Elevator Counterweight

Elevators are highly complex systems formed by the combination of many different components such as elevator cabin, cable system, reel, and Deceleration weight. Elevator counterweight, which refers to the maximum amount of load that an elevator can carry, is calculated by taking into account the durability and safety of these components. In an elevator, the cabin and the counterweight are placed on a shaft located in the vertical plane, which will provide protection against any interference. The cabin and counterweight are supported by guide rails to prevent a collision or unintentional friction and maintain a linear trajectory.

The elevator car is pulled by means of metal cables driven by a pulley system connected to the motor. The counterweight fixed to the shaft to make it easier for the engine to move the cabin and to achieve a higher movement speed by saving energy moves in the opposite direction to this when the cabin moves up or down.

The elevator counterweight covers the weight of the passengers in the elevator cabin, as well as the total weight of other loads to be transported, such as items, equipment, and other objects. In addition to the total weight of these loads, the elevator counterweight also includes a safety margin necessary for the safe operation of the elevator. The purpose of this safety margin is to provide protection against unexpected load increases or system errors.

The elevator counterweight is calculated by taking into account local and international safety standards during the design and configuration phase of the elevator and is of extremely critical importance for the effective and safe operation of the elevator. For this reason, it is essential for elevators to undergo safety and performance tests and to carry out regular maintenance and inspection.

Elevator counterweight is one of the materials used in elevator systems and determines the carrying capacity of the elevator. The elevator counterweight consists of the elevator carcass and the elevator filler weight.

The elevator counter frame is made of metals. It holds the elevator filler weights like a cage. It is a steel construction that prevents the displacement of the filler weights because of the weight carcass falling during the operation of the elevator or at the time of an accident.

Elevator filler weights are called the masses contained in the weight frame. The most used filler weights are counterweights made of metal and concrete. Iron sheet plate, cast iron, pressed iron weight, lead and different metal alloys can also be used to produce high-quality filling weights with different load-bearing capacities for elevators. Filler weights made of metals ensure the optimum use of the available space in the mechanical lifting system due to their high specific gravity.

Elevator filler weight, which is widely used in elevator counterweights, concrete filler weights are at the beginning of the materials due to cost advantages. However, this type of filler weights are used in elevators with low carrying capacity due to low material density.

Other materials that are often preferred in elevator counterweights are iron sheet plates and cast iron. Among the main reasons why metals are preferred are durability and high density. Dec. In some cases, it is used in elevator filler weights in lead due to its high specific gravity despite its high economic cost. It is especially preferred in buildings where more load-bearing capacity is needed.

The choice of the material to be used in the elevator counterweight depends on various factors such as design requirements, building structure, load-bearing capacity, and cost. Generally, durable, dense, and cost-effective materials are preferred to ensure the safe and effective operation of the elevator.

The counterweight has an important function in the movement of the cabinet and the counterweight inside the elevator shaft. Incorrectly selected counterweight mass can lead to serious risks and may cause accidents that may lead to injury or death.

The counterweight, a mass that provides movement through friction, is calculated by adding 40% to 50% of the declared load to be carried in the cabin. A correctly selected elevator counterweight ensures stable and safe operation of the elevator system and prevents problems of excessive acceleration or stalling by balancing the movement of the elevator. In addition, it also saves energy by reducing energy consumption, since it allows the engine to work more efficiently.

However, if the counterweight is not selected properly, serious risks may arise in the elevator system. Insufficient counterweight can cause the elevator to overspeed and lose control, while excessive counterweight can cause the elevator to slow down and underperform. In both cases, the safety of the elevator may be compromised and may lead to accidents.

For this reason, it is important to calculate the counterweight correctly in elevators and create it with the appropriate materials. This ensures the safe and efficient operation of the elevator and guarantees the safe transportation of users.

Two methods are usually used to determine the counterweight mass.

In the first method, a load equal to half the carrying capacity of the cabin is placed and the cabin is moved up and down while it is at half load. When the cabinet and the counterweight are side by side, at least 3 measurements are made for 3 phases using a clamp ammeter. In the light of the measurements made, it can be said that the counterweight balance is appropriate for situations where the current does not exceed 1 Ampere. If the current exceeds 1 Ampere, the counterweight balance is not suitable. That is, if the cabinet draws a lower current while moving downstream in a half-loaded state, weight should be added to the counterweight. In cases where the cabinet is half-loaded, the weight should be removed from the counterweight in case of excessive current draw while the cabinet is moving downwards. It is important to select a contactor suitable for the current engine power before this test. If a large contactor is selected, the current values drawn may be misleading.

