International University of Sarajevo

Faculty of Engineering and Natural Sciences

B.Sc. Department of Electrical and Electronics Engineering

Green Elevator

By

Oktay ÇAVUŞ
Orhan GAZI KEDEROĞLU

JUNE, 2013
This thesis submitted to the graduate school of engineering and natural sciences of
International University of Sarajevo

GREEN ELEVATOR

BY
OKTAY ÇAVUŞ (1210383)
ORHAN GAZI KEDEROĞLU (1210379)

IN PARTIAL FULFILLMENT OF REQUIREMENTS FOR

THE DEGREE OF BACHELOR OF SCIENCE IN
ELECTRICAL AND ELECTRONICS ENGINEERING

SARAJEVO, JUNE 2013

Approval of the Faculty of Engineering and Natural Science

________________________

Dean ( Prof. Dr. Fehim FINDIK)

We certify that this thesis satisfies all the requirements as a thesis for the degree of
Bachelor of Electrical and Electronics Engineering

_______________________

Head of Program (Asist. Professor Dr. Emir Karamehmedovic)

This is to certify that we have read this thesis and that in our opinion it is fully
adequate, in scope and quality, as a thesis for the degree of Bachelor of Engineering

______________________

Supervisor (Asist. Professor Dr. Emir Karamehmedovic)

_______________________

Co-Supervisor (Senior Assistant Tarık Namas)

Examining Committee Members (first name belongs to the chairperson of the jury
and the second name belongs to supervisor)

_______________________

_______________________

_______________________

Date:

ii
 I hereby declare that all information in this document has been obtained and
presented in accordance with academic rules and ethical conduct. I also declare that,
as required by these rules and conduct, I have fully cited and referenced all material
and results that are not original to this work.

Name, Last name : Oktay ÇAVUŞ

Signature : _________________

Name, Last name : Orhan Gazi KEDEROĞLU

Signature : _________________

iii
 ABSTRACT

Elevator is one of the systems which can be controlled by programmable

logic controller, PLC. Elevator was built to help people to move from one floor to
another without consuming a lot of energy. Besides, it’s also are used to move the
goods or even car upward or downward in many application. It’s a system which has
some basic operations with a few extra operations to make the system more reliable,
efficient and safe to use. There are two types of elevators depending on its
application and its place installed, these are hydraulic and cable lifted elevator. The
programmable logic controller, PLC, is the one of the best controller to handling this
system operation due to its reliability system. This thesis an application and
prototype for a water powered elevator using PLC control. It is a mechatronic’s
project which combine the knowledge of mechanical, electronical, electrical and
physical in the project. The subjects of this project is to design and implement an
energy-saving elevator by the help of potential and kinetic energy of water. This
system uses a solar-powered small pump, which push the water from lower capital
tank to the upper capital tank. The potential energy in upper tank help to occur a
kinetic energy for moving of the elevator’s counterweight tank and this tank balance
the elevator’s cabin. All of these components and control systems can be powered by
solar panels. Green elevator uses programmable logic controller for controlling
proximity switches, level switches, valves, buttons, lights and break mechanism.
These electrical components send a signal to PLC and PLC perceives and makes the
necessary procedures. The primary goal of the application and prototype are to use
water potential energy instead of large amount of electrical energy and to take
advantage of renewable energy sources.

iv
 CONTENTS
ABSTRACT ............................................................................................................... iv
CONTENTS ................................................................................................................ v
LIST OF TABLES ................................................................................................... vii
LIST OF FIGURES ................................................................................................. vii
LIST OF ABBREVIATIONS ................................................................................ viii
CHAPTER 1 - INTRODUCTION ............................................................................ 1
1.1 Problem Statement ........................................................................................ 1
1.2 Organization of Thesis .................................................................................. 3
CHAPTER 2 – ELEVATORS .................................................................................. 4
2.1 HISTORY OF ELEVATOR ......................................................................... 4
2.2 ELEVATOR (LIFT) ...................................................................................... 5
2.2.1 How an Elevator Works ......................................................................... 5
2.3 USES OF ELEVATORS ............................................................................... 7
2.3.1 Passenger Elevator ................................................................................. 7
2.3.2 Freight Elevator ...................................................................................... 8
2.3.3 Vehicle Elevator ..................................................................................... 8
2.3.4 Aircraft Elevator..................................................................................... 9
2.3.5 Boat Elevator .......................................................................................... 9
2.3.6 Dumbwaiter Elevator ............................................................................. 9
2.3.7 Paternoster Elevator ............................................................................. 10
CHAPTER 3 - SOLAR ENERGY .......................................................................... 11
3.1 WHAT ARE PHOTOVOLTAICS? ............................................................ 11
3.2 BENEFITS OF PHOTOVOLTAICS .......................................................... 11
3.3 TYPES OF PHOTOVOLTAICS ................................................................. 12
3.3.1 Hybrid Photovoltaic ............................................................................. 12
3.3.2 Monocrystalline Photovoltaic Panels.................................................. 13
3.3.3 Polycrystalline Photovoltaic Panels .................................................... 13
3.3.4 Amorphous (Thin Film) ....................................................................... 13

