1

A REPORT

ON

ENERGY CONSUMPTION AND CONSERVATION OF ELEVATORS

BY

TANIA STANLY 2010A3PS279U

AT

THYSSENKRUPP ELEVATOR DUBAI, UAE

A Practice School – II station of

BITS Pilani, Dubai Campus Dubai International Academic City, Dubai

UAE

(August 2013– January 2014)

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A REPORT

ON

ENERGY CONSUMPTION AND CONSERVATION OF ELEVATORS

BY

TANIA STANLY 2010A3PS279U EEE

Prepared in Partial Fulfillment of the

Practice School – II Course

AT

THYSSENKRUPP ELEVATOR DUBAI, UAE

A Practice School – II station of

BITS Pilani, Dubai Campus

Dubai International Academic City, Dubai UAE

(August 2013– January 2014)

3

BITS PILANI, DUBAI CAMPUS Dubai International Academic City, Dubai

UAE

Station: ThyssenKrupp Elevator U.A.E LLC Centre: Dubai Duration: 04.08.2013 - 09.01.2014 Date of Start: 04.08.2013 Date of Submission: 09.01.2014 Title of the Project: ENERGY CONSUMPTION AND CONSERVATION OF ELEVATORS ID No. / Name of the student: 2010A3PS279U / TANIA STANLY Discipline of Student: B.E. (Hons) Electrical and Electronics Engineering

Name(s) and Designation(s) of the Expert(s): Ms. Stefanie Heidester (HR Manager & PS Coordinator), Mr. Sukhminder Aushat (Service Manager) , Mr. Bibin Thomas (Service Sales Engineer), Mr. Afan Basu (Service Engineer) Name of the PS Faculty: Dr. V. Kalaichelvi Name of the PS Mentor: Mr. Aushat (Senior Sales Manager) Key Words: Elevators , Regenerative drives , Sales , Quotation , Repair Request, Work Order, Completion Certificate, Energy efficiency Project Area(s): Company history, Products, Service Department, Service Process Abstract: In this report, few of the most innovative energy efficient technologies are discussed. Factors affecting energy consumption, how this can reduced without compromising on the quality of service and how such technologies prove to be a great investment. The report also discusses the various procedures undertaken during maintenance works, the legal procedures and documentations associated with it. The report concludes with how such technologies can be out to practice. Signature of Student Signature of PS Faculty Date: Date:

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Chapter 1 ThyssenKrupp Elevators – An Epitome

1.1 History

Based in Duisberg and Essen, Germany, ThyssenKrupp AG is a multi industry

company. It was formed as a result of two companies, Thyssen AG and Krupp, founded

in 1891 and 1911 respectively decided to merge togerther.

The company combined Sthier flat steel activities as early as 1997 and after a lot of

negotiations, in 1999 March, TK came into being. Along with provision of services and

components for elevators, escalators, material trading and industrial sevices, TK is also

the largest producers of steel in the world! [4]

Thyssen Krupp is ranked 122 in the Global500 of the annual ranking of the world's best

corporations.

Heinrich Hiesinger is the CEO of the company and has about 150,000 emplyess

worldwide.

As of 2013, TKEwith their global business spread all over the world, with units

operating. When it comes to the competition among the escalators and even the

elevators, TKE is ranked 3rd in the world. Also, about 1% of the overall market share is

owned by TKE.[5]

1.2 Structure of the Company

60% of their activities revolve around maintenance, disassembling and assembling of

elevators units, modernization and repair, all of which come under the service

department.

The remaining 40% comprises of Manufacturing of elevators, installation of

manufactured elevators and (R&D) Research and Development Department, all of

which comes under the new installation and sales department.

About 150,000 humans and resources are working under the Thyssen Krupp company

in about 80 different countries!

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CHAPTER 2 THYSSEN KRUPP PRODUCT RANGE

2.1 Introduction

For high rise buildings, warehouses, restaurants or even private villas, name it and

Thyssen Krupp is also able to supply and also offer transportation for any kind!

As you can see, different products that are sold in the different parts of the world are

mentioned for your kkind informaation.

(as shown in the figure 2.1)

Fig 2.1: Product range of Thyssen Krupp in the world

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2.2 Elevators

• For any kinds requirements, be it elevators for passengers or car lifts or

dumbwaiters, TKE is able to offer its expertise.