In the second method, a load equal to half the carrying capacity of the cabin is placed and the energy is cut off by bringing the cabin and the counterweight side by side. Then the brake lever is opened, and the flywheel is turned up and down. If the flywheel rotates in both directions with the same ease, it can be said that the counterweight balance is appropriate. However, if the flywheel rotates comfortably to the cabin side, the counterweight is insufficient, and weight should be added. If the flywheel rotates comfortably to the side of the counterweight, the counterweight is too much, and the weight should be removed. If the counterweight is not suitable, the ropes on the drive pulley run the risk of slipping uncontrollably. This risk exists even if the people riding the elevator do not give the movement command.

In general, it is possible to say that the overall quality of counterweights is determined by three main factors: the mobility of the counterweight, the logistical convenience it offers and the flexibility it has. To briefly explain these features:

The elevator counterweight provides balance by applying an equal and opposite force against the movement of the elevator cabin. Mobility is a feature that depends on the suitability of the design and structure that allows the weight to move smoothly and quickly. Adequate mobility improves the energy efficiency of the elevator and ensures a safe journey.

High-quality counterweights are easy to transport and install thanks to their light weight and convenient dimensions. This can speed up the construction process and reduce labor costs. In addition, proper packaging and transportation of weights reduces possible risks in the workplace and ensures safety.

In addition to these three basic features, elevator weights should not contain flammable materials, should not be oxidized, and the tensile strength of iron elevator weights should be at least 350 N/mm2, and the compressive strength of iron reinforced concrete elevator weights should be at least 32 N/ mm2. Counterweights can be in different shapes and designs. Each counterweight is determined by the weight it needs to balance. Dimensional accuracy is another important feature of the counterweight since it is an element that determines how efficiently it can be used.

The counterweight systems used in elevators also bring with them some risks. Being aware of these risks and taking the necessary precautions are very important to ensure the safe operation of the elevator. Some important risks that you may face in relation to the counterweight in elevators are as follows:

Counterweight Imbalance

If the counterweight is not balanced correctly, the stability of the elevator system may be compromised. The imbalance can prevent the elevator from working properly, lead to sudden stops and jerks, or make it difficult to control its movement. This situation may cause passengers to face the risk of falling or injury.

Insufficient Counterweight

Insufficient counterweight can reduce the carrying ability of the elevator and lead to overload. This can lead to damage and malfunction of elevator components such as cables, pulleys and motors operating under excessive stress.

Counterweight Control

Timely and periodic checking of the counterweight ensures that the weight distribution is correct and ensures a safe elevator operation. If control and maintenance are not carried out regularly, the counterweight system may malfunction and lead to unexpected accidents.

Excessive Weight and High Speed

If the counterweight is too heavy in the elevator system or moves at high speed, mechanical stress increases and may lead to excessive strain on the system. This, in turn, can lead to wear, damage and even malfunction of components.

Counterweight Safety

Considering all the risks, regular checking, maintenance, and operation of the elevator counterweight system in accordance with safety standards plays a critical role both in terms of ensuring the safety of passengers and ensuring the long service life of elevators.

The counterweight is an important component of elevator systems and has a large number of benefits. Here are some of the benefits of using a counterweight:

Makes It Easier to Lift Weights

The counterweight makes it much easier for the engine to move up and down the cabin. Thanks to the counterweight, the engine does not need much force to move the cabin up and down. Assuming that the cabin and its contents are heavier than the counterweight, it will be enough for the engine to Decouple the weight difference between the two and generate some extra force to overcome the friction on the pulleys.

Provides Security

The counterweight is very important to ensure safety in the elevator system. Because less power is used, less tension is generated on the cables, which makes the cables last longer while making the elevator safer. In addition, the counterweight system also prevents sudden stops, jerks or uncontrolled movements of the elevator, providing a safer journey.

Increases the Carrying Capacity

The counterweight system increases the carrying capacity of the elevator. Thanks to the balancing of part of the load to be carried in the elevator cabin by the counterweight, it may be possible to carry more load. This increases the usability and efficiency of the elevator.

Provides Energy Efficiency

The engine needs a lot of energy to move the cabin. The counterweight system reduces the amount of energy that the engine must expend to move the cabin upwards. Thus, the engine consumes less energy to move the cabin the same distance. Less energy consumption means lower costs and maintenance costs.

Acts as an Additional Energy Source October

The elevator counterweight reduces the amount of braking that the elevator needs to use. Thanks to the counterweight, it will be very easy to pull up a heavily loaded elevator car, and since there is a counterweight that will stop it on the return trip, it will prevent it from hitting the ground quickly.

Space Saving

Elevator counterweight also provides space saving in elevator systems. The counterweight system located inside the elevator shaft is designed in accordance with the movement of the cabin. Thanks to this, the usable space of the elevator can be used more efficiently.