v
CHAPTER 4 - PLC (Programmable Logic Controllers) ..................................... 15
4.1 HISTORY OF PLC ..................................................................................... 15
4.2 INTRODUCTION TO PLC ........................................................................ 16
4.2.1 Basic Design of PLC ............................................................................ 17
4.2.2 Advantages and Disadvantages of PLC ............................................... 18
4.2.3 Inputs And Outputs For Green Elevator .............................................. 19
CHAPTER 5 - IMPLEMENTATION.................................................................... 20
5.1 GREEN ELEVATOR SYSTEM FEATURES............................................ 24
5.1.1 Cable Connection ................................................................................. 24
5.1.2 Algorithm of The System ..................................................................... 25
CHAPTER 6 - CONCLUSION ............................................................................... 26
REFERENCES ......................................................................................................... 31
APPENDİX ............................................................................................................... 32

vi
 LIST OF TABLES
Table 1 Annual energy consumption for different types of elevators .......................... 2
Table 2 Inputs and Outputs of System ....................................................................... 19
Table 3 Chosen Solar Panel Features ......................................................................... 29
Table 4 Chosen Water Pump Features ....................................................................... 29

LIST OF FIGURES

Figure 1 Elevator design by the German engineer Konrad Kyeser (1405) .................. 4
Figure 2 Passenger Elevator ......................................................................................... 7
Figure 3 Freight Elevator ............................................................................................. 8
Figure 4 Vehicle Elevator ............................................................................................ 9
Figure 5 Paternoster Elevator ..................................................................................... 10
Figure 6 Types Of Photovoltaic ................................................................................. 12
Figure 7 Hybrid Photovoltaic ..................................................................................... 12
Figure 8 Monocrystalline Photovoltaic ...................................................................... 13
Figure 9 Polycrystalline Photovoltaic Panels ............................................................. 13
Figure 10 Amorphous (Thin Film)............................................................................. 13
Figure 11 Performance of PV Panels ......................................................................... 14
Figure 12 Basic Design of PLC ................................................................................. 17
Figure 13 Laboratory tests ......................................................................................... 20
Figure 14 Pulley Mechanism ..................................................................................... 21
Figure 15 Green Elevator ........................................................................................... 21
Figure 16 Cabin .......................................................................................................... 22
Figure 17 PLC Input Connection ............................................................................... 24
Figure 18 PLC Output Connection ............................................................................ 24
Figure 19 Algorithm of the System ............................................................................ 25

vii
 LIST OF ABBREVIATIONS

CO2 : Carbon Dioxide

EL : Amount of consumed energy in a year (kWh)

Estandby : Amount of standby position energy

g : Gravity (9.81 m/s2)

h : Differential head (m)

ISO : International Standards Organization

KE : Kinetic energy

Kw : Kilowatt

Kw-h : Kilowatt hour

Kw-p : Kilowatt peak

P : Power of Motor (kW)

PE : Potential Energy

Ph : Power (kW)

PLC : Programmable Logic Controller

PV : Photovoltaic

q : Flow capacity (m3/h)

S : Total number of stop in a year

th : Cruise time

ρ : Density of fluid (kg/m3)

viii
 CHAPTER 1 - INTRODUCTION
The following of the thesis are mentioned the problems of elevators and their
analysis. These problems and their solution methods are explained in the following
three points.

1.1 Problem Statement

Uncontrolled use of energy and CO2 emission caused global warming and
environmental pollution problems. That’s why elevator systems stipulate to optimum
energy usage. Buildings account for 40% of the world’s energy consumption.
Elevators and escalators account for 2–10% of a building’s energy consumption,
which is the biggest problem for the elevators. Average power consumption of
elevator is given Table 1. The International Standards Organization (ISO) determined
the formula of annual energy consumption of elevators.

ISO’s formula is;

(Formula is taken from “Adrian OTETEA, Ascensori Eco – efficienza e modernizzazione, 2009-2010,
Milano Politechnic University, Milano”)

EL is the amount of consumed energy in a year (kWh); S is the total number

of stop in a year, P is the power of motor (kW); th is the cruise time.

Estandby includes door locks, cabin lights, cabin buttons, electric control
board, floor buttons and lights. Estandby position spends big amount of energy in an
elevator systems. As a result of the work of Swedish scientists found this amount
which is identified 58%. (1)

1
 The calculated annual energy
consumption
Cruise Height : 9m Cruise Height : 12m
Type of Elevators
Speed : 0.63m/s Speed : 1,0 m/s
Weight : 450 kg Weight : 630 kg
Indirect Hydrolic Elevators 350 kW 700 kW
(Motor 9-11 kW)

Gear ACC 350 kW 700 kW

200 kW 500 kW
(Motor 3.5-7.5 kW)

Gear VVVF 200 kW 400 kW

(Motor 3.5-6 kW)

Without Gear VVVF 150 kW 350 kW

(Motor 3-5 kW)
Table 1 Annual energy consumption for different types of elevators

The second problem is security of elevators. Elevator companies try to solve

different kinds of ways to these problems. Nowadays, the standardization institutes
check their systems, but when power of the elevators cut, any systems don’t work
and people have to wait electricity. Many buildings don’t have a generator in their
structure, this situation loss the time for people. In some cases this problem even be
dangerous for their lives.

The carrying capacity of elevator, which affect to size of elevator engine. If

carrying capacity increases, engine capacity and volume will increase. This situation
causes both more energy consumption and more costs.