Fig 2.2: Various types of elevators produced by Thyssen Krupp

None of the high rise buildings that you see no would have been possible without the

industrial revolution. Cities expansion is also another important factor. All of which

began about a hundred and fifty years ago. Dubai wants to be the best in everything

hen it comes to architecture, tourism or surveys. And elevator technology has helped it

achieve what it wanted to achieve. Neither the Burj Khalifa nor the greatest and oldest

world trade center would have been possible. When it comes to safety, nothing can beat

that of the amazing elevators which is the greatest mode of transport for all those

people on earth. [8]

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TKE just like any other elevator companies provide geared and gearless elevators and

also those that might require machine rooms and the ones that might not depending on

the requirements, governments etc.

How can one describe the awesome Thyssen Krupp elevators without talking about

their much acclaimed and greatest innovation of the TWIN elevators? These are those

in which one car acts as the counterweight for the other, and they travel at different

kilometer per hours and in different directions. This helped reduce the elevator traffic,

saving the energy and time, things once lost that can never be gotten back.

Fig 2.3: Figure showing amount of space saved when using TKE’s TWIN Elevator.

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Fig 2.4: TWIN Elevator

2.3 Escalators/Moving walks

See, when we talk about moving freely in the airports or office complexes or shops,

bargain place, department stores, blue marts etc, elevators play a key role. Of all the

things that it can do, its major purpose is to transport homo sapiens over small distance

steadily fast and comfortably. And nothing can beat the qualities of our Thyssen Krupp

elevators.

Fig 2.5: Thyssen Krupp manufactured elevators, high in quality and style.

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Fig 2.6: Deira City Centre (TKE Escalators)

If you have noticed, these moving walks are very slow. Testing our patience’s to the

maximum. TKE recognized this problem especially for the passengers who want to

travel long distances on landing their native countries after long breaks. So they came

up with the Turbo Track, which travels upto two meters per second. The first of its kind

was installed in Toronto Airport way before Dubai.

2.4 INNOVATIONS

Of all the products Thyssen Krupp offer, the major ones are elevators be it traction or

the hydraulic elevators and even the escalators and even the freight elevators. Mainly

includes the tracks, the moving walks, the turbo tracks, and most of the escalators. all of

these for tenders and the dumbwaiters and the chairs and the stand lifts and also the

PPC's (Passenger Boarding Connections).

Of all their innovations, the that are significant would be the TWIN and the High speed

double Decker elevators.

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2.4.1 TWIN ELEVATORS

The creative innovation of the TWIN Elevator not only condenses building spaces, it

also sees to it that the passenger waiting time is considerable reduced, a considerable

amount of elevator traffic is considerably reduced and also saves heck loads of time. All

of this being possible because of journey's end variety controller (DSC) which gives the

impression very useful in high rise buildings. What it actually does is maneuver two self-

regulating elevators in the same shaft.

Fig 2.7: Shaft of TWIN elevator

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CHAPTER 3: SERVICE DEPARTMENT

3.1 Introduction

Service sector plays a decisive role in the smooth functioning of TKE. Below mentioned

are a few of their major highlights.

3.2 Structure of the Service Department

The service department is the most important department in the company as this is

what gives revenue to the same. This mainly consists of the Call Back Team, the PPM

(Preventive Personal Maintenance) team and last but not the least, the Repair team.

These teams together work to compose the framework of the dissection.

Fig 3.1 Service Department Structure

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3.2.1 Maintenance & Service

Maintenance and the servicing of Thyssen Krupp is as well as third party elevators are

also dealt by the Thyssen Krupp elevators.

3.2.2 Third Party Maintenance

This section of the company, apart from drawing considerable profit, also increases the

the exposure of the company and hence, the marketability shoots up.

This section, also carries out the compulsory monthly checks on elevators and then,

servicing of those elevators which would have had problems during the PPM.

Major brands that are serviced and maintained would include the great Otis, Schindler

Mitsubishi and even Kone!

Fig 3.2: Unit of Third Party

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3.2.3 Conducting Enquiries

When the call centre locks in on a call, the first step done is the initial scrutiny. And then

comes the launch of the conversational convention. This in turn is always supported by

the some service sales department. Here the main ales executive would question and

guide them toa sole owner who attend to the basic needs and steps or repairs to be

carried out. Once it’s approved, the same department old request the engineers to

proceed with whatever is necessary.

Fig 3.3: Third Party Maintenance flow process

3.2.3.1 Call Back Report

When we get a call at the call centre, from the passenger either due to sudden

breakdown or other such sudden problems, or technical assistances, the assistant at

the call centre would collect details of the lift, the unit details, the problem, timing of the

call and the caller name.

Once this is done, the operator would coordinate between the technicians and the

nearest trouble shooter and dispatch the technicians to the site. They would attend to

the problem. Some might be genuine and some might be just false calls.

