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Remote Monitoring 178 Educational Focus Compilation EDUCATIONAL FOCUS: REMOTE MONITORING complex and detailed analysis of diagnostic information. Effective objective methods of measuring allow us to document a precise image of the lift. Monitoring The lift unit itself can establish communication between the lift unit and the operator or this may be initiated by the operator. In the former case, this might have been preceded by a malfunction, prompting the lift unit to communicate with the operator by means of a brief message using an SMS, fax, e-mail or directly in the diagnosis monitor. In the latter case, the operator communicates with the lift unit to call up diagnostic tools, depending upon how technically developed the lift is. Figures 1 and 2 show some examples of effective monitoring programs offering a series of status and diagnosis displays. Statistics and Database It is not only important to have the actual remote diagnosis facility. Statistics are also essential for making a fast assessment of all units involved. All of the data required for the lift are filed in a database including past malfunction situations and the actions taken so that the observer can get a detailed understanding of the unit’s state at the remote location. Diagnosis Tools Modern lift control mechanisms with their peripheral devices have a pivotal role to play in diagnosing lift units. They receive a wide array of messages on the state of a Figure 2 In many areas of technology today, it is entirely natural to observe technical processes from a distance and to exert an influence on them from that location. We use all kinds of modern telecommunication equipment ranging from the simple telephone or cellular lines all the way to super-fast Internet connections to monitor and control processes. Remote diagnosis of processes is moving into all areas of modern technology ranging from automation engineering to medical science. And it’s obvious what the benefits are many. Scaling down service costs, faster reaction times to failures or even preventing failures from occurring in the first place by taking controlled preventative actions are just some of the reasons for availing yourself of the benefits of remote diagnosis. At the end of the day, it’s remote diagnosis that provides the prerequisites for doing next-generation service work. Systems are used in lift technology these days that make it possible to call up information on system states and exert an influence on these systems, thus constantly increasing quality and reliability. The main differences between these systems are the diagnostic tools. They start with passing on centralized alarms all the way to a DIAGNOSIS AT A DISTANCE by Peter Zdun Figure 1 EDUCATIONAL FOCUS: REMOTE MONITORING

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Page 1: EDUCATIONAL FOCUS: REMOTE MONITORING DIAGNOSIS · Remote Monitoring 180 Educational Focus Compilation EDUCATIONAL FOCUS: REMOTE MONITORING Escalators, although not the primary mode

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complex and detailed analysis of diagnostic information.Effective objective methods of measuring allow us todocument a precise image of the lift. Monitoring

The lift unit itself can establish communication betweenthe lift unit and the operator or this may be initiated bythe operator. In the former case, this might have beenpreceded by a malfunction, prompting the lift unit tocommunicate with the operator by means of a briefmessage using an SMS, fax, e-mail or directly in thediagnosis monitor. In the latter case, the operatorcommunicates with the lift unit to call up diagnostictools, depending upon how technically developed thelift is. Figures 1 and 2 show some examples of effectivemonitoring programs offering a series of status and diagnosis displays.Statistics and Database

It is not only important to have the actual remotediagnosis facility. Statistics are also essential for makinga fast assessment of all units involved. All of the datarequired for the lift are filed in a database includingpast malfunction situations and the actions taken sothat the observer can get a detailed understanding ofthe unit’s state at the remote location.Diagnosis Tools

Modern lift control mechanisms with their peripheraldevices have a pivotal role to play in diagnosing lift units.They receive a wide array of messages on the state of a

Figure 2

In many areas of technology today, it is entirely naturalto observe technical processes from a distance and toexert an influence on them from that location. We use allkinds of modern telecommunication equipment rangingfrom the simple telephone or cellular lines all the way tosuper-fast Internet connections to monitor and controlprocesses. Remote diagnosis of processes is moving intoall areas of modern technology ranging from automationengineering to medical science. And it’s obvious what thebenefits are many. Scaling down service costs, fasterreaction times to failures or even preventing failures fromoccurring in the first place by taking controlled preventativeactions are just some of the reasons for availing yourselfof the benefits of remote diagnosis. At the end of the day,it’s remote diagnosis that provides the prerequisites fordoing next-generation service work.

