JP2024533301A - Insert element for guiding a rope or cable, rope guide roller or cable guide roller and method for manufacturing the insert element - Patents.com - Google Patents

Abstract

An insert element (1) for guiding a rope or cable, in particular for a cable car system, comprising a cover layer (2) having a first cover layer side (6) designed to be in contact with the rope or cable to be guided and a second cover layer side (7) opposite to the first cover layer side (6), and an indicator element (3) arranged on and/or in the cover layer (2). The indicator element (3) is designed to indicate a wear state of the insert element (1). Furthermore, a rope pulley comprising the insert element (1) and a method for manufacturing the insert element (1) are provided.

Description

The invention relates to an insert element for guiding a rope or cable, a rope or cable guiding roller and a method for manufacturing the insert element.

Insert elements, sometimes called linings, are used in rope pulleys or deflection pulleys of ropeways, whether aerial ropeways, rail ropeways or drag lifts. The purpose of the insert elements is to support and guide the rope or cable. In addition, the insert elements also have sound absorbing and vibration damping effects. Due to the installation of such elements in sensitive systems such as ropeways, the wear of such insert elements must be monitored regularly so that they can be replaced in time before they fail. Such monitoring is usually carried out by trained workers who inspect the insert elements. The shape of the insert element is measured using a gauge or calipers and compared with the initial state. Based on the deviation of the shape of the insert element from its initial state, the wear state can be inferred. Since the insert elements are often difficult to reach (e.g., on the support columns of cable cars), monitoring the insert elements is labor intensive, difficult, time consuming and therefore expensive.

Therefore, an object of the present invention is to simplify monitoring of insert elements.

This problem is solved by an insert element having the features of claim 1, a rope or cable guide roller having the features of claim 13 and a method for manufacturing an insert element having the features of claim 14. Preferred embodiments are given in the dependent claims.

According to one aspect of the invention, there is provided an insert element for guiding a rope or cable, in particular for a cable car installation, comprising a surface layer having a first surface layer side designed to be in contact with the rope or cable to be guided and a second surface layer side opposite to the first surface layer side, and an indicator element arranged on and/or in the surface layer, the indicator element being designed to indicate a wear state of the insert element.

According to one aspect of the invention, the insert element can also be used in pulleys of lifts, elevators, cranes, etc. Basically, wherever a cable or rope is guided, run or deflected. The invention also relates to so-called wear strips, which can be provided not as one-piece closed rope pulley insert elements, but as lockable strips. For example, such wear bands can protect the rope or cable from direct contact with buildings or other structures. The rope or cable can also be a load-bearing structure. In particular, the cable or cord can be a non-current-carrying (i.e. power-carrying) element. Such a dual function would be counterproductive, since a cable used for power supply should not be used to carry a load at the same time. Nevertheless, a test current or the like can be conducted through the cable or rope.

According to one aspect of the invention, an insert element, lining or lining for a rope pulley protects, on the one hand, the rope or cable and, on the other hand, the rope pulley itself, or rather the pulley bundle which forms it, usually made of metal. In addition, it can also protect the bearings of the rope pulley and the support structure. Furthermore, the insert element can also provide increased comfort by ensuring a mechanically and acoustically quiet running when guiding the rope through the pulley. For this purpose, the insert element can be made of a softer and/or more elastic material than the pulley for which it can be provided. Thus, the insert element can be made, for example, from an elastomer or rubber as a one-piece ring. The insert element can be realized with or without a flexible woven or flexible wire mesh insert. For high loads, the insert element can be made of plastic, which can include polyurethane as base polymer and can belong to the category of thermoplastic or thermosetting resins.

In contrast to the prior art, with the insert element of the present invention, it is not necessary for a person to be in the immediate vicinity of the insert element in order to check the wear state of the insert element. On the contrary, it is sufficient to inspect the insert element from a distance, since the wear state of the insert element can be easily recognized using the indicator element. For example, when used in a ropeway system, it may be sufficient to inspect the insert element from the ground, for example using binoculars, thereby immediately obtaining information about the wear state. This can significantly reduce the time required for inspection, and the wear state of the insert element can be inspected, for example, when it passes by during a driving trip. In this way, the previously known time-consuming and dangerous insert element checking operations can be reduced or avoided, and at the same time it can be ensured that, thanks to the objective indication by the indicator element, the wear state can be objectively determined, independently of the person performing the inspection. This ensures that the insert elements are always replaced at the same time. In contrast, a purely visual individual inspection by a person does not guarantee that several insert elements are objectively evaluated at the same time. As a result, the use of the insert element of one aspect of the present invention makes it possible to standardize the replacement intervals of the insert elements.

