second axis.

11. The brake system of claim 2 , further comprising an overspeed controller connected to the actuator and configured to control actuation of the actuator, the overspeed controller including a backup battery for powering the actuator in the event of a main power failure.

12. The brake system of claim 11 , wherein the overspeed controller is a standalone controller configured to be interposed between a main controller of a powerhead of an elevator and to selectively supply power to the main controller, the overspeed controller configured to prevent supplying power to the main controller when an overspeed event is sensed.

13. A brake system for use with a rotating cable drum around which a cable operably coupled to an elevator car of an elevator is wound, comprising:

a brake rotor operably attachable to the cable drum to rotate with cable drum;

a brake caliper assembly including:

a brake member for selectively engaging with the brake rotor;

a brake member actuation lever having a first position in which the brake rotor is free to move relative to the brake member and a second position in which the brake member is biased into engagement with the brake rotor and the brake rotor is prevented from moving relative to the brake member under the weight of the elevator car and any rated load;

a biasing member acting on the brake member actuation lever biasing the brake member actuation lever from the first position towards the second position;

a speed sensing arrangement for sensing a rotational speed of the cable drum;

a latch arrangement having a first orientation maintaining the brake member actuation lever in the first position and a second orientation releasing the brake member actuation lever such that the brake member actuation lever can transition from the first position to the second position, the latch arrangement transitioning from the first orientation to the second orientation when the speed sensing arrangement senses that the rotational speed of the cable drum is at least a predetermined rotational speed;

an actuator coupled to the latch arrangement to drive the latch arrangement from the first orientation to the second orientation when the predetermined rotational speed is sensed; and

a controller connected to the actuator and configured to control actuation of the actuator and to activate the actuator when the predetermined rotational speed is sensed, the overspeed controller including a backup battery for powering the actuator in the event of a main power failure.

14. The brake system of claim 13 , wherein the controller is part of a controller configured to control other operations of the elevator.

15. The brake system of claim 13 , wherein if the controller senses a failure in the battery backup, the controller prevents operation of the elevator.

16. A powerhead for an elevator comprising:

a motor;

a cable drum operably driven by the motor;

a brake system comprising:

a brake rotor operably attachable to the cable drum to rotate with cable drum;

a brake caliper assembly including:

a brake member for selectively engaging with the brake rotor;

a brake member actuation lever having a first position in which the brake rotor is free to move relative to the brake member and a second position in which the brake member is biased into engagement with the brake rotor and the brake rotor is prevented from moving relative to the brake member under the weight of the elevator car and any rated load;

a biasing member acting on the brake member actuation lever biasing the brake member actuation lever from the first position towards the second position;

a speed sensing arrangement for sensing a rotational speed of the cable drum;

a latch arrangement having a first orientation maintaining the brake member actuation lever in the first position and a second orientation releasing the brake member actuation lever such that the brake member actuation lever can transition from the first position to the second position, the latch arrangement transitioning from the first orientation to the second orientation when the speed sensing arrangement senses that the rotational speed of the cable drum is at least a predetermined rotational speed;

the brake system being operably attached to the cable drum such that when the brake member actuation lever is in the first position the brake rotor is free to move relative to the brake member and when the brake member actuation lever is in the second position the brake member is biased into engagement with the brake rotor and the brake rotor is prevented from moving relative to the brake member inhibiting rotational motion of the cable drum;

an actuator coupled to the latch arrangement to drive the latch arrangement from the first orientation to the second orientation when the predetermined rotational speed is sensed; and

an overspeed controller connected to the actuator and configured to control actuation of the actuator, the overspeed controller including a backup battery for powering the actuator in the event of a main power failure.

17. A powerhead for an elevator comprising:

a motor;

a cable drum operably driven by the motor;

a brake system comprising:

a brake rotor operably attachable to the cable drum to rotate with cable drum;

a brake caliper assembly including:

a brake member for selectively engaging with the brake rotor;

a brake member actuation lever having a first position in which the brake rotor is free to move relative to the brake member and a second position in which the brake member is biased into engagement with the brake rotor and the brake rotor is prevented from moving relative to the brake member under the weight of the elevator car and any rated load;

a biasing member acting on the brake member actuation lever biasing the brake member actuation lever from the first position towards the second position;

a speed sensing arrangement for sensing a rotational speed of the cable drum;

a latch arrangement having a first orientation maintaining the brake member actuation lever in the first position and a second orientation releasing the brake member actuation lever such that the brake member actuation lever can transition from the first position to the second position, the latch arrangement transitioning from the first orientation to the second orientation when the speed sensing arrangement senses that the rotational speed of the cable drum is at least a predetermined rotational speed;

the brake system being operably attached to the cable drum such that when the brake member actuation lever is in the first position the brake rotor is free to move relative to the brake member and when the brake member actuation lever is in the second position the brake member is biased into engagement with the brake rotor and the brake rotor is prevented from moving relative to the brake member inhibiting rotational motion of the cable drum;

an actuator coupled to the latch arrangement to drive the latch arrangement from the first orientation to the second orientation when the predetermined rotational speed is sensed; and

a controller connected to the actuator and configured to control actuation of the actuator, the controller including a backup battery for powering the actuator in the event of a main power failure, the controller being configured to control the motor that drives the cable drum.

18. The powerhead of claim 17 , wherein the controller prevents actuation of the motor upon sensing a loss of main power, the controller activating the actuator upon the loss of main power.

19. The powerhead of claim 17 , wherein if the controller senses a failure in the backup battery, the controller prevents operation of the elevator.

20. A method of operating a brake system for an elevator comprising:

sensing a rotational speed of a cable drum of a powerhead of the elevator;

actuating a brake member to engage a rotor when the rotational speed of the cable drum is at least a predetermined rotational speed to engage a brake rotor operably attached to the cable drum, the brake rotor rotating with the cable drum, engagement of the brake member with the rotor reducing or stopping rotational motion of the rotor and cable drum;

transitioning a brake member actuation lever from a first position in which the brake rotor is free to move relative to the brake member and a second position in which the brake member is biased into engagement with the brake rotor and the brake rotor is prevented from moving relative to the brake member under the weight of the elevator car and any rated load when the predetermined rotational speed is sensed;

biasing the brake member actuation lever from the first position towards the second position;

transitioning a latch arrangement from a first orientation maintaining the brake member actuation lever in the first position to a second orientation releasing the brake member actuation lever such that the brake member actuation lever can transition from the first position to the second position, the latch arrangement transitioning from the first orientation to the second orientation when the speed sensing arrangement senses that the rotational speed of the cable drum is at least a predetermined rotational speed;

wherein transitioning the latch arrangement includes actuating an electrically powered actuator, wherein actuating an electrically powered actuator occurs upon a failure of main power and the electrically powered actuator is powered by a backup battery.

21. The method of claim 20 , further comprising:

monitoring the operational state of the battery backup; and

preventing operation of the elevator when the operational state of the battery backup has failed.