Systems are used in lift technology these days thatmake it possible to call up information on system statesand exert an influence on these systems, thus constantlyincreasing quality and reliability. The main differencesbetween these systems are the diagnostic tools. Theystart with passing on centralized alarms all the way to a

DIAGNOSISAT A DISTANCE

by Peter Zdun

Figure 1

EDUCATIONAL FOCUS: REMOTE MONITORING

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lift unit, such as the state of the safety circuit, the positionof the lift, the state of the call and display units, and awide variety of other information. Fault Memory and the Lift Control Mechanism

Modern control mechanisms are equipped with afault memory that indicates the current fault state andhow the fault arose. It is often extremely important toascertain information on previous states before there isa malfunction in order to localize faults. It stands toreason that observing this fault memory is essential fordoing modern diagnosis on lift units. We also shouldnot forget that having information on a potential mal-function in the lift’s control mechanism saves time and money.The State of the Safety Circuit

We can often draw conclusions on faults or sources offaults from the state of the safety circuit. A good exampleis when the technician sees that the safety contact of thecabin doors is not closed. This makes it much easier forhim to zero in on the range of potential malfunctions. It’sfair to say that the safety circuit state display is an impor-tant component of remote diagnosis. The State of the Drive Unit

Most frequency converters have diagnostic mechanisms,and the frequency converter is integrated into an overalldesign strategy, either through the lift control mechanismwith a serial bus, such as CAN, or by means of a directconnection. Remote diagnosis enables us to set parametersand call up states in the same manner as with the operator’scontrol mechanism. However, it should be noted thatremote parameter adjustment should be done with ut-most caution. The State of the Door Drives

The door drive can be integrated into a diagnosticstrategy just like the drive unit, and there are a seriesof ways to do this that are analogous to the frequencyconverter. Serial data exchange between the lift con-trol mechanism and door control unit is definitely afuturistic idea. This allows the exchange of com-mands, feedback, parameters and diagnostic data forremote diagnosis.Lift Performance Data

The performance data can be ascertained when the liftis traveling. This information is passed onto a diagnosis con-trol center. For tracking these performance data, it is obvi-ously necessary to have special sensors that track the lift’smovement in the lift shaft. An example is the German-based Henning GmbH, that ascertains these data by mea-suring the acceleration in the x-, y- and z-directions andsubsequently calculating the performance data aschanges in acceleration and delay in the direction of

travel, the change in velocity at creep rate, changes inpath/time in order to localize rail malfunctions, andimpact and jolting movements from the rail guideswith analysis and documentation in conformity withthe ISO18738 standard. Hence, remote diagnosis pro-vides precise and objective information on the travel-ing behavior of the lift being monitored.Door Functioning

The method of ascertaining traveling behavior describedabove also enables you to ascertain door functioning. Remotediagnosis identifies malfunctions in the doors’ runningbehavior and allows preventative actions to be taken. Forinstance, this enables the replacement rollers before theybreak down. The Cable Load

The appropriate sensors allow you to detect the cableload on each of the cables and passes this informationonto the diagnostic tool, thus tracking the service life ofthe load-dependant component parts such as cables,driving discs, bearings and guides much more preciselythan with simple trip counters. The State of the Peripheral Devices

Every peripheral device, such as the light curtain andload measuring instrument, etc. (with fault detector orstate control device), can be linked to remote diagnosisfor visual data display.

There is a wide range of diagnostic monitor programsbeing offered on the market today, although the inter-faces for these programs are not compatible with one an-other. This means that operators with lifts in operationswith a variety of different lift control mechanisms mayalso be using a series of remote diagnosis tools. Therewill surely be a harmonization of interfaces in diagnosticsystems in the future. In Germany, a group of leading liftcomponent manufacturers have joined together to form aCANopen group with the idea of developing a uniformstandard protocol (CANopen for lifts) for electrically net-working lift components. They will be exhibiting initialresults at a joint stand at the Interlift 2003 fair in Augsburg,Germany, among them remote diagnosis systems basedupon the CANopen system. Especially holistic applications,such as integrating lift components into a diagnostic systemtransmitting data to a remote control center includingelectronic documentation of the state of the lift, will bepointing the way to the future. If this system has open orstandard interfaces, the user will then be able to matchthe diagnostic tools to the individual unit.