The insert element can be a separate part and designed to be fixed to the roller. The roller can in turn be rotatably held on a structure such as a support. For example, the pulley can be rotatably attached to the structure by means of plain or rolling bearings. The rope or cable can be placed on the insert element and supported and/or guided by the insert element. A cable guiding direction can specify the direction in which the guided cable extends. The insert element can also be designed to protect the cable from lateral displacements transverse to the cable guiding direction. For this purpose, the insert element can have a lower strength than the pulley. In other words, the insert element can be made of an elastic material that at least partially surrounds the guided cable. To improve the guiding performance, the insert element can at least partially adapt to the shape of the guided rope.

Preferably, the insert element is designed as a single part. In other words, the insert element cannot be disassembled into its component parts in a non-destructive manner. This can ensure high stability and simple manufacture of the insert element. In particular in the case of a single-part or one-piece insert element, a defined position is guaranteed (e.g. during centralized production of the insert elements) so that even with several insert elements, the indicator element always has the same relative position, e.g. with respect to the surface layer. This can ensure a consistent determination of the wear of the insert element.

The surface layer can be a volumetric layer that extends in all three spatial directions. In particular, in a cross section transverse to the direction in which the cable is guided, the surface layer can have a first surface layer side and an opposite second surface layer side. The surface of the surface layer on the first surface layer side and the surface of the surface layer on the second surface layer side can be many times larger than the side of the surface layer. The first side of the surface layer can have a shape such that the rope or cable can be reliably guided through the insert element. For this purpose, the first surface layer side can have, for example, a shape that is complementary to the rope or cable to be guided. Preferably, the first surface layer side has a shape such that the rope is at least partially housed in the surface layer. For this purpose, the surface layer can, for example, be recessed on the first surface layer side or can have areas that are made of a different (for example softer) material.

The indicator element can be influenced and/or changed by operation (i.e. by contact between the rope and the surface layer and/or the indicator layer) in such a way that the wear state of the insert element, in particular the surface layer, can be indicated by the indicator element (e.g. the state of the indicator element). For example, the indicator element can be a further layer, for example arranged on the second surface layer side of the surface layer. The indicator element then becomes visible as a result of wear of the surface layer, such that when looking from the outside at the first surface layer side, it is possible to quickly and easily determine that the surface layer or the insert element is in a certain wear state. In the case of a ring-shaped core element, for example, the wear state can be determined by looking radially outwards of the core element (i.e. the contact side between the core element and the rope or cable). For this purpose, the indicator element can for example have a different colour than the surface layer. For example, the surface layer can be black and the indicator element white. This ensures that a high contrast makes it quick and easy to recognise that the indicator layer has come into contact with the surface of the core element.

According to a further aspect of the invention, the indicator element can be a strip provided on the first surface layer side of the surface layer at least in the area where the rope is guided through the surface layer. For example, the indicator element can be a strip-like element located in or on the first side of the surface layer transversely to and/or along the direction in which the rope is guided. In this case too, the indicator element can have a different color than the surface layer. During operation, the surface layer and the indicator element can wear away. In this case, the indicator element can have a material thickness smaller than the surface layer, such that at some point during the wear the indicator element disappears (i.e. is no longer visible) so that when viewed on the first surface layer side it is possible to recognize whether the indicator element is still there. Furthermore, the indicator element can also have a shape that narrows or widens with distance from the first surface layer side. Thus, the visible indicator element can thicken or thin depending on the wear. Thus, the indicator element can indicate whether and/or to what extent the surface layer is worn. In particular, in the embodiment in which the indicator elements extend transversely to the rope guide direction, it is easy to see which areas of the first surface layer are subject to particularly high wear by the ropes or cables. It is also possible in this way to draw conclusions regarding operational conditions (e.g., biased rope guides, uneven loading of the core elements, etc.), which can result in further optimization of operation and increased safety.

Preferably, several indicator elements can be provided in or on the surface layer. For example, several indicator elements can be provided as layers parallel to the first surface layer side in a stacked manner. Each indicator layer can have a different color. For example, it is conceivable that the indicator element closest to the first surface layer side has a green color, the next indicator element has an orange color, the next indicator element has a red color, and so on. Thus, in this embodiment, the insert element can have a total of three indicator elements, each designed as a separate layer. In that case, during operation, first the surface layer is at least partially worn away and the first (green) indicator element becomes visible. In this way, the indicator element can indicate that the surface layer is already worn away, but further operation of the insert element is still possible (by the green color of the first indicator element). If the first indicator element also wears away, the second indicator element (yellow layer) appears, indicating that the insert element will soon be worn away and will have to be replaced. As soon as the red indicator element becomes visible, the indicator element indicates that the insert element must now be replaced. Similarly, the insert element can have many different layers as indicator elements, allowing for close monitoring of the insert element. It is also conceivable that the indicator element extends variably relative to the first surface layer side. In this way, a visible pattern can be created on the first side of the surface layer when the surface layer is worn. The pattern can vary depending on the sealing condition. For example, the indicator element can extend wavy relative to the first side of the surface layer. The variable arrangement of the indicator element means that only specialized personnel and/or image recognition systems can detect the wear condition, but not passengers or visitors. This prevents laypeople from misinterpreting the indicator element.

