Detailed Project Report (DPR) on Elevator (Lift) Manufacturing Plant (1100 Numbers per year)

ELEVATOR (LIFT) MANUFACTURING PLANT

[EIRI/EDPR/4634] J.C.: 2851XL

An elevator system is a vertical transport vehicle that efficiently moves people or goods between floors of a building. They are generally powered by electric motors. The most popular elevator is the rope elevator. In the rope elevator, the car is raised and lowered by transaction with steel rope. Elevators also have electromagnetic brakes that engage, when the car comes to a stop. The electromagnetic actually keeps the brakes in the open position. Instead of closing them with the design, the brakes will automatically clamp shut if the elevator loses power. Elevators also have automatic braking systems near the top and the bottom of the elevator shaft. Many modern elevators are controlled by a computer. The computers job is to process all of the relevant information about the elevator and turn the motor correct amount to move the elevator car in correct position.

In order to do this the computer needs to know at least three things those are where people want to go where each floor is where the elevator car is Finding out where people want to go is very easy. The buttons in the elevator car and the buttons in each floor are all wired to the computer, when anyone presses these buttons, the computer logs this request.

COST ESTIMATION

Plant Capacity            1100 Nos./Year  

Land & Building (8000 sq.mt.)    Rs. 1.07 Cr    

Plant & Machinery                    Rs. 3.94 Cr 

Working Capital for 2 Months    Rs. 8.31 Cr 

Total Capital Investment          Rs. 13.63 Cr 

Rate of Return                          25%

Break Even Point                      53%

CONTENTS

INTRODUCTION

IN ORDER TO DO THIS THE COMPUTER NEEDS TO KNOW AT LEAST THREE THINGS THOSE ARE:

HISTORY OF ELEVATOR

FIG. 1.1 (STANDARD ELEVATOR)

FIG. 1.2 (ELEVATORS IN HOSPITAL)

ELEVATOR SYSTEM OVERVIEW

DESCRIPTION 

METHODOLOGY:

ELEVATOR TECHNOLOGY-

TYPES OF ELEVATOR CONTROL SYSTEMS:

SINGLE AUTOMATIC OPERATION:

SELECTIVE COLLECTIVE OPERATION:

GROUP AUTOMATIC OPERATION:

HYDRAULIC ELEVATORS OPERATION-

FIG. 2.1 HYDRAULIC LIFT

THE CABLE SYSTEM-

GEARED VERSUS GEARLESS ELEVATORS

FIG. 2.2 DETAILED VIEW OF ERECTION

ELEVATOR SAFETY MECHANISM:

THE ROPE SYSTEM:

SPEED GOVERNOR:

ELECTROMAGNETIC BRAKES:

SEQUENTIAL LOGIC CIRCUITS:

COMPONENTS OF ELEVATOR

ELEVATOR FABRICATION:

FIG. 3.1 HOSITWAY OF A 6 STORYED BUILDING

MARKET POSITION

INDIA ELEVATOR MARKET OVERVIEW:

INDIA ELEVATOR MARKET KEY PLAYERS

DESIGN SPECIFICATIONS:

CAR HEIGHT AND OVERHEAD CLEARANCE:

PLATFORM CONFIGURATION:

NUMBER OF STOPS:

FIG. 3.2 MODERN DAY MOTOR

TYPES OF MATERIALS USED AND IT’S PROPERTIES:

ELEVATOR CAR: STAINLESS STEEL/3CR12

GUIDE RAILS/HAND RAILS: STEEL E235B

SUSPENDING ROPES: UNALLOYED CARBON STEEL (CARBON 0.4-0.8 %)

CONTROLLING METHODS

FIG. 4.1 MANUAL PUSHBUTTON ELEVATOR CONTROLS

FIG. 4.2 OTIS 1920’S CONTROLLER

GENERAL CONTROLS

A TYPICAL MODERN PASSENGER ELEVATOR WILL HAVE:

FIG.4.3 TYPICAL FRIEGHT ELEVATOR CONTROL

SOME ELEVATORS MAY HAVE ONE OR MORE OF THE FOLLOWING:

FIG. 4.4 DUAL DOOR OPEN AND CLOSE DOOR BUTTONS

FIG. 4.5 SIGNAL BUTTON

EXTERNAL CONTROLS

FIG. 4.6 AN EXTERNAL CONTROL PANEL

THE ELEVATOR ALGORITHM

RELAY LOGIC ELEVATOR

CONTROLLER

THE PRIMARY FUNCTION OF THE ELEVATOR CONTROLLER

YPES OF ELEVATOR CONTROLLERS:

1- RELAY BASED CONTROLLER (ELECTROMECHANICAL SWITCHING)

FIG.4.7 RELAY BASED CONTROLLER (ELECTROMECHANICAL SWITCHING)

SOLID-STATE LOGIC TECHNOLOGY

FIG.4.8 SOLID-STATE LOGIC TECHNOLOGY

PLC CONTROLLER (COMPUTER BASED TECHNOLOGY)

FIG.4.9 PLC CONTROLLER (COMPUTER BASED TECHNOLOGY)

COMPUTER BASED CONTROLLERS ARE SUITABLE FOR THE FOLLOWING:

ELEVATOR CONTROL SYSTEM SEQUENCE DIAGRAMS

1- FROM THE POINT OF VIEW OF AN INDIVIDUAL USER:

DISCRETE CONTROL AND COMMUNICATION INTERFACES IN ELEVATOR CONTROL SYSTEM:

UNDER THIS TITLE, (5) COMPONENTS AS FOLLOWS:

CAR OPERATING PANEL COP

FIG.4.12 OPERATING PANEL

CAR OPERATING PANEL-

FIG.4.13 CAR OPERATING PANEL COP BUTTONS

A- DOOR-CLOSE-BUTTON

B- DOOR-OPEN-BUTTON

C- ALARM BUTTON

D- FAN BUTTON

E- OVERLOAD INDICATOR

F- CAR POSITION INDICATOR/DIRECTION INDICATOR

G- FIREMAN BUTTON

H- FLOORS BUTTON

I- INSTRUCTION PLATE

FIG.4.15 CONTROLLER CABINET

COMMUNICATIONS INTERFACE

A- STANDARD PHONE

FIG.4.16 STANDARD PHONE

B- HANDS FREE ADA PHONE

FIG.4.17 HANDS FREE ADA PHONE

SUPERVISORY CONTROL PANEL

FIG.4.18 SUPERVISORY CONTROL PANEL

SPECIAL OPERATING MODES FOR ELEVATOR CONTROL SYSTEM

1- ANTI-CRIME PROTECTION (ACP)

2- UP PEAK (MIT)

3- DOWN PEAK

SABBATH SERVICE (SHO)

FIG.4.20 SABBATH SERVICE

4- INDEPENDENT SERVICE (ISC) 

5- INSPECTION SERVICE (INS)

6- FIRE SERVICE MODE (EFS)

7- MEDICAL EMERGENCY/'CODE BLUE' SERVICE (EHS)

8- EMERGENCY POWER OPERATION (EPO)

CONTROL ROOM ELECTROMECHANICAL REQUIREMENTS

ELEVATOR MODERNIZATION

FIG.5.1 AN ELEVATOR TEST TOWER

USES OF ELEVATORS

BRIEF DESCRIPTION OF PROJECT & PRODUCT

ABOUT THE LIFT AND THEIR COMPONENTS

1) LIFT COMPONENTS

PLAN AND SECTION OF A PASSENGER ELEVATOR

I) HOIST WAY OR SHAFT

II) MACHINE ROOM

III) LIFT PIT

IV) OVERHEADS

V) COUNTERWEIGHT

VI) GUIDE RAILS

VII) BUFFERS

2) CLASSIFICATION

I) DRUM TYPE

II) TRACTION TYPE 

GEARLESS TRACTION ELECTRIC ELEVATORS

GEARED TRACTION ELEVATORS

TYPES OF COMMERCIAL LIFTS AND THEIR USES

1. TRACTION LIFTS

2. GOODS LIFTS

3. LOW PIT LIFTS

4. FREIGHT ELEVATORS:

5. DUMBWAITER ELEVATOR:

MANUAL ELEVATOR DOOR: 

AUTOMATIC DOORS: 

MS THREE FOLD TELESCOPIC ELEVATOR DOOR

STAINLESS STEEL AUTO ELEVATOR DOOR

GLASS ELEVATOR DOOR

COLLAPSIBLE ELEVATOR DOOR

IMPERFORATE ELEVATOR DOOR

IMPERFORATE ELEVATOR DOOR

G. P. BRACKET

DOOR LOCK

GUIDE SHOE

SAFETY BLOCK

SPRING BUFFERS

ELEVATOR COUNTER WEIGHT

ELEVATOR RETIRING CAM

ELEVATOR DOOR HEADERS

ELEVATOR GUIDE RAILS

ELEVATOR INSPECTION BOXES

PASSENGER ELEVATORS

PASSENGER ELEVATORS MAIN FEATURES

PASSENGER ELEVATORS - SAMPLE DRAWING

HOME ELEVATOR

EXPLAINING ELEVATOR COMPONENTS

ELEVATOR RAILS

CABIN

SPEED GOVERNORS

ELEVATOR SHAFT AND BUFFERS

DOORS

SAFETY DEVICE

SAFETY SYSTEMS IN ELEVATORS

OVER SPEED GOVERNOR

DOOR SENSORS

DOOR & DOOR LOCK

OVERLOAD SENSOR

AUTOMATIC RESCUE DEVICE

BUFFER SPRINGS

INTERCOM

OVER TRAVEL PROTECTION

MACHINERY AND EQUIPMENT

PILLAR/VERTICAL DRILL MACHINE

CUT OFF SAW MACHINE

GRINDING   MACHINE

MANUAL DRILL MACHINE

GENERAL TOOL KIT

GLASS CUTTER

PRODUCTION PROCESS FLOW

BRIEF DESCRIPTION OF THE PROCESS FLOW IS AS FOLLOWS:

PROCUREMENT OF RAW MATERIALS

CUTTING

DRILLING AND SCREW FITTING

GRINDING

GLASS FITTING

QUALITY CHECK

PACKAGING

DELIVERY AND PAYMENT

ELEVATOR MANUFACTURERS

ELIVATORS PARTS MANUFACTURERS

D.G. SET

LABORATORY TESTING EQUIPMENTS

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

ADDRESSES OF FINANCIAL INSTITUTIONS

LOCATION OF SITE

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

DEPRECIATION:

FIXED ASSETS:

WORKING CAPITAL:

BREAK-EVEN POINT:

OTHER FIXED EXPENSES:

MARGIN MONEY:

TERM LOANS:

TOTAL LOAD:

LAND AREA/MAN POWER RATIO:

UTILITIES 

POWER

WORKING 

TOTAL MANPOWER AND PAYROLL 

UTILITIES

PRODUCTS PHOTOGRTAPH

PLANT LAYOUT

ORGANIZATION CHART

LIST OF DOCUMENTS REQUIRED TO GET FOR LICENSES

DOCUMENTS:

OTHER LICENSES REQUIRED FOR THE SETUP:

PROJECT IMPLEMENTATION SCHEDULE

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)