Case Studies: Where Others See a Problem, We See an Engineering Challenge
The true value of a technology partner is revealed not by how they handle standard orders, but by how they deal with challenges that are insurmountable barriers for others. Below we present ten real problems that clients brought to us – and the unique solutions we delivered through a combination of experience, flexibility, and full control over our technology.
Challenge: "Impossible" Modernization with Friction Encoder
The client had Kone EcoDisc elevators with an unusual drive solution, where cabin position information was obtained from an encoder on a friction wheel. No standard frequency inverter could properly work with such a system. All other suppliers offered only complete elevator replacement or, at minimum, replacement of the entire drive unit along with control. Both cases involved enormous costs and long-term construction work related to elevator shaft modernization.
Solution: Dedicated Electronics and Self-Learning Algorithm
Our engineers designed and manufactured a dedicated electronic module that real-time translated signals from the friction encoder into a language understandable by modern frequency inverters. Moreover, we created special software with machine learning elements that continuously corrected readings, compensating for potential micro-slips and guaranteeing precise, smooth arrivals at floors.
Result: Spectacular Savings and Proof of Engineering Superiority
Thanks to our unique solution, the client avoided enormous costs of replacing the entire elevator, retaining high-quality, original components: drive units, door drives, shaft construction, cabins, part of installation and suspension cables. This project is proof that true engineering can deliver solutions that will forever remain beyond the reach of "component assemblers".
Challenge: Cost Escalation in Closed Manufacturer Ecosystem
The direct cause of modernization was failure of the original OTIS frequency inverter, whose replacement was extremely costly: higher than the price of new SterDźwig control equipment. Additionally, one of the hoisting machines overheated to such a degree that UDT recommended installing air conditioning in the machine room. Handling original Otis hoisting machines and adapting equipment to Otis cabin door drives was problematic.
Solution: Open Architecture and Intelligent Replacement
We proposed comprehensive modernization based on our open platform. We replaced the faulty hoisting machine with a new, energy-efficient synchronous unit. We integrated both hoisting machines (original and new) with our control system. We managed to retain the original door drives thanks to controller firmware modification.
Result: Large Savings and Complete Independence from Expensive Service
The client not only avoided costly frequency inverter replacement, but thanks to the new hoisting machine, the overheating problem disappeared, allowing for abandoning the costly air conditioning installation. Most importantly, the client gained a fully open system, giving freedom to choose the servicing company. They became completely independent from the price dictatorship of the corporation.
Challenge: Non-Standard Logic for Hydraulic Drive Control
The Mars food corporation faced the necessity of replacing or radically modernizing their freight elevator. The cost of such operation was estimated at approximately 600,000 PLN. The elevator required unusual handling of the hydraulic aggregate and safety catches – special bolts blocking the cabin at the floor. This required creating from scratch a non-standard, precise start and stop sequence, which no standard control system offered. Non-standard was also the synchronization of door handling in the travel cycle.
Solution: Dedicated "Tailor-Made" Software
Thanks to full control over the controller source code, our engineers wrote special software that perfectly manages the entire start and stop cycle and synchronizes the operation of doors and safety catches.
Result: Uncompromised Safety and Reliability for a Fraction of New Elevator Price
Thanks to us, the client gained a completely modernized elevator for 15% of the price from the previous offer. They also received guarantees of free choice of servicing company and access to cheap, easily available spare parts. We delivered a solution 100% meeting the client's rigorous safety requirements, proving our ability for deep software modification for the most demanding industrial applications.
Challenge: Integration with Closed Schindler Technology in Operating Hospital
Due to astronomical annual maintenance costs, the hospital decided to replace or modernize the elevators. Hospital elevator modernization is surgery on a "living organism". The client wanted to modernize the control as quickly as possible, while retaining high-class original Schindler synchronous drives. Important for the client was also retaining complete door drive beams and the existing (old) access control system.
Solution: Perfect Integration with Existing Drive
Thanks to our know-how, we implemented our control system that fully took control of Schindler drives, ensuring smooth and comfortable travel. We managed to fully utilize existing door drives. We also made special versions of call panels that we connected to the existing access control system.
Result: Modernity Without Replacing the Best Components
The hospital gained the most modern control system while retaining the most valuable element of their system – original, reliable drives. They freed themselves from expensive maintenance and very high spare parts prices. They managed to retain the entire existing access control system, whose change would be an organizational nightmare for the management. This is proof that we can intelligently cooperate with components from other leading manufacturers.
Challenge: Maximizing Savings and Flexibility
Faced with complete lack of technical support and spare parts, the client sought a way to modernize older elevators in the most cost-effective way, avoiding general overhaul and replacement of entire devices. The goal was to conduct modernization while retaining the maximum number of installed components: cabins, hoisting machine foundations, main drives and door drives, electrical installations and suspension cables.