The above-mentioned insert elements, on the one hand, reduce the potential danger for personnel who have to inspect the insert elements, and on the other hand, reduce the effort involved in determining the wear of the insert elements. For example, the insert elements can be checked from a certain distance during the operational process.

Preferably, the indicator element at least partially or partially covers the first surface layer side and/or the second surface layer side.

If the indicator element is designed as a voluminous layer, it can cover the surface layer at least in the area where the rope or cable comes into contact with the surface layer. In other words, in this case, the indicator element can be arranged on the first surface layer side. Alternatively or additionally, the indicator layer can be provided on the second surface layer side (i.e. the side of the surface layer opposite the rope or cable) and extend to the second surface layer side. In this case, the indicator layer only appears when the surface layer is worn. Alternatively or additionally, the indicator layer can also partially cover the first side of the surface layer and/or the second side of the surface layer. In this case, the indicator element can be arranged as a strip element (for example transversely to or along the rope guide direction). The indicator element can thus be arranged depending on the application of the insert element. For example, a partial arrangement of the indicator element can be advantageous when the cable or rope comes into contact with the surface layer in a known area. On the other hand, if it is not clear in advance where the wear will occur, a flat arrangement of the indicator element can be provided. The latter can apply, for example, to large-area insert elements. This means that the insert element can always be provided appropriately for the intended application. It is also conceivable to provide an indicator element in the surface layer, for example at half the material thickness of the surface layer. This means that it is possible to indicate the wear state, for example, when the insert element is half worn down. As a result, a reliable monitoring of the expected service life of the insert element can be provided.

Preferably, the surface layer comprises SBR, NR, NBR, EPDM, CSM, BR and/or FKM.

This means that the surface layer can have sufficient elasticity to ensure that the cable or rope is reliably guided and that the required soundproofing and vibration damping effects are achieved. Furthermore, the materials SBR (styrene butadiene rubber), NR (natural rubber), NBR (acrylonitrile butadiene rubber), EPDM (ethylene propylene diene rubber), CSM (hypalon), BR (polybutadiene rubber) and/or FKM (fluoro rubber) are easy to process and the surface layer can be easily manufactured into the appropriate shape. In particular, the insert element can be a vulcanized product. In addition, the above-mentioned materials are inexpensive, thus making the manufacturing process of the insert element efficient. Furthermore, the surface layer can comprise a mixture of the above-mentioned materials. The above-mentioned materials or their blends can each constitute a base polymer and can be augmented by additives such as carbon black. In this way, the desired properties (such as color) required for the intended use of the insert element can be easily achieved.

Preferably, the indicator element comprises PE, PP, TPE, PA and/or PETP.

The use of said materials allows the indicator element to have suitable properties, on the one hand, to indicate the wear state well and, on the other hand, to have sufficient strength to safely guide, for example, a rope or cable and still indicate the wear state of the insert element even in contact with it. In other words, the indicator layer can comprise PE (polyethylene), PP (polypropylene), TPE (thermoplastic elastomer), PA (polyamide) and/or PETP (polyethylene terephthalate). Furthermore, the indicator element can also comprise a mixture of the above materials. The above materials merely represent the base polymer and can also contain further additives such as carbon black. As a result, the indicator element can also be suitably adapted to the respective use area of the insert element and have sufficient strength and resistance for long-term operation.

Preferably, the indicator element and the surface layer have different properties, in particular hardness, density, tensile strength, elongation at break, wear, rebound resilience, compression set, tear propagation resistance, glass transition temperature, electrical conductivity and/or degree of swelling.

The surface layer preferably has a Shore A hardness greater than 81 Shore. In contrast, the indicator element can have a Shore A hardness less than 80 Shore. It has been found that, when using insert elements in guide rollers for cable car systems, particularly high energy efficiency (particularly with regard to deformation of the insert element) can be achieved within the above-mentioned ranges. The fact that the indicator element has a lower hardness compared to the surface layer ensures that, when in contact with a rope or cable, the indicator element is eroded faster than the surface layer, so that the wear state can be clearly and easily recognized even from a certain distance. The hardness can be measured, for example, according to DIN 53505, DIN EN ISO 868, etc.