2
1.2 Organization of Thesis

The concept of green design development was a solution for the energy crisis
and the environment pollution concern. Green design systems use renewable energy
sources and this situation decreases energy generation from fossil fuels. This project
produces its energy from solar panels and uses potential and kinetic energy of the
water. The annual energy consumption of the standard elevators are average 250kWh
over the world.

In this project, solar panels will be used for energy efficient and different
application fields (regions of electrical energy not being moved). Green Elevator can
produce its energy with to help of solar panels, wind turbines or hydro power. That’s
why it can build hard environmental conditions. For example; there are many
villages which are founded on the hills in Turkey and these villages have
transportation problems from one settlement to another because of rivers and cliffs
which affect people’s health, education and social life, because electricity doesn’t
carries these areas. This problem can solve with green elevator project which can
improve to build vertical and horizontal types. Horizontal type of green elevator can
use transportation to cross over on the river. Vertical type of green elevator can move
load or person from ground to hill. This project is very useful where there is no
electricity and hard environmental conditions.

When the standard elevator’s capacity wanted to increase, capacity of engine

and volume increase. This situation negatively affects the energy consumption and
costs, but if personal or load capacity wanted to increase in this project, just
dimension of elevator tanks will increase. Engine of the elevators are very expensive
and this project can decrease costs of elevators for bigger situation.

3
 CHAPTER 2 – ELEVATORS

This chapter treats a small history of elevators, elevators general concepts,

how elevator’s system works and introduces their different types of usages

2.1 HISTORY OF ELEVATOR

he first reference to an elevator is in

T the works of the Roman

architect Vitruvius, who reported
that Archimedes (c. 287 BC – c. 212 BC)
built his first elevator probably in 236 BC. In
some literary sources of later historical
periods, elevators were mentioned as cabs on
a hemp rope and powered by hand or by
animals. (2)

In 1853, American inventor Elisha

Otis demonstrated a freight elevator
equipped with a safety device to prevent
Figure 1 Elevator design by the
falling in case a supporting cable should German engineer Konrad Kyeser
(1405)
break. This increased public confidence in
such devices. Otis established a company for
manufacturing elevators and patented (1861) a steam elevator. In 1846, Sir William
Armstrong introduced the hydraulic crane, and in the early 1870s, hydraulic
machines began to replace the steam-powered elevator. The hydraulic elevator is
supported by a heavy piston, moving in a cylinder, and operated by the water (or oil)
pressure produced by pumps.Electric elevators came into to use toward the end of the
19th century. The first one was built by the German inventor Werner von Siemens in
1880. (3)

4
2.2 ELEVATOR (LIFT)
A lift known throughout the world is known as an elevator in the United
States. An elevator or lift is a transport device used to move goods or people
vertically, from one floor to another. The elevator turns electrical power into
mechanical (rotational) power. The elevator must pick up and drop off passenger as
efficiently as possible. If collection of elevator is used, a complex controller usually
controls them. There are many type of elevator or lift depending on the uses of it but
they all work in the same way. These are passenger elevator, freight elevator, vehicle
elevator, boat elevator, aircraft elevator, dumbwaiter, paternoster and others.

A lift / elevator is made up of 4 major components. The lift/elevator cab or

platform, the shaft or hoist way, the drive system and the counterweight. The cab is
moved vertically using either hydraulic piston or a pulley system. The weight of the
cab is balanced by counterweights so that the drive system uses minimal energy.

The elevator must fit within the given space requirements of the building. It
must be made large enough to deal with the normal daily traffic and to move the
necessary objects within the building. It cannot be made too large and, therefore,
affect the structure of the building itself. Possible restrictions on the weight carried
within the elevator may be determined from the size of the motor and the other
components within the elevator system. This weight limit must be large enough to
handle daily usage. (4)

2.2.1 How an Elevator Works

The elevator turns electrical power into mechanical (rotational) power. The
brake of the elevator must be designed in order to guarantee safety during normal
day use. The brake must also be able to engage in extreme cases in which the
elevator cable is broken or other unforeseen circumstances arise. In addition, the
elevator must pick up and drop off passengers as efficiently as possible. If a
collection of elevators is used, a complex controller usually controls them.

The elevator must fit within the given space requirements of the building. It
must be made large enough to deal with the normal daily traffic and to move the

5
necessary objects within the building. It cannot be made too large and, therefore,
affect the structure of the building itself. Possible restrictions on the weight carried
within the elevator may be determined from the size of the motor and the other
components within the elevator system. This weight limit must be large enough to
handle daily usage. A roping system is used to attach the motor/gear reducer, the
elevator car and the counter weight. There are many different kinds of arrangements
that can be used. In one possible arrangement, both ends of the elevator rope are
anchored to the overhead beam. Both the elevator car and the counter weight are
attached to free moving pulleys. The traction drive is attached to a stationary pulley.
The traction drive is the method of converting the input mechanical power (in this
case the turning of a shaft) into useable mechanical power in the system (the vertical
movement of the elevator). The friction between the ropes and the sheave grooves,
which are cut on the pulley, initiates the traction force between the traction drive and
the rope. When the traction drive is rotated power is transferred from the traction
drive to the elevator car and counter weight. Power is only needed to move the
unbalanced load between the elevator and the counterweight.