On arriving at the site, the technician would first check the lift to see whether it’s a major

problem or not. If its a minor fault, the technicians would do the repair works, else not he

would call the repair team. On completion of the necessary repair works, the technicians

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would fill up a repair completion report and is sent back to the call centre. The repair

completion report consists of the work done, date and time of work done and the unit

details, the name of technicians who did the work and the duration of time spent in

completing the work.

Fig 3.4: Report (Call Back)

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3.2.3.2 Repair Request

After all this is done, the repair request form will be entered into the software View.

Then the engineers, mainly service sales engineers will use the information and then

prepare quotations for those items that are required and need to be replaced. All if this

varies depending on the type of contract. Before all of this, a repair costing is prepared

which has list of items, man hours required for repairing and their cost with 10% profit.

And finally, this list would be sent to the client for approval and changes if any.

Fig 3.5: Repair Request

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3.2.3.3 Inspection Report

Monthly inspections are conducted on the various sites. Some with and others without

prior notice. These inspections are conducted based on a pre assembled format and

series of methods.

3.3 Preparing Quotation

This is that document that will be submitted to the client once you have fixed the prices

and got approval from the client for the proposed rates. This document generally

consists of the list of items that needs to be replaced or those that had already been

replaced, the number of spares, cost per spare, man hours spent for each item and then

in the end, net price with the margin[3]

.

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Fig 3.6: Sample Quotation

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3.4 Preparing Repair Work Order

On getting approvals from the client for the submitted quotations, especially those

repairs that haven’t been done but needs to be replaced, we prepare a repair work

order.

This repair work order consists of the specific SAP number, the reference number from

the quotation, the list of spares and their quantity.

Once all the details of the work unit are entered in SAP, its sent to the warehouse. At

the warehouse, the coordinator would check in SAP whether the mentioned SAP

number is there in the software.

If so they would give approval to the technician and release the required spare parts to

the technician. He would in turn complete the works and submit the completion report to

the service sales engineers.

And this document would prove to be a proof of the completed works. On completing

the necessary works, completion reports would be prepared and send for approval.

An example of a work order is shown in the next page.

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Fig 3.7: Repair Work Order Form

3.5 Work Completion Report

Work completion report is proof of the repair works being completed. On receiving the

approved work order, this report is prepared. This is proof that all the works have been

completed by Thyssen Krupp Elevators and the next step is invoicing.

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Fig 3.8: Sample Work Completion Report

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3.6 VIEW Dubai

VIEW will have details of the different units, the technicians that had worked there, the

amount f time spend by each technician on various projects and the days in which these

had been undertaken.

Fig 3.9: VIEW – Unit search

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Fig 3.10: VIEW- Elevator specification

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CHAPTER 4: ENERGY EFFICIENT ELEVATOR TECHNOLOGIES

4.1 Legislative Provisions

The increasing dependence of European Community on external energy sources has

lead to people finding possible ways to reduce energy consumption and improvement in

energy efficiency. [8]

The Energy Performance of Buildings Directive was published by the European Union in

June 2002.

An Energy White Paper was published by the UK Government in February 2003 and

then the energy provisions were revised of the Building Regulations Part L.

all of which were begun from April 2006 as Building Regulations 2000 Approved

Document L2A: Conservation of Fuel and Power.

As a result of these consultations, the 2010 edition of Approved Document L2A was

published and came into effect from April 2011.

4.2 Energy Consumption and Conservation

Fig 4.1: Relationship of lifts to other energy consumers in an office building

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Of any equipment, their entire life cycle has to be taken into consideration for total

energy conservation such as manufacture, installation, operation, dismantling and

disposal.

The operational phase is the most important of these phases. The following figure

illustrates the relationship of energy consumption of lifts with that of the other energy

uses in an office building.

The traffic requirements of the occupant’s in a building determine the type of

transportation equipments installed in a building. Designers should keep in mind that the

transportation requirements can be minimized through good building layout.

Just by reducing the number of units, energy cannot be sensibly saved. It can only be

done through appropriate selection of components to meet traffic demands, good

equipment design and efficient operational control of the transportation equipment.

Modernization of elevators for efficient use might involve higher initial capital

investment, but over time this can be recovered through energy savings. With new and

cheaper speed drives, capital and operational costs have been reduced.

Fig 4.2: Elevator operating modes

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4.3 Energy Consumption of Lifts

The four major motivations or reasons behind energy consumption estimation and lift

system’s energy measurement are mentioned below[9]

.

• To understand the energy consumption of one specific installation.