The density of the indicator element is preferably lower than the density of the surface layer. Preferably, the density of the indicator element is less than 1.25 g/ ^cm3 and the density of the surface layer is preferably higher than 1.25 g/ ^cm3 . This ensures that the wear state of the insert element can be clearly indicated. The density can preferably be measured according to the EN ISO 1183-1 standard. Preferably, the surface layer has a density in the range of 1.26 g/ ^cm3 to 1.28 g/ ^cm3 . This ensures that the weight of the insert element is in a suitable range, especially when used with pulleys for cableway systems. In this case, a particularly efficient operation of the pulleys is possible.

The tensile strength may indicate the maximum mechanical tensile stress that the material can withstand before it breaks (e.g. breaks). Preferably, the surface layer has a tensile strength of more than 15 N/ ^mm2 . In contrast, the indicator element may have a tensile strength of less than 15 N/ ^mm2 . In this range, it can be ensured that the surface layer has sufficient resistance to breakage. This can ensure the necessary safety when guiding the rope or cable. In contrast, a lower tensile strength is sufficient for the indicator element, since it is only partially used at most to guide the rope or cable. The previously indicated areas can be used to form a particularly efficient insert element, since the indicator element only needs to have a lower tear resistance and is therefore cheaper.

The elongation at break can be a characteristic value which indicates the permanent elongation of a component relative to its initial length when the component is loaded by a force. In other words, the elongation at break can indicate the deformation capacity of the component. Preferably, the elongation at break can be measured according to the DIN 53504-S2 standard. Preferably, the surface layer has an elongation at break of at least 120%. In contrast, the indicator element has an elongation at break of at least 200%. This ensures that a safe operation of the insert element is guaranteed without the risk of premature breakage, even when the indicator element is involved in the guiding of a rope or cable.

Abrasion (also known as abrasion or erosion) can refer to the loss of material at the surface of a component. Abrasion can be caused by mechanical stresses such as friction or environmental influences. When material is removed from a component, usually very small particles can be generated. In material science, abrasion can also be called wear. Preferably, the abrasion is measured as a volume according to the ISO 4649-Method A standard. Preferably, the surface layer has an abrasion greater than 160 ^mm3 . In contrast, the indicator element preferably has an abrasion less than 160 ^mm3 . Furthermore, the abrasion of the surface layer and the indicator element can be limited to a maximum ^{of 200} mm3. This can also ensure permanent operation of the insert element. This is particularly advantageous when the indicator element is located in the material of the surface layer. Furthermore, an upper limit on the abrasion can prevent excessive material from entering the environment.

The rebound resilience can be used to evaluate the elastic behavior of an elastomer under impact stress. Preferably, the surface layer has a rebound resilience of at least 40%. In contrast, the indicator element preferably has a rebound resilience of less than 40%. Preferably, the rebound resilience is measured according to the DIN 53512 standard. Furthermore, the surface layer and the indicator element can have a rebound resilience of at least 25%. This ensures that the rope or cable is reliably guided on the insert element without bouncing off the insert element, and thus the rope is reliably guided.

Compression set is a measure of how an elastomer behaves during long periods of constant compression and subsequent relaxation. Preferably, the compression set is measured over 24 hours at 70°C and 20% strain according to the ISO 815 Type B standard. Preferably, the surface layer can have a compression set of less than 20%. In contrast, the indicator element can have a compression set of at least 20%. This ensures that the rope is reliably guided even when the insert element is subjected to long-term loads. Furthermore, it can be ensured that the indicator element reliably indicates the wear state of the core element. The above-mentioned areas can be provided with particularly durable insert elements.

Volume resistivity can be a measure of how well a component conducts electric current. It is obtained by multiplying the measured volume resistivity by the measurement area and dividing it by the sample length. Preferably, the volume resistivity is measured according to the IEC 62631-3-2 standard. Preferably, the surface layer has a volume resistivity of less than 6.7 ^* 10 ¹³ ohms ^* cm. In contrast, the indicator layer preferably has a volume resistivity of at least 5×10 ¹⁴ ohms ^* cm. This ensures that the indicator element is non-conductive. This is advantageous, for example, when a conductive surface layer (for example with a volume resistivity of 1.9×10 ⁵ ohms ^* cm) is used. In this case, it is possible to detect when the rope comes into contact with the insert element only through the indicator element, which results in a significant increase in the electrical resistance. In other words, a voltage can be applied to the guided rope or cable and the voltage can be measured on the conductive surface layer. As soon as the surface layer wears away and the rope or cable comes into contact with the insert element only via the indicator element, an increase in the resistance can be detected. This makes it possible to draw the conclusion that the surface layer is worn away. Alternatively, this arrangement can also be designed the other way around, in that the surface layer is non-conductive and the indicator element establishes a conductive connection between the detector element (e.g. the sensor element) and the guided cable. In this case too, it is possible to detect that the surface layer is worn away (in this case by establishing an electrical connection).