Peter Zdun is the project manager for elevator controllerswith Wittur AG. Zdun has worked with Wittur Germany forthe last three years.

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Escalators, although not the primary mode of transporta-tion, have become a prominent feature of many transitsystems, and in terms of safety are often considered benign.However, they pose a far greater risk. Due to the logisticsof typical escalator maintenance, safety is routinely com-promised – a fact that is confirmed by an accident ratethat is higher than that of elevators.

What is really disturbing are studies that suggest asfew as 15% of accidents are caused by unsafe acts, whichmeans that up to 85% could be prevented. Unfortunately,these problems are often compounded by extended oper-ating hours, intolerance for downtime and a lack of clearstatistical data, promoting a “quick fix” approach to repairswhere faults remain elusive, and units are returned toservice only to fail again. Ultimately, accident expensesspiral as the equipment becomes less safe, satisfactionlessens as shutdowns become prevalent, and repair costsrise as problems increase in severity.

Realizing these issues, Vertical Analysis pioneeredthe development of a new system designed to enhancethe entire maintenance process, from upper manage-ment to the mechanic in the field. This resulted in Elevision,a real-time remote monitoring and management systemfor escalators, elevators and other electro-mechanicaldevices. The system comprises three main components:A remote user interface, a local equipment interfaceand networking.Remote User Interface

Utilizing the latest ASP technology, engineers devel-oped a web-based system, which is accessible with anyInternet Explorer equipped PC, with no special softwarerequirements. Knowing the mechanics need for mobility,the system has been designed to include an automatednotification module.

Compatible with most text capable devices, includinge-mails, cell phones and pagers, notification gives theflexibility to specify who gets notified, to what device(s),and at what times of the day. This means that someonecan be notified within minutes of an event regardless ofwhere the user is or what the user is doing.Advanced Features

The system incorporates many advanced features, includ-ing an MS-SQL Server database, facilitating the creationof detailed statistics and reports. Yet, as with any web appli-cation, navigation is simple and intuitive.Status

Status can be viewed on three levels, with red andgreen icons indicating fault and clear respectively. Themain window displays the status of all buildings. Statusindication is limited to buildings containing equipmentthat the user is authorized to view, which are predefinedby the users access control parameters (see AccessControl). Choosing a building reveals the status of eachunit in that building, similarly limited by the users accessrights. Finally, selecting a unit displays the status of eachmonitored device.

ELEVISION MONITORING – NEW TECHNOLOGYFOR ESCALATOR MAINTENANCE

by Stephen C. Hope and Charles E. Choux

250200150100500

Elevators Escalators

Accidents Annually(per 1,000 units)

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Users are also assigned an administrative level. Thisfurther defines what a user is allowed to do within thesystem. Some users can merely view data, whereas otherscan modify parameters.Equipment Interface

Utilizing state-of-the-art technology, and capitalizing onthe success of the Escalator Analyzer, engineers createdthe RMS-2040 remote monitoring controller. The RMS-2040 is designed to interface to any electro-mechanicalequipment. However, it includes many enhanced featuresspecifically designed for escalators.

The RMS-2040’s modular design provides flexibility,with the ability to monitor up to 200 individual inputs(from 5VDC to 240VAC), and provision for custom devices.These currently include a step and handrail speed monitor-ing device, and three-phase metering unit. Furthermore,the RMS-2040 incorporates two onboard analog inputsfor voltage and current sensors, which can be programmedto provide designed motor overload protection.

Additionally, the RMS-2040’s exclusive overlay tech-nology allows integration without the need for controlleror safety devices updates, and with a fully configurable,code-compliant manual reset option, it is excellent forupgrading existing equipment.Local User Interface

The RMS-2040 also includes an intuitive menu-drivenuser interface for the field technician or mechanic. Eachunit is capable of storing and displaying the last 1,000events in date/time order, with each monitored devicedisplaced as an alpha-numeric message (e.g., Upper StopButton) as opposed to a cryptic fault code.Alternate Equipment Interface

Although the RMS-2040 is the preferred equipment inter-face, in some cases, existing controllers can be used. Thiswill mean, however, that the advanced features of theRMS-2040 will not be available to the onsite mechanic.Networking

The RMS-2040 includes onboard networking, allowingdirect connection to an existing network, or sub-networking

Charts and ReportsAt each status level, the system includes “Event View”

and “Chart View” options, allowing event history to beviewed in tabular or graphical formats.