• This would answer the common question, ‘’How much energy does the

installation consume?’’.

• To compare the energy consumption of two different types of lifts (e.g. different

drives).

• This would answer the common question, ‘How much energy can be

saved by replacing drive A with drive B?’’.

• To minimize the energy consumption of lifts on a journey by journey basis.

• This would answer the common question, ‘What is the optimum speed

profile for the next journey that would minimize the energy consumed

based on the load, travel distance and direction?’’.

• To predict the energy consumed by a lift system based on its various parameters

(eg: travel distance, speed, capacity, gearing, type of drive etc).

• This would answer the common question, ‘What would the energy

consumption of a new design of lift system be with a certain configuration

and a specified set of components?’’.

When taking into consideration the configurations of new lifts and predicting energy

consumption improvements or changes for modernization, the above mentioned points

need to b carefully analyzed. The last method takes into consideration the lift

parameters.

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4.4 Factors Affecting Lift Energy Consumption

The following mentioned factors affect the energy consumed by lifts:

• Mechanical system

• Compensation system

• Counterbalancing ration

• Guidance system (rails/slider/rollers)

• Roping (reeving) ration (1:1/2:1 etc)

• Idler sheave efficiency

• Drive sheaves efficiency (traction etc.)

• Drive system

• Brake consumption

• Creeping/leveling time

• Acceleration/deceleration profile

• Drive regeneration

• Gear efficiency

• Motor efficiency including any cooling fans

• Control system

• Traffic (dispatcher) efficiency

• Door system (drive, passenger detection etc)

• Controller (traffic and drive) consumption

• Electrical system

• Well/machine room/car lighting

• Heating and cooling

• Power factor

• Operational Aspects

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• Number of starts

• Travel distance

• Speed

• Load

• Duty

The operational aspects describe about the way the lifts are used and they are the

crucial factors concerned with energy consumption.

Factors such as number of possible stops, rated speed, car capacity and travel

distance, which are fundamental to providing transportation service, cannot be changed

and should be considered at the design and specification stage itself. These affect

energy consumption too.

Fig: 4.3: Elevator Energy Consumption for various systems

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4.4.1 Mechanical System

In a lot of instances, the type of gearing employed affect consumption. Worm

Gearboxes are less efficient than Helical Gearboxes. The efficiencies of worm type

gearboxes approach 70% for high torque systems. Modern gearboxes are have

efficiencies as high as 70-90%. [9]

Fig 4.4: Helical Gearboxes

Fig 4.5: Spring Gearboxes

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Another important factor is the roping systems such as 1:1, 2:1 etc. and single wrap and

double wrap. Generally simple roping systems (1:1), lead to more efficiency.

Fig 4.6: Elevator Roping Systems

In order to reduce the sudden changes in torque, flywheels are used at times. Using

flywheels can reduce efficiency of the system as the inertia of other moving masses

should always be minimized.

Lift systems need to overcome friction in the guide rails, guide shoes etc. and air

resistance to the car moving in the pit. The weight of the car should be kept minimum

and has an important effect. While maintaining traction, the empty car should weigh

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twice that of rated load for larger car sizes. Reduced weight of empty car would imply

lighter counterweight and hence, conserved energy.

4.4.2 Drive System

The main drive systems available today are based on VVVF, which is variable voltage

and variable frequency. A VVVF system without regeneration back to the supply

conserves more energy.

Fig 4.7: VVVF Drives used in Elevators

Same is the case with traction and hydraulic drives. Conventional hydraulic drives are

unable to recover any of the energy consumed in driving the lift up during the return

downward journey. And so, these days, pressurized accumulators are used to recover

some of the energy during the down trip. Some of the systems also use a VVVF pump

system to control oil flow more accurately.

4.4.3 Control System

The drive control system can allow the drive to operate competently by profiling the

movement between stops in the best possible manner. The standards selected for

speed and also its acceleration and even the jerk (all of this are often dictated by the

ride comfort requirements and traffic design) can affect the energy conservation.

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Some traffic control systems move lifts to parking floors during the idle hours. This

comes in handy during peak hours, but is wasteful during out of hours or in light duty

environments.

4.4.4 Electrical System

When it comes to electrical systems, efficiencies of each components are important.

There are always losses due to system running at power factors less than unity and

also motor and generators incur copper and iron losses that would suffer internal

windage losses. Connecting wires can cause additional losses.

The drive and traffic controller uses energy (standby power) even when the lift is not

moving. A system of powering-off a controller during low traffic conditions should be

considered in a way similar to the MG (motor generator) set shut down progression

used on older Ward- Leonard systems.