The tear propagation resistance can be measured, for example, according to ONORM C9446:2007 02 01. The tear propagation resistance can be the maximum force required to form a tear in the material and can be correlated to the thickness of the material. The ratio of the tear propagation resistance of the surface layer to the tear propagation resistance of the indicator element can preferably be in the range of 0.7 to 1.9. It has been found that in this range, the indicator element can be reliably held in or on the surface layer even when the surface layer is already highly worn. This ensures that the indicator element reliably indicates the wear state even when the surface layer is worn to an advanced stage. Furthermore, the rope or cable can be reliably supported by the indicator element even when the wear of the surface layer is already in an advanced stage.

The glass transition temperature can preferably be measured according to the ISO 11357-2 standard. Preferably, the surface layer has a glass transition temperature of at least 70°C. In contrast, the indicator element can have a lower glass transition temperature. The glass transition temperature can be the temperature above which the polymer changes from a rubbery to a viscous state. In other words, above the glass transition temperature, the surface layer suddenly changes its properties that are necessary for guiding the rope. It is therefore advantageous for the surface layer to have a glass transition temperature high enough to ensure safe guiding of the rope through the core element even during continuous operation. In contrast, the indicator element can have a lower glass transition temperature, since it does not primarily play a role in guiding the rope, especially if it is only provided piecewise or partially on the surface layer. As a result, an efficient interaction between the surface layer and the indicator element can be achieved. Furthermore, thanks to the above measured glass transition temperature of the surface layer, the insert element can be used even with pulleys that rotate at high speeds (i.e., with a higher heat generation during operation).

Preferably, the indicator element comprises a fabric, at least one thread, a fluorescent material, a coloring liquid, in particular an ink and/or a film.

The fabric can be, for example, a surface woven fabric provided broadly in or on the surface layer, including at least two thread systems. If the surface layer is worn to such an extent that the fabric is visible from the outside, the wear state of the insert element can be determined. The fabric can also be made of, for example, wires, cords or other elements. Preferably, the fabric also has a stabilizing effect such that radial forces acting on the insert element can be absorbed by the fabric. This allows the insert element to be thinner, which can save manufacturing costs. Furthermore, the insert element can also be used in small rolls.

At least one thread can be arranged in or on the surface layer in such a way that the thread becomes exposed (i.e. becomes visible from the outside) when the surface layer is worn. This makes it possible to draw conclusions about the wear state of the insert element. The thread can be arranged straight or curved in the surface layer. Preferably, the thread can have a striking color (e.g. a lighter color than the surface layer) so that it can be easily identified from a greater distance.

The fluorescent material can be used to detect the wear state of the insert element. Moreover, the fluorescent material can have the further property that after its excitation, an emission of light occurs. When the light is emitted, photons can be emitted. For example, the insert element to be tested is illuminated with a light source so that the fluorescent material recognizable on the surface emits light accordingly. This means that the insert element can be checked for wear even in the dark. This can simplify the maintenance of the insert element. The fluorescent material can be applied in the form of a paint or lacquer on or in the indicator element. The light source used to excite the fluorescent material can be, for example, a UV light source. In principle, any fluorescent material is suitable for use with the indicator element.

The colored liquid can be arranged, for example, in capsules in the surface layer. In case of wear or abrasion of the surface layer, these capsules can be damaged and the liquid can come out to the surface of the insert element. This makes it easier to recognize that the insert element has reached a certain wear state. In this embodiment, it is advantageous that even in the case of small wear, the liquid is distributed over a wide area on the surface of the insert element, making it easier and simpler to recognize that a certain wear state has been reached even in the case of small damage to the surface layer. The capsules containing the liquid can be arranged in the surface layer at a certain radial distance from the first surface layer side. Furthermore, it is also possible to provide liquids of different colors depending on the position in the insert element (for example, depending on the distance from the first surface layer side). In this way, the various colors appearing on the surface of the insert element can be used to determine how far the insert element has been worn.

The foil can be a plastic foil or an aluminum foil arranged parallel to the side of the first surface layer in the insert element. When the surface layer is worn, the foil can be partially or completely exposed, thereby indicating the wear state of the insert element. It is also conceivable to mix aluminum powder into the surface layer, which becomes visible when the surface layer is worn. This makes the indicator element particularly simple to realize.