Solution: Engineering Flexibility in Practice
Besides retaining (still well-working) hoisting machines and door drives, the biggest advantage proved to be the ability to fit all our new control equipment inside the original, old Monitor control cabinets. Such a solution was forced by building conditions and machine room location. Our engineers designed special mounting plates that allowed clean and quick installation without the need to replace entire cabinets. The control was also immediately prepared for future door drive beam replacement.
Result: "Surgical" Modernization – Replacing Only What's Necessary
Thanks to our flexibility, the client received a solution perfectly tailored to the budget. They regained control over the entire elevator substance for less than 15% of new elevator price. They received modern LCD call panels and a new dispatch panel. We proved that modernization doesn't have to mean "replacing everything", and we, as engineers, can precisely diagnose what needs replacement, generating enormous savings.
Challenge: Ensuring Precise Arrival in Old, Heavy Freight Elevators
The client sought maximum savings with simultaneous requirement for radical improvement in travel quality. Modernization of old single-speed and two-speed elevators required using frequency inverters, which is crucial for precise goods transport. Due to financial constraints, it was necessary to retain existing infrastructure, including manual doors and 'attendant operation' mode.
Solution: Frequency Inverter Control and Dedicated Software
We applied frequency inverter control that ensured very precise start and floor arrival, incomparable with the previous solution. Additionally, we created special software for "attendant operation elevators", where instead of standard call panels we used "call panels" to inform the elevator operator.
Result: Precision, Reliability and Full Adaptation to Attendant Operation Mode
The client gained precise and reliable elevators, fully adapted to the facility's specifics. The solution met all standards and client requirements. The cost of complete modernization of 6 elevators was comparable to replacing one elevator!
Challenge: Recurring Failures of Key Components
The main cause of modernization was permanent failures of original Ziehl-Abegg frequency inverters, which threatened production continuity in the plant. The production facility required express modernization pace and strict adaptation to existing factory processes.
Solution: Complete Control System Replacement and New Features
We performed complete replacement of control equipment with our new, reliable control using 40KW Yaskawa frequency inverters. We manufactured the entire control system in record time of 10 working days. Additionally, we implemented our proprietary emergency descent solution.
Result: Guaranteed Work Continuity and Increased Safety
The client received a reliable elevator whose operation is no longer threatened by frequency inverter failures. Close cooperation with our team allowed for express modernization pace. Additionally, the safety level was increased thanks to the emergency descent function, which was not previously available.
Challenge: Replacing Outdated, Worn and Energy-Inefficient Drives
The goal was to find a modern and efficient replacement for very popular but outdated two-speed drives, with minimal interference with existing infrastructure.
Solution: Implementation of Modern Synchronous Drives
At SterDźwig work today people who designed ODA elevators! So we know their construction 'inside out'. We replaced old R4 type machines with modern, energy-efficient synchronous hoisting machines and replaced control equipment. After replacing call panels and dispatch panels, the elevators gained modern appearance and travel comfort not inferior to the best solutions available on the market.
Result: Comfort, Reliability and Lower Energy Bills
The client retained the 'armored' mechanics of the elevators, and gained radical improvement in travel comfort, greater reliability, modern appearance and significant reduction in electricity consumption. For everything they paid less than 25% of new elevator price.
Challenge: Control Replacement While Retaining MacPuarsa Cable and Hydraulic Drive Units.
The challenge was working with two different types of drives (cable worm and hydraulic) within one large system. The client expected to retain original MacPuarsa drive units, including cabin door drives.
Solution: One System to Control All
We implemented a new, unified control system that was compatible with both types of drives, while retaining original, efficient Puersa hoisting machines and hydraulic aggregates. Thanks to software modification, we also managed to handle door drive beams.
Result: Simplified Management and Optimized Costs
We unified the control system for all elevators in the facility, which significantly facilitated their servicing and management. Cost optimization was achieved by retaining expensive drive components. Meanwhile, replacing call panels and dispatch panels gave a new appearance and solved the MacPuarsa spare parts unavailability problem. The client regained peace of mind and certainty for years of undisturbed and cheap elevator operation.
Challenge: Ensuring Absolute Reliability in Healthcare Facility
Modernization of a hospital elevator whose key components came from Wittur company required ensuring handling of unusual hoisting machines and door drives. It also had to be carried out at express pace.
Solution: Implementation of Proven Control System
We implemented our proven control system that ensured the highest operational reliability in the critical hospital environment. We added emergency descent function, replaced call panels and dispatch panel. We managed to utilize part of existing electrical installation and suspension cables.
Result: Modernizing Key Elevator for Patient Transport
At a small cost, the hospital modernized and updated a critical element of hospital infrastructure. We ensured modern and reliable operation of an important elevator for patient and equipment transport in the medical facility, which is proof of our expertise in the medical sector. The implementation resulted in additional contracts for modernization in this hospital.
Your Challenge is Our Specialty
Each of the above projects started with a conversation about a problem that for others was too difficult, too unusual or too complicated. If you are facing a similar modernization challenge, we invite you to contact us. Our team of engineers is ready to analyze your case and propose a solution that will turn "impossible" into "accomplished".
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