An elevator's function is to convert the initial electrical power, which runs the
motor, into mechanical power, which can be used by the system. The elevator is
composed of a motor and, most commonly, a worm gear reducer system. A worm
gear system is made up of a worm gear, typically called the worm, and a larger round
gear, typically called the worm gear. These two gears which have rotational axes
perpendicular to each other, not only decrease the rotational speed of the traction
pulley, but also change the plane of rotation. By decreasing the rotation speed, with
the use of a gear reducer, we are also increasing the output torque, therefore, having
the ability to lift larger objects for a given pulley diameter. A worm gear is chosen
over other types of gearing possibilities because of its compactness and its ability to
withstand higher shock loads. It is also easily attached to the motor shaft, sometimes
through use of a coupling. The gear reduction ratios typically vary between 12:1 and
30:1. The most common elevator brake is made up of a compressive spring
assembly, brake shoes with linings, and a solenoid assembly. When the solenoid is
not energized, the spring forces the brake shoes to grip the brake drum and induce a

6
braking torque. The magnet can exert a horizontal force for the break release. This
can be done directly on one of the operating arms or through a linkage system. In
either case, the result is the same. The break is pulled away from the shaft and the
velocity of the elevator is resumed. In order to improve the stopping ability, a
material with a high coefficient of friction is used within the breaks, such as zinc
bonded asbestos. A material with too high a coefficient of friction can result in a
jerky motion of the car. (5)

2.3 USES OF ELEVATORS

2.3.1 Passenger Elevator

 Designed to move the people between a building’s floors.

 Passenger elevators capacity is related to the available floor space. Generally,
it capacities from 1,000 to 6,000 lb (455-2,727 kg) in 500 lb (230kg)
increments.
 Usually, for eight floors or less building, hydraulic or electric are used with
speeds up to 200 ft/min (hydraulic) and up to 500 ft/min (electric). But for
buildings up to ten floors, electric and gearless elevator are used with speeds
up to 500 ft/min, and for ten floors above, speeds begin at 500 ft/min up to
2000 ft/min.
 Sometimes, it is used as a city transport along with funiculars.

Figure 2 Passenger Elevator

7
2.3.2 Freight Elevator

 Designed to carry goods rather than passengers.

 Often exempt from some code requirements from some of the requirements
for fire service.

Figure 3 Freight Elevator

Generally, it required to display a written notice in the car that the use by
passengers is prohibited, though certain freight elevator allows dual use through the
use of an inconspicuous riser.
It is typically larger and capable of carrying heavier loads than a passenger
elevator, generally from 2,300 to 4,500 kg.

2.3.3 Vehicle Elevator

 It is installed where ramps are considered space-in conservative for smaller

buildings (usually in apartment building where frequent access is not an
issue).

 The car platforms are raised and lowered hydraulically and are connected to
chain steel gears. The platform also can rotate about its vertical axis (up to
180 degrees) to ease driver access and accommodate building plans.

8
 Figure 4 Vehicle Elevator

2.3.4 Aircraft Elevator

 It carries aircraft between the flight deck and the hangar deck for operations
or repairs.
 It is designed for much greater capacity than any other elevator ever build, up
to 200,000 pounds of aircraft and equipment.
 Smaller elevators lift munitions to the flight deck from magazines deep inside
the ship.

2.3.5 Boat Elevator

 Used in some smaller canals.

 The boats and small ships can pass between different levels of a canals with a
boat lift rather than through a canal lock.

2.3.6 Dumbwaiter Elevator

 Often used for the moving of small items such as dishes in a 2-story kitchen
or books in a multistory rack assembly
 Modern dumbwaiters are generally driven by a small electric motor with a
counterweight and their capacity is limited to about 750 lb (340 kg).
 Dumbwaiters are used extensively in the restaurant business (hence the name)
and may also be used as book lifts in libraries, or to transport mail or similar
items in an office tower.
9
  Dumbwaiters, especially older ones, may also be hand operated using a roped
pulley.

2.3.7 Paternoster Elevator

 It is a constantly moving chain boxes.

 A similar concept moves only a small platform, which the rider mounts while
using a handhold and was once seen in multi-story industrial plants.

Figure 5 Paternoster Elevator

10
 CHAPTER 3 - SOLAR ENERGY

In order to make this elevator powered by renewable energy, solar power is

chosen. In the following chapter, can be found introduction to photovoltaic and its
different types.

3.1 WHAT ARE PHOTOVOLTAICS?

Photovoltaic (PV) systems convert energy from the sun into electricity
through semi-conductor cells. PVs supply electricity to the building they are attached
to or to any other load connected to the electricity grid. Electricity is usually fed into
the grid when the generated power exceeds the local need. More electricity is
produced with more sunlight, but energy can still be produced in overcast or cloudy
conditions. Photovoltaic panels can be fitted to existing buildings, designed into new
buildings or attached to individual items such as street lights, parking meters or the
sides of bridges. Ideally PVs should face between south-east and south west, at an
elevation of about 30-40°.