Fig: 4.8 Drives used in Elevators

Energy is also utilized for car and machine room lighting, heating, cooling etc. If the car

lighting can be concentrated when the lift is inoperative, significant energy savings are

possible. Pit lighting can often be left on inadvertently and contemplation should be

given to routinely turning it off after (say) five hours.

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For low-use lifts, the energy harried on standby maybe superior than that used when

operating.

The Hong Kong Government had proposed limiting the size of the hoist motor as a

means of limiting energy consumption[8]. This however can have a substantial

consequence on the management capability, person along for the ride waiting and

person along for the ride waiting period and would not be sufficient in most situations.

4.4.5 Duty

The following factors have a significant effect on energy consumption.

• Car mass

• inoperative time

• Travel course

• Load disparity in the car

• Number of journeys made by occupants and their destinations

• Number of occupants demanding service

The following figure shows the potential amount of energy that can be recovered back

to the power supply for a 75% encumbered down trip.

Lifts are generally designed to be counter unprejudiced at 40-50% rated load. This can

be prepared by assembling the mass of vacant car plus 40-50% of rated load equal to

counterweight. Figure 13.2 assumes that the setting up has a 42% counterbalancing.

Thus the most well-organized use, in this case, is when car is 42% encumbered.

The traffic control algorithm can have an authority on how some of the traffic stipulate is

handled. For example, when under high stipulate conditions, what happens is that the

identical floors at the same time together. It is also possible for the traffic controller to

provide an algorithm designed for energy saving operation.

Another scheme to diminish energy convention is to eliminate lifts from service outside

the climax periods. This has the consequence of increasing the car habitation levels and

hence brings the lift system closer to equilibrium condition. There can be an augment in

person along for the ride waiting times using this practice.

4.4.6 Regenerating Energy Back into Supply

In any hoisting function, latent energy is power [9]. When a lift system is in operation up

empty (or down full), it is ‘overhauling’. The motor is efficiently driven by the load, under

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the pressure of gravity thus braking the lift structure and preventing plummeting. Lifts

always need to fritter away unnecessary energy from the system, either as waste heat

into banks of resistors, or by rejuvenation. Whether the energy can be regenerated and

the mechanism for achieving it depends on the brand of drive.

Regenerating lift drive systems return the stored energy back to the supply through the

supply metering structure.

Fig 4.9: Regenerating Energy Working Principle

On the other hand, not every meter can testify this repeal power and abstract units from

the total. A unique meter has to be built-in by conformity with the utility company. Where

this is not possible arrangements should be made for the regenerated power to be used

by other energy ‘sinks’ in the building, such as lighting, HVAC, etc. it is important to bear

in mind that regeneration can cause the supply voltage to rise at the lift input terminals,

unless it is coupled to a low impedance supply.

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Chapter 4: CONCLUSION

4.1 Conclusion

Installing energy efficient elevator technologies might cost more initially, however in the

lost run, these are a much better bet than investing in stock markets or in banks. As we

know, the two major reasons behind saving energy is so as to reduce resource

depletion and then the most important reason being, saving money.

In this report, we have discussed the various technologies that can be installed to save

energy. Right from installing motion detectors ad presence sensors to save cabin light

energy wastage, to appropriate use of controllers, perfect combination of the different

operating modes to save startup energy.

We have also concluded that machine-roomless, gearless elevators save upto 75%

more energy than the traditional hydraulic elevators. A lot of energy is dissipated as

heat into the shaft. Instead of wasting this energy, this can be regenerated using

regenerative drives and used to power cabin lightings or other office equipments.

As gearless elevators use permanent magnets, thereby reducing internal losses and

reducing size of motors and hence saves space.

4.2 Future Works

I would keep in mind all the technical knowledge I had learnt from this internship in my

future projects. Topics such as control systems, fuzzy logic, neural networks and

genetic algorithms are very important topics when it comes to elevators and other fields.

Through this internship, I was exposed to an entirely different perspective of how it is

like to work in an office atmosphere, deal with clients and negotiate. I would surely put

all my knowledge into practice.

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References

1. http://www.thyssenkruppelevator.com/

2. http://en.wikipedia.org/wiki/Elevator

3. http://inventors.about.com/od/estartinventions/a/Elevator.htm

4. TKE Presentations

5. Company profile

6. www.thyssenkrupp-elevator.com

7. Elevator 101 manual

8. Brochures and manuals of ThyssenKrupp elevator

9. http://www.e4project.eu/documenti/wp6/E4-WP6-Brochure.pdf