The “Event View” provides a tabular event listing for allbuildings, a specific building or specific unit. It providesan entire event history and can be searched and/orarranged in virtually any order.

Likewise, “Chart View” allows event history to be analyzedin a graphical format, with similarly extensive options.

Common charts include run-time analysis, which displaysup or down time for the selected unit, building or buildings;event frequency; and fault number by device. Graphs canbe displayed as line, pie or bar charts with options to definethe data set, date range, period, etc. Access Control

Access is restricted with a user ID and password,which are assigned by the system administrator and canbe changed or deleted at anytime. In addition to security,access control allows the administrator to define usergroups. Each monitored unit is assigned to one or moregroups. Similarly, each user is given access to one or moregroups. This allows multiple users to access the site whilerestricting their data access only to their equipment.

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from a single network node. In each case, communica-tion can be wired or wireless using 10 base-T, RS-485,RS-232, POTS or license free 900Mhz DSS wireless.Network Security

Central to the system, Elevision employs one PC con-figured as an LAN-WAN client. Acting as a data hub, theLAN-WAN client facilitates data transfer from each remotedevice to the Internet. Using this configuration enhancesnetwork security by allowing DHCP device addressing. Italso eliminates any issues that would be associated withdevices being connected directly to the Internet.Data Reliability

In addition to any network protocols, presented dataincludes embedded error checking and handshaking. This isdesigned to ensure that data is valid, and to confirm thatit has been received and understood.

Moreover, to cope with the potential for network failure,each RMS-2040 includes sufficient, non-volatile memoryto store the last 1,000 events. Similarly, events are alsobuffered by the LAN-WAN interface, prior to transmissionto the Elevision Server. Additionally, each network nodeis continually checked by the LAN-WAN client to verifynetwork integrity, automatically notifying an administratorin the event of any network failure or errors.Conclusion

By combining the accessibility of a web interface, withthe advanced features of the RMS-2040, Elevision substan-tially enhances the ability of all maintenance personnel,from the contract administrator to the mechanic in the field.

Ultimately, this will ensure better maintenance, withimproved reliability and enhanced safety.

Stephen C. Hope graduated in Electronics from TVU in 1990 andobtained QEI certification in 1997.Charles E. Choux is a 30-year-industry veteran. He started withWestinghouse in 1970 as a mechanic and obtained QEI certificationin 1990. Choux and Hope founded Vertical Analysis in 1995 anddeveloped the Escalator Analyzer, the Escalator Safety AnalysisProgram and Elevision. For more information, visit Vertical Analysison the web at www.VerticalAnalysis.com.

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Greek monks escaped pirates by building monasterieson tall, virtually unscalable rock spires called the Meteora.Many times, the only way up was by elevator. A wovenbasket on a system of ropes and pulleys (the first tractionelevator) was used to transport visitors and supplies up thecliff face. As the rope showed signs of wear, the elevatoroperators would lighten the loads. When the rope broke, itwas time for a new rope. The monk assigned to monitorthe lift probably got flogged; a sensation not unfamiliar topresent day elevator monitoring and service people respond-ing to a service outage or customer emergency.

Our ability to monitor the status of elevators has comea long way. Today, we can monitor the status of a bank ofelevators, connecting to each elevator group in turn usingan electronic link and checking to see if any cars are out-of-service or are operating in a non-standard mode. Typi-cally, when elevator monitoring reveals that an “event”has occurred, a human operator intervenes to see whichmechanic should be assigned, dials their number and reportsthat a certain unit needs immediate attention.

Today’s monitoring is a marked improvement over thebroken rope scenario, but still leaves room for frustrations:Passengers are forced to climb stairs or postpone appoint-ments, business tenants lose money, building owners andmanagers get angry phone calls, and the elevator mechanicresponds to a failure with very little data. Monitoring hasthe potential to improve service and satisfaction, but there’sa lot of room for improvement.

What can monitoring do for you? To answer this question,we need to examine four things:u What is the current state of monitoring?u What are the goals of monitoring?u What are the technical requirements to meet those goals?u How will monitoring make life easier?Current Monitoring

Current elevator monitoring practices include:u Scheduled visitsu Electronic monitoringScheduled Visits

Many maintenance contracts include regular site visits forinspection. Drawbacks to this type of monitoring include:u The mechanic may be making a scheduled visit to a jobthat needs no attention while another customer’s elevatoris out of service.u The mechanic spends valuable time traveling betweensites – unproductive time. u If a problem is uncovered, the mechanic has no fore-warning and is less likely to bring the proper tools andparts. Repairs are delayed, elevator downtime and lostdollars increase, etc.

Electronic MonitoringElectronic monitoring evolved over the last decade. Effec-

tively used, electronic monitoring enables elevators to bemonitored from a central location. A particular elevator orgroup of elevators can be examined in fair detail, not onlyfor event or fault code generation but also to evaluatesystem performance and system security.

When a problem is detected, monitoring personnel are ableto quickly alert a mechanic via a cell phone or pager, and themechanic is able to head to the job with some insight aboutwhat is happening. Travel time and elevator downtime arereduced. The efficiency of the mechanic is increased, alongwith building tenant satisfaction. But even at its current best,electronic monitoring has some shortcomings:u Although downtime may be reduced, the elevator is stillout of service (usually at an inopportune time).u The mechanic is dispatched efficiently but still withoutthe advance knowledge to be prepared with the right toolsand parts.u Systems typically use modems where point-to-pointconnectivity is fragile, and disconnects are common.u The mechanic is unable to schedule his time effec-tively because failures occur without warning, and thetime required to affect repairs cannot be easily predicted.

The “information age” has recently provided tools thatenable development of “next-generation” monitoringsystems. What should we expect? What can monitoringdo to improve elevator uptime?Monitoring Goals

An elevator monitoring system is a tool that can enablebetter service to be provided at a lower cost. The goalsaround which modern elevator monitoring should bedesigned read like a wish list for elevator mechanics,building owner/managers and building tenants. Immediatelyattainable goals include:u Better serviceu Reduced costu Increased profitu Improved response timeu Reduced elevator downtimeu Reduced customer callbacks u Solid information for the mechanic, allowing preparationbefore site arrivalu Reliable scheduling of mechanics u Factual, non-interpretive data about each elevatoru A service history database for each elevatoru Education targeted toward problem areasu Proactive responseu Contribution to building security

REMOTE ELEVATOR MONITORINGby Motion Control Engineering, Inc. (MCE) Technical Staff

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and reporting faults – without human dial-up or interven-tion. No scheduled monitoring or pre-scheduled dial-uptimes are required. Controllers may be “told” to reportparticular events or fault occurrences that have predictivevalue to the monitoring system and the mechanic. Whenthese conditions occur, the controller will initiate com-munication with the monitoring equipment, which in turncommunicates with designated personnel via e-mail, fax,pager, text-messaging or other means. A monitoring systemwill place a call when a reporting event occurs, tell whatthe indications are and recommend the solutions.Reliable Communication

The Internet offers broad, multi-stranded communicationcapacity. A single PC used for monitoring is capable ofmaking simultaneous connections to multiple controllers.The multi-threading nature of the Internet means thatsingle-point failures are unlikely to interrupt communication.Internet-ready, intelligent elevator and group controllerswill also accept simultaneous connections from multiplePCs. This combination not only opens a world of monitoringpossibilities, but also allows troubleshooting experts toprovide assistance “hands on” in real time. This synergywill allow for rapid diagnosis, solid prediction of probablefaults and up-front preparation for the mechanic.Solid Record Keeping

Record keeping is crucial to monitoring. Today, depend-able solid-state memory and large, inexpensive hard drives– backed up by versatile, inexpensive long-term storagemedia like CD-RWs or magnetic tape – allow data to beeasily and economically collected and preserved. Dataarchives can provide a wealth of information. Monitoringsoftware can mine data to uncover patterns for predictiverepair scheduling and accurately predict when failure willoccur. Additionally, monitoring systems can maintain arecord of elevator access/egress, stops and times (coupledwith the performance characteristics of the elevator overthat time) that can be invaluable for legal defense andincreasingly useful for security purposes.The Right Software

Capable PCs, intelligent controllers, reliable communi-cation and a dependable data archive provide the potentialfor powerful monitoring capability. To realize this potential,monitoring software will be developed that is easy to install,easy to configure and easy to use. On-screen controls willbe intuitive and, if help is needed, pop-up windows andin-depth online help will be available. Software and hard-ware will be both scalable and adaptable, so that futureadditions can easily be “plugged-in.” When new equip-ment is added, your monitoring system will notice the newparticipant, establish communication and gather the neces-sary data. In the near future, software will be available toaccommodate not only the monitoring system manufac-turer’s equipment, but also legacy or current equipment

In the near future, capabilities will expand to include:u Compatibility with different generations of equipmentu Broader compatibility with products from multiple vendorsu Remote reassignment of parking floors and prioritiesu Remote assignment of parameters for all modes ofoperationu Correction of potential problems before failures occuru Remote reconfiguration of timed/automated modeassignmentu Remote reassignment of lobby parametersu Record retention for code compliance and legal defenseu Monitoring and evaluation of errors to reveal currentproblems and accurately predict future problemsu Easy integration of additional equipmentu Monitoring of elevators and other controlled-motionequipment

Technical RequirementsAll the goals listed are practical and attainable. The tech-

nology and expertise are available. Next-generation elevatormonitoring will use artificial intelligence, microprocessorsand the communication power of the Internet, to deliver:Intelligent Elevator Controllers

Microprocessor-based controllers will monitor thehealth and performance of the cars they control. Groupsystems will monitor the cars/controllers they dispatch.With sufficient onboard memory, each controller willmaintain an event log that provides both a history ofwhat has occurred and an archive that may be processedto reliably “predict” future problems. For example, if aparticular fault pattern historically occurs prior to a doorproblem, intelligent software will note when the patternrecurs. A mechanic can then be dispatched, with the righttools and parts, to prevent the problem when work can bedone at a convenient time before a failure occurs.

Unlike earlier electronic monitoring technology, intelligentcontrollers will be capable of initiating communication

Figure 1

Reliable Remote Monitoring & Control

Monitoring

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FAX

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from any manufacturer to the extent practical for thatequipment. Monitoring software will evolve past tradi-tional passive monitoring capabilities to allow for controlof selected system parameters and capabilities to be exertedfrom the monitoring site should the need arise.What Will Monitoring Do for Me?

Ultimately, a well-deployed monitoring system willcontribute to the business needs of mechanics, buildingowner/managers, building tenants, building security andto the safety and comfort of elevator passengers. The ef-ficiency of the mechanic will be improved. The predictiveand analytical capabilities of the monitoring system, coupledwith the interactive intelligence of microprocessor-basedcontrollers, means that a mechanic can arrive at a job, ata time convenient to the customer, with the right partsand tools, and with the best possible forecast of the timenecessary to perform the required tasks – all before a failurehas occurred. Mechanics can use hard, non-interpretivedata to proactively support their clients, saving customersmoney and frustration, and ensuring that the need forservice or repairs is evidenced not by opinion but by ac-curate, reliable data collecting. Together, these capabili-ties mean better margins for the service company andbetter service for the building owner/manager.

Motion Control Engineering, Inc. (MCE) is beginning toship the new Internet-ready, “i” product line. Built aroundthe Power PC chipset and incorporating artificial intelli-gence, “i” products combine MCE hardware capabilitieswith new graphical user interfaces. Configure, control andmonitor with mouse-clicks and simple keyboard entries.Monitor elevator performance, movement, status and secu-rity from virtually anywhere on the planet. Tomorrow’smonitoring capabilities are here. . .today. c

Figure 2

Provide Better ServiceReduce CostReduce CallbacksIncrease ProfitImprove Response TimeImprove PreparationSchedule ReliablyPredict/Avoid Failures

Monitoring Benefits Everyone

Improve ServiceIncrease Elevator EfficiencyReduce CostIncrease ProfitReduce Elevator DowntimeFactual, Non-interpretive DataRecord RetentionProactive Tenant Relations

Provide Better Service

Service Providers

Security

Building Owners,Managers, Tenants

Improved Tenant SecurityImproved Passenger SecurityImproved Response TimePredictable Emergency ResponseHard, Reliable DataRecord Retention R

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