3.2 BENEFITS OF PHOTOVOLTAICS

Incorporating photovoltaic into a development will enable the building to

produce a percentage of its electricity for free. These are clearly two important
benefits but as a technology it has a number of others:
 No moving parts and therefore require little maintenance

 No emissions in use

 Easy to install as modular and light

 Helping to meet national, regional or even local renewable energy and carbon
dioxide emission targets

 PV produces electricity at point of need so energy is not lost moving it from one
place to another

11
  One of the few renewable technologies that can be used very successfully in
urban areas
 Cost savings - although PVs generally add to the cost of a building.

There are still some major disadvantages with PVs. The major one being
high cost. They are also still a relatively novel technology so that there are not
many architects, engineers, electricians or roofers with much experience of them.
This means that projects involving PV will be new to many on site and therefore
possibly more time consuming and problematic than without (6).

3.3 TYPES OF PHOTOVOLTAICS

There are four main photovoltaic technologies to choose from and each one
has different characteristics.

Figure 6 Types of Photovoltaic

3.3.1 Hybrid Photovoltaic

High performance. Hybrid modules
contain a layer of both amorphous and
crystalline cells providing best all round
performance. Although more expensive, they
provide much better output per m2. This is
particularly useful when the roof is limited.

Figure 7 Hybrid Photovoltaic

Compared to other technologies, Hybrid PV
Panels will generate more Kwh per year

12
3.3.2 Monocrystalline Photovoltaic Panels
Economic, efficient and reliable.
Monocrystalline photovoltaic cells are cut
from a single crystal of silicon and are
generally considered to be the workhorses of
the PV market due to their high efficiency
and dependability. They can be distinguished
by their uniform appearance and are usually
Figure 8 Monocrystalline Photovoltaic dark blue or black in color.

3.3.3 Polycrystalline Photovoltaic Panels

Lower cost, lower performance.

Polycrystalline cells are cut from
multifaceted crystalline silicon and are
distinguishable by their crystal-like
appearance. Polycrystalline panels provide
slightly lower annual output than
monocrystalline panels, but they are in turn
Figure 9 Polycrystalline Photovoltaic Panels
slightly less expensive.

3.3.4 Amorphous (Thin Film)

Flexible but lowest efficiency.
Amorphous PV, also known as Thin Film
is made entirely differently from the
crystalline modules and the annual output
tends to be much lower. They are however,
flexible so can be used in many more
applications, such as shingles, curved
Figure 10 Amorphous (Thin Film)
roofs, bus shelters and portable solar
panels

13
 The performance of a PV panel is measured in kilowatt hours per kilowatt
peak (kWh/kWp), which translates as the number of electrical units of energy
(kWh) the panel will produce at maximum output (kWp), or in other words during
the brightest sunlight.

Figure 11 Performance of PV Panels

14
CHAPTER 4 - PLC (Programmable Logic Controllers)

In control of elevators, PLCs are useful among many other applications. PLCs
receive the inputs and make decisions via outputs to open and close doors, start the
engine for direction of cabins for purpose of the elevator and some others according
to the program. In this project Siemens S7-200 model and 224cpu is used and the
following chapter brief a small history of PLC and introduce PLC’s basic design with
considering advantages of it. This chapter includes the inputs and outputs of Green
Elevator systems for PLC.

4.1 HISTORY OF PLC

The PLC was introduced around 1969 largely as a result of specifications
written by the General Motors Corporation. The automotive industry had
traditionally been a large buyer and user of electromechanical relays to control
transfer lines, mechanized production lines, and other automated systems. In an
effort to reduce the cost of new relays purchased each year, GM prepared the
specifications for a “programmable logic controller” in 1968. The requirements
included:

• The device must be programmable and re-programmable.

• It must be designed to operate in an industrial environment.

• It must accept 120-V ac signals from standard pushbuttons and limit switches.

• Its outputs must be designed to switch and continuously operate loads such as
motors and relays.

• Its price and installation cost must be competitive with relay and solid-state logic
devices then in use.

15
 Several companies saw a commercial opportunity in the GM initiative and
developed various versions of a special-purpose computer. There are significant
advantages in using a programmable logic controller rather than conventional relays,
timers, counters, and other hardware elements. (7)

4.2 INTRODUCTION TO PLC

The National Electrical Manufacturers Association (NEMA) as defines a

programmable logic controller:

A digitally operating electronic apparatus which uses a programmable

memory for the internal storage of instructions for implementing specific functions
such as logic, sequencing, timing, counting, and arithmetic to control, through digital
or analog input/output modules, various types of machines or processes.

Programmable Logic Controllers (PLC) are used in almost every aspect of

industry to expand and enhance production. Where older automated systems would
use hundreds or thousands of electromechanical relays, a single PLC can be
programmed as an efficient replacement (8) (9). The functionality of the PLCs has
evolved over the years to include capabilities beyond typical relay control.
Sophisticated motion control, process control, distributive control systems, and
complex networking have now been added to the PLC’s functions (10). Therefore,
PLCs provide many advantages over conventional relay type of control, including
increased reliability, more flexibility, lower cost, communication capability, faster
response time and convenience to troubleshoot (11).

16
 4.2.1 Basic Design of PLC

Figure 12 Basic Design of PLC

By referring to the programmable logic controller, PLC design as shown in

Figure 12 above. The functions of each component are:

Function:

 Input Module - Convert incoming signals into signal which can be processed by
PLC and pass it to central control unit.