Preferably, the insert element includes at least one conductivity sensor designed to detect a voltage applied to a rope or cable passing through the insert element.

This embodiment can be realized in two ways. First, the surface layer can be an insulating material, as for example in the case of an aerial cableway. In this case, the cable running through the insert element is used to carry a signal (for example a telephone signal). If the insert element is not insulated, this signal will be disturbed and will not reach the receiver in a proper form. In contrast, the indicator element can be designed to be conductive. If the surface layer rubs off to such an extent that the cable passing through the insert element comes into contact with the indicator element, the circuit is closed and the signal conducted through the cable can be detected by a sensor on the insert element. This means that remote monitoring can be used to determine whether the insert element is worn out. Furthermore, the system can also detect the exact location of the worn core element within a larger system. On the other hand, it is also possible that the surface layer is designed to be conductive and the indicator element is provided in the surface layer or on the second side of the surface layer and has insulating properties. If the surface layer wears out, tension can be transmitted from the rope passing through the insert element to the insert element as long as the surface layer has a certain thickness. If the surface layer wears away and the wear is so great that the rope comes into contact with the indicator element (e.g. with the indicator layer), the rope becomes insulated and tension can no longer be measured. In this case too, it is possible to detect that the core element is worn away.

Preferably, the indicator element comprises at least one metal rod and/or wire.

For example, a metal rod can be located in the surface layer at a right angle to the direction in which the cable is guided. If the upper layer is worn or abraded to such an extent that the wire reaches the surface (i.e. the first side of the surface layer), it can be determined that the upper layer is worn. This provides the advantage that further wear is not possible or is at least significantly reduced by the metal rod, since the metal rod has a significantly higher strength than the surface layer. For this purpose, the metal rod can be placed in the surface layer at a predetermined position (i.e. at a predetermined distance from the first surface layer side) where it is desired to replace the insert element. In this way, the wear limit of the insert element can be determined in a simple manner, which still allows the insert element to continue operating.

Similarly, wires can be placed in or on the surface layer, thereby having a similar effect as metal rods. Furthermore, different wires separated from each other can be placed in different positions in the surface layer. For example, each wire can have a different distance from the first side of the surface layer. For example, the wires can be different colors. If the surface layer is worn down to such an extent that the wire comes into contact with the surface of the surface layer, the wire can be recognized and a worn state can be indicated. During further operation, the wire (as opposed to the metal rod) can further wear, i.e., come off the insert element (until the next wire appears). Different colors of the different wires can indicate different wear states. It is also conceivable to apply a voltage to each wire and measure this separately for each wire. If the applied voltage can be measured, it can be assumed that the insert element is still intact. On the other hand, if the voltage cannot be measured on one or more wires, it can be assumed that these wires have already come off the insert element due to the reduced material thickness of the surface layer. Since the distance of the individual wires from each other and to the first surface layer side is known, the depth of wear or the worn state can be accurately determined according to the spacing at which the wires are provided in the insert element. Moreover, this wear state can also be determined by remote and/or automated maintenance. This means that detailed monitoring of a system, which for example comprises a large number of system elements, is easily possible. It is also conceivable to provide an automated system for monitoring the wear state of at least one insert element. The monitoring system can, for example, automatically issue an alarm when a predefined wear state is reached. This can ensure that worn insert elements are detected and replaced in good time.

Preferably, the insert element includes a plurality of indicator elements radially distributed about the insert element, each indicator element having a different property.

The radial direction of the insert element can refer to an insert element having a ring-like shape. Nevertheless, the insert element can also be a flat object. In any case, the radial direction can be a direction perpendicular to the first overlay side and extending to the second overlay side. Providing some indicator elements is similar to providing different wires at different distances from the first coating layer side in the above embodiment. In other words, by providing indicator elements at different distances from the first surface layer side, different wear conditions can also be achieved by other indicator elements.

Preferably, the ratio of the material thickness of the surface layer in the radial direction of the insert element to the material thickness of the indicator element is in the range of 0.01 to 0.7, preferably in the range of 0.07 to 0.5, more preferably in the range of 0.1 to 0.3.

It has been found that in the first zone there is an optimal interaction between the surface layer and the indicator element. This is particularly true if the indicator element is designed as an indicator layer. The first-mentioned zone is particularly favorable with regard to the occurrence of stresses between the two layers, since the thicknesses of the two layers are in such a ratio to one another that no stress peaks occur at the interface between the surface layer and the indicator layer. This ensures the durability of the insert element.