 Output Module - Perform a reverse task of input module. It converts the PLC signal
into signal suitable for the actuators.

 Central Control Unit -Process the signal according to the program stored in
memory. It’s also provides intelligence to command and govern the activities of the
entire PLC systems.

 PLC Program - The desired program of sequence of operation and control

instruction which is entered by programmer.

17
4.2.2 Advantages and Disadvantages of PLC

 Flexibility: One single Programmable Logic Controller can easily run many
machines.

 Correcting Errors: In old days, with wired relay-type panels, any program
alterations required time for rewiring of panels and devices. With PLC control any
change in circuit design or sequence is as simple as retyping the logic. Correcting
errors in PLC is extremely short and cost effective.

 Space Efficient: Today's Programmable Logic Control memory is getting bigger

and bigger this means that we can generate more and more contacts, coils, timers,
sequencers, counters and so on. We can have thousands of contact timers and
counters in a single PLC. Imagine what it would be like to have so many things in
one panel.

 Low Cost: Prices of Programmable Logic Controllers vary from few hundreds to
few thousands. This is nothing compared to the prices of the contact and coils and
timers that you would pay to match the same things. Add to that the installation
cost, the shipping cost and so on.

 Testing: A Programmable Logic Control program can be tested and evaluated in a

lab. The program can be tested, validated and corrected saving very valuable time.

 Visual observation: When running a PLC program a visual operation can be seen
on the screen. Hence troubleshooting a circuit is really quick, easy and simple.

18
4.2.3 Inputs And Outputs For Green Elevator

These are the inputs and outputs for program which written for green
elevator. (In this PLC program assumed that, the cabin weight is same in every time.
Because a level switch is used inside of the counterweight tank instead of level
sensors. And there is no pressure sensors below the cabin).

Inputs Service Outputs Service

I0.0 System Start Button Q0.0 Upper Tank Valve
I0.1 1.Floor Button Q0.1 Lower Tank Valve
I0.2 2.Floor Button Q0.2 Contactor (Break Mechanism)
I0.3 3.Floor Button Q0.3 Pump
I0.5 1.Floor Proximity Switch Q1.1 1.Signal Lamp
I0.6 2.Floor Proximity Switch Q1.2 2.Signal Lamp
I0.7 3.Floor Proximity Switch Q1.3 3. Signal Lamp
I1.1 Upper Tank Level Switch Q2.0 Working signal
I1.2 Counter Tank Level Switch
Table 2 Inputs and Outputs of system

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 CHAPTER 5 - IMPLEMENTATION

At the beginning of this prototype many experiments were done with plastic
bottles. Experiments are started from kinetic and potential energy lows. Kinetic
energy exists whenever an object which has mass is in motion. Everything you see
moving about has kinetic energy (KE = (1/2)mv2). An object can store energy as the
result of its position. For example, the heavy ball of a demolition machine is storing
energy when it is held at an elevated position. This stored energy of position is
referred to as potential energy (PE = mgh). In formulation, when there are same mass
at two bottle they should stay at their own place. Because there is no external force
on the rope. When the counterweight has more mass than cabin or reverse condition,
difference of two masses creates a force to heavy one and the movement starts. But
whenever it starts to move it can’t balance each other in an exact place which is
wanted. It will continue its movement on its own direction. For that reason stopper
mechanism is necessary for the Green Elevator.

Figure 13 Laboratory tests

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 When experiments had finished with plastic bottles to solve kinetic and
potential energy problem, there are made counterweight tank from bottle to test
valves and pulleys. In this tests there are used many different kind of pipes and
chosen one is the thin one for flexibilities and this thin pipe made the system
movements slow because of the flow rate. For this experiments there were built a
small structure with wood for proximities. After these second part of experiments,
learned that main idea is working. After 2 month with testing, marketing research
started and taken some materials from different places. After all capital experiments,
two 10cm diameters, one 15cm and one 20cm diameter pulleys, a contactor for break
mechanism and three different kind and size of counterweight tank ordered from
Turkey. When all these materials came and planning finished for structure, wood has
chosen for main structure instead of metal to make all the system lighter and wood is
easy to shape it. After obtaining the necessary boards and parts for all, the system has
built according to 3D drawing on AutoCAD.

Figure 14 Pulley Mechanism

Figure 15 Green Elevator

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 In the prototype there are two valves to control the water in the counterweight
tank, there is a contactor to constrict rope for break mechanism and there is a pump
to carry water from lower tank to upper tank. This pump give potential energy to
water. The challenge at the beginning with the contactor for break mechanism is
making a small hole through the piece of plastic which between the contactor’s
springs. This hole is made by driller when the contactor at working position. After
prepared all main part for control panel, they are attached to system and a thin rope
passed on pulleys and inside the contactor’s hole. The pulleys and break mechanism
is tested with several weight and they passed in all tests. Pulleys are chosen from
wood, because when system tried with plastic pulleys, there are no enough friction
between rope and pulley. That is why plastic pulleys sticks their beginning position
and the rope slides over pulleys.

After the control level attachments had finished and tested, counterweight
tank had put at its position. In this stage a metal sheet had used instead of cabin. The
water level measured in the counterweight tank for the movement of metal sheet
from lower to up and reverse. Then the cabin had built from wood.

Figure 16 Cabin

At first this cabin is made with a better closed shape but when it tried in the
system it observed that this cabin become heavy for our counterweight tank which
decided to use. Therefore, right and left side surfaces had been cut to make it lighter.
Then, holes for our valves are opened at two of our capital tank and this valves
sealed to these tanks. After thin pipes is connected between valves and counterweight
tank, electrical connection are made for contactor and valves. All of these main
components are connected to PLC and tested with a basic program just for checking.

22
 Than the Green Elevator structure’s front and back sides are covered with
wood to make all structure stronger and for panels. For front panels lightening,
buttons and signalization with LED, there were lots of holes opened at front door
panel. LEDs are attached this holes with silicone and 4.7k.ohm resistors are used
serial with all LEDs and cabling is made for front panel. These LEDs are also used
for the lightening of the cabin.

When this structural part is finished, ladder diagram is written for PLC with
Step 7 MicroWIN for 3 levels. This program doesn’t remember when pressed two
button at the same time. When somebody presses a level button, other buttons are not
working until the progress finished. When the progress finished and the cabin reach
its level which the button called it, contactors stops cabin. There are several decisions
in that point. If cabin called from first floor to second floor break mechanism just
hold the cabin and valves stops. If this cabin will called from third level, it means
whenever break mechanism release the cabin it will continue to its previous
direction. No need to open valves because counterweight tank still has potential
energy. The same thing is true for the opposite option. If cabin called from third level
to second level break mechanism hold the cabin. And if the cabin will be called at
first floor, its direction will be same. So no need to do without opening and closing
the break mechanism. But when the direction is changed there is another progress for
it. For example cabin called from first floor to second floor. When cabin reaches
second floor break mechanism hold the cabin. After that if the cabin again called
from its original position, break mechanism still hold the cabin until the water which
inside the counterweight tank comes to balance level. When the level switch which
inside the counterweight tank detect the water, break mechanism release the cabin
and cabins movement direction will changed. This series of progress will continue
unless the start button turned it of which has pushed at the beginning.

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5.1 GREEN ELEVATOR SYSTEM FEATURES

5.1.1 Cable Connection

Figure 17 PLC Input Connection

Figure 18 PLC Output Connection

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5.1.2 Algorithm of The System

Figure 19 Algorithm of the System

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 CHAPTER 6 - CONCLUSION

Energy allows people to use new technologies and to improve their life style.
Everyday people needs more energy sources to produce new components. That’s
why, companies apply to produce different types of energy, but uncontrolled use of
energy caused global warming and environmental pollution problems. Therefore,
energy saving products are very important for the nature. Nowadays, developed
countries and developing countries improve renewable energy sources and use eco-
friendly products which are called green technology, green energy, green structure
etc.

In this project, solar panels will be used for energy efficient and different
application fields (regions that electrical energy not able move). Green Elevator can
produce its energy with help of solar panels, wind turbines or hydro power. Green
Elevator can save electrical energy even if it works in grid. However the main idea of
this project is a renewable energy based elevator which is using water potential
energy and for getting this potential energy, it uses solar panels that are taken source
for pump. This project can be investigated in many scenario.

Assume that there is a hotel which has 4 floors and 2 floors for car parking.
Every floor height is 2.50 m, every car parking floor height is 3.80 m and every
girder height is 30 cm. Total height of this hotel is 20 m. One Green Elevator is
wanted to design for costumers.

Due to the date of 21.03.2013 in our experiments; we measured for this

project when cabin weight is 500ml we need for moving this cabin to upstairs 625ml
in the counterweight tank. For the revers option we need 300ml for take this cabin
down stairs. If we apply this measurement for real life we can get;

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If the cabin capacity is 5 person (that mean 80*5=400kg) and

If total unloaded elevator weight: 100 kg

So the cabin weight at max 500kg. (If we obey our experiments, tank need
625liter to move this cabin up and 300liter to move down). If we add +-%10 to
counterweight tank capacity, elevator’s total counterweight tank capacity will be
over 700 liter.

 Elevator is balanced ;

Elevator load capacity is 500 kg – load of counterweight is 500 liter.

 Elevator is moved up;

Elevator load capacity is 500 kg – load of counterweight is 625 liter.

 Elevator is moved down;

Elevator load capacity is 500 kg – load of counterweight is 300 liter.

(Gravity affects load of counterweight when elevator moved down. That’s why, load
of counterweight is 300 liter in placed of 375 liter).

There is always 300 liter in the counterweight tank at min. if the direction of
movement of elevators cabin from downstairs to upstairs, 325 liter must add into this
counterweight tank. So the alteration is just 325 liter. This 325 liter is equal to
0.325m3. If green elevator is used around 100 times per day, the 325 liter water must
to be added 50 times (assumed half amount of usage from up to down and other half
from down to up). So that means for one day of usage, green elevator need at upper
tank 16.25 m3 water (50 times*0.325m3 = 16.25m3) to take counterweight tank
down. So the pump which must to pump 16.25m3 water from lower tank to upper
tank for a day. And that D.C water pump is wanted that lift water from ground to an
elevated storage tank over 20m. (Taking available peak sun hours to be 10 hours and
acceleration due to gravity to be 9.81m/s).