In the second region mentioned above, the advantage is that even if multiple indicator elements are provided (in the second ratio specified above, the material thicknesses of all present indicator layers are added together), sufficient adhesion of all the individual layers is ensured.

Furthermore, it has been found that in the last defined zone, the wear state of the insert element is indicated for a long enough period of time for the maintenance worker to notice it. This means that the wear state of the insert element can be reliably indicated and reliably detected for a sufficient period of time.

Preferably, the insert element comprises a fabric layer designed to absorb radial forces, and the ratio of the material thickness of the surface layer to the material thickness of the fabric layer in the radial direction of the insert element is in the range of 0.8 to 9, preferably in the range of 1 to 8, more preferably in the range of 2 to 6.

The above-mentioned first zone provides the advantage that the insert element can be used in a wide range of applications. For example, the insert element can also be used in systems where large radial forces act on the insert element. Even in such cases, safe operation is achieved.

In the second area mentioned above, the fabric layer is just as thick as the surface layer or thinner. The advantage here is that an overall thinner insert element can be provided and sufficient wear reserves can be achieved by the surface layer. At the same time, the insert element provides sufficient resistance to absorb radial forces.

The latter section has been found to be optimal, especially when operating cable car systems, as the radial forces occurring in the cable car system can be sufficiently absorbed and yet the insert elements can be provided thin enough to allow efficient operation.

Preferably, the surface layer has, on its first surface layer side, a cross section transverse to the cable or cable guide direction, a guide area, and two protective areas adjacent to the guide area, the guide area has a recess that is recessed by a recess distance relative to at least one of the shoulder areas, and the ratio of the width of both shoulder areas in the cross section transverse to the cable or cable guide direction to the recess distance is in the range of 0.2 to 5, preferably in the range of 0.4 to 3, and more preferably in the range of 0.7 to 2.5.

This means that the first side of the surface layer can be structured in such a way that the cable can be guided through it in a defined manner. Preferably, the recesses are circular and have the recess spacing as radius. This allows the first side of the surface layer to be complementary to the cable or rope to be guided, which improves the guidance. The specified ratio indicates the ratio of the depth of the recess to the width of the insert element transverse to the cable guiding direction. The first ratio offers the advantage that any type of rope or cable can be fitted into the insert element without problems. For example, even very thick ropes can be suitably guided through the insert element. Furthermore, the range of use of the insert element in the first zone defined above is very large, making it possible to use the insert element for a variety of applications. In the second range defined above, there is the advantage that even in applications where forces are applied to the insert element transverse to the radial direction of the insert element and the direction in which the rope is guided, the insert element has sufficient strength or resistance to such forces, allowing permanent operation. In other words, the force acting on the shoulder area depends on the depth to which the rope sinks into the recess of the insert element. Thus, the second area defined above provides optimal lateral stiffness while efficiently guiding the rope. The last area defined above provides the advantage that the insert element provides optimal lateral guidance for the rope or calf, which can be realized with minimal material usage.

According to a further aspect of the invention, there is provided an insert member including a surface layer having a first surface layer side adapted for contacting a rope or cable to be guided and a second surface layer side opposite the first surface layer side, and an indicator member disposed on and/or in the surface layer side adapted to indicate a wear condition of the insert member, and a bearing portion for rotatably supporting the rope or cable guide pulley.

Such pulleys can be used, for example, for deflecting and/or guiding ropes or cables in cable cars, elevators, cranes, etc. The insert element can also be designed according to one of the insert elements described above.

According to a further aspect of the invention there is provided a method of manufacturing a core member for guiding a rope or cable, in particular according to any of the above aspects, comprising the steps of:
providing an indicator element;
A method is provided that includes the steps of applying an indicator element in or on a surface layer, and vulcanizing the indicator element and the surface layer, where the indicator element is capable of indicating a wear condition of the insert element.

Furthermore, the method may include a step of cutting or milling a groove in the first surface of the surface layer. The groove may extend in the cable guiding direction. An indicator element (e.g. a tape of a different color) may be inserted into the groove and then vulcanized together with the surface layer. In this way, the indicator element may be glued to the surface layer. Preferably, the indicator element is located at the deepest point of the recess in the surface layer. The recess may be designed in such a way that at the start of operation of the insert element, the guided rope or cable does not touch the deepest point of the recess. The cable or rope may only touch the deepest point of the recess as a result of wear or abrasion of the surface layer and wear away the indicator element. It may be determined that a certain wear state has been reached if the indicator element is no longer visible. For example, the insert element may be replaced when the indicator element is no longer visible.

The variants and advantages of the embodiments mentioned above in relation to the device apply equally to the method and vice versa. Individual features of the individual embodiments can also be combined with one another to form new embodiments. The advantages of the individual features also apply to the new embodiments. Preferred embodiments are described in detail below with reference to the drawings.

2 is a schematic perspective view of an insert element according to one embodiment of the present invention; FIG. 2 is a cross-sectional view of the insert element shown in FIG. 1 transverse to the rope guiding direction. 4 is a schematic surface view of an insert element according to a further embodiment of the present invention; FIG. 4 is a schematic surface view of an insert element according to a further embodiment of the present invention; FIG. 4 is a schematic cross-sectional view of a further embodiment of an insert element according to the invention; 4 is a schematic cross-sectional view of an insert element according to a further embodiment of the present invention;

1 is a schematic perspective view of an insert element 1 according to an embodiment of the present invention. The insert element 1 according to this embodiment has a ring-like shape, only a part of which is shown in FIG. 1 for simplicity. The insert element 1 has a surface layer 2. The surface layer 2 has a first surface layer side 6 representing the outside of the surface layer 2 (i.e. facing the environment) and a second surface layer side 7 representing the inside of the surface layer 2. On the second surface layer side 7, an indicator layer is provided as an indicator element 3. Furthermore, on its first surface layer side 6, the surface layer 2 has a cable guide section 5 and two shoulder sections 4. The two shoulder sections 4 enclose the cable guide section 5 in their center. The rope or cable to be guided (not shown) stops at the rope guide section 5 and comes into contact with the surface layer 2. The cable guide section 5 has a recess 8 that is recessed radially inwardly with respect to the shoulder section 4. The cable is guided through the insert element 1 in a cable guide direction 10 (from right to left or from left to right in FIG. 1). In other words, the cable can move in the cable guiding direction 10. The insert element 1 can also move (i.e. rotate) according to the movement of the rope. For example, the pulley on which the insert element 1 is arranged can rotate. In particular, the guidance of the rope can wear the surface layer 2, since the relative speed between the rope and the core element is not equal to zero. Wear causes fraying, which causes the surface layer 2 to lose material. If the surface layer 2 wears to such an extent that the indicator layer 3 appears (i.e. is visible from the outside in the surface view of the core element), the wear state of the core element can be recognized from the outside. It can therefore be determined that the insert element 1 needs to be replaced.

2 is a cross-sectional view of the insert element 1 shown in FIG. 1, viewed perpendicularly to the cable guide direction 10. In FIG. 2, the cable guide direction therefore runs into and out of the plane of the paper. In FIG. 2, a recess 8 can be seen in the cable guide area 5. It can also be seen that the recess 8 has a radius that defines the recess. Furthermore, in FIG. 2, a radial direction 20 and an axial direction 30 are shown. The indicator layer 3 in this embodiment is bonded to the surface layer 2 by a vulcanization process. This can ensure that there is sufficient adhesion between the surface layer 2 and the indicator layer 3.

Figure 3 is a surface view of an insert element 1 according to a further embodiment of the invention. In this embodiment too, the surface layer 2 has two shoulder regions 4 and one rope guide region 5. However, in this embodiment the indicator elements are not arranged as indicator layers on the second surface layer side 7 of the surface layer 2, but as strip-like elements extending axially parallel to each other and transverse to the cable guide direction 10. The indicator elements 3 extend in both the shoulder region 4 and the rope guide region. This means that wear can be indicated over the entire width of the core element 1. In this embodiment, the indicator elements 3 are located on the surface of the core element 1 (i.e. on the first surface layer side 6) such that if the indicator elements 3 are no longer present it can be concluded that a certain wear state of the core element 1 has occurred.

In another embodiment, not shown, in addition to the indicator element 3 attached to the surface, further indicator elements are arranged in the surface layer 2. The indicator elements 3 are different in color. More precisely, the indicator elements 3 arranged on the surface of the surface layer 2 (i.e. on the first surface layer side 6) are different from the indicator elements 3 arranged in the surface layer 2. This means that using different color coding it is easy and quick to identify how worn the insert element 1 has become.

Figure 4 shows a surface view of an insert element 1 according to a further embodiment of the invention. This embodiment corresponds substantially to the embodiment shown in Figure 3, with the difference that in this case the indicator elements 3 extend in the cable guiding direction 10. In this embodiment, one indicator element is arranged at the deepest point of the recess 8 in the cable guiding section 5, and one indicator element 3 is arranged in each shoulder section 4. This means that even uneven loads that occur periodically on the insert element 1 due to uneven wear of the indicator elements 3 can be detected.

Figure 5 is a cross-sectional view of an insert