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 If green elevator works 10 hours per day, the pump’s flow capacity must to be
1.625m3/h (16.25 m3 / 10 hours = 1.625m3/h). Values when substituted into the
formula for calculation to pump power;

Ph = q ρ g h / (3.6 106)

Where;

Ph = power (kW)

q = flow capacity (m3/h)

ρ = density of fluid (kg/m3)

g = gravity (9.81 m/s2)

h = differential head (m)

(This formula is taken from “International Conference on Applied Energy, ICAE 2012, Jul 5-8, 2012,
Suzhou, China”)

Ph = (1.625*1000*9.81*20)/ 3.6 106 =0.0885625 kW which is approximately

90Watt powered pump is needed.

The power needed by the pump is 90W and the system will require a PV
array that will produce 88.562 Watts [1J/s = 1 Watt]. It is important to add an
approximately extra 15% power to the array to prevent the losses associated with
the system. So an array of approximately 100 Watts in direct sunlight will operate
the pump smoothly.

In this scenario, the power consumption and amount of water usage are
calculated. Due to these calculation results, total power consumption is 100 Watt,
total water which is needed 16.25 m3 (the pump which must pump 16.25m3 water
from lower tank to upper tank for a day). In common elevators systems motors’
powers start from 3.5kW to 11kW as can be seen at Table 1. That means Green
Elevator saves at least 39 times more electrical energy from the grid than normal
elevators and Green Elevator doesn’t need a powerful motor like common elevators.

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Due to these calculations, solar panel and water pump can be chosen like below.

Solar Panel Features Water Pump Features

Type Mono Solar Panel Model 10L-120W

Max Power 120 Watt Pump Capacity 120W/24VDC

Vmp 17.2V Water Flow 45L/min

Imp 5.8 A Outlet Size 32mm

Weight/Size 9kg/1061*670*35mm Max Head 20m

Table 3 Chosen Solar Panel Features
Diameter of Pump 530*76mm

Rotation Speed 18000 rpm

Table 4 Chosen Water Pump Features

In another scenario assume this Green Elevator wanted to apply for a village
hillside of a mountain. If there is a river or a water source at the top of this mountain,
system doesn’t need a pump any more. Even this system doesn’t need any capital
upper and lower tank. For upper tank a pool or river can be use, also for lower tank,
this water which comes from counterweight tank can be used to water a field or this
village can use this water for a pool or general usage.

Another good point for this project, if the system structure, like counterweight
tank, cabin weight and break mechanism, is get bigger, it gets easier to control it.
When in both arm’s weight is so small, the balance internal for elevator and
counterweight tank changes quickly. But for bigger system it can be modified by
bigger valves or with a pressure for water. Or sensors can be used for measuring the
number of people weight and counter water is arranged with a sensors for this cabin
weight instead of switches.

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 This prototype system also can be used in horizontal ropeway. A well (deep
hole) can be excavate for the counterweight tank. Also this well can be used as a
water source.

For example there is a mountain or a high place for tourists. Two ropeway
can be built for two opposite side of mountain and for example hourly this system
can be used with minimum water source. Because two cabin weight also balanced
each other. So the water source just will use for make difference between two cabin
weight. Also this water not have to come from a source. It can be a closed loop.
When the direction wanted to change, the water which used for a cabin can be
portable for the other cabin. So there is no need a water source, just two tank that
each of them above a cabin, enough for this approach.

Dozens of application can be thinkable for this Green Elevator. But the main
idea which tried to explain is very useful for saving energy sources and applicable
easily to place which hard to generate or carry electrical energy. Also this project can
encourage some other people to use renewable sources and invent better or different
ideas like Green Elevator.

30
 REFERENCES

1 Elektrizitätsverbrauch und Einspar-Potenziale beä Aufzügen , J.Nipkow. Zurich

,S.A.F.E 2005.

2 Laying the foundation for today's skyscrapers, Gellner,Arrol. San FranciscoSan

Francisco Chronicle,2008.

3 The History of Elevators New York City , Bellis,Marry. Institute of Electrical and
Electronics Engineers.

4 Lift Control By Using PLC for Students Kits, MalaysiaFaculty of Electrical

Engineering of Technology University of Malaysia, 2008.

5 How an elevator works ,Salzmon Rhonda . Cambridge ,Massachusetts Institute of

Technology ,1998

6 Solar Power Feasibility Study Sustainable Eastside, Maunsell,Faber. 22nd

December 2003.

7 An interactive electronic book approach for teaching computer implementation of

industrial control systems Hassapis,G. IEEE Transaction on Education,2003.

8 A course in industrial controls and manufacturing for EE students and other

engineering majors,Kamen, E.W.G.M. J. USA Proceeding of the 1997 American
Control Conference , June 1997

9 Design a flexible industrial controls lab module, Anderson, J.C. 32nd Annual
Frontiers in Education Nov,2002.

10 A Web-based programmable logic controller laboratory for manufacturing

engineering education. Saygin,C.K.F. The International Journal of Advanced
Manufacturing Technology ,2002.

11 PLC laboratories – the next generation , Rehg,L. Washington DC , ASEE Annual

Conference & Exposition 2002

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 APPENDİX
Green Elevator PLC Program

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3D drawing for Green Elevator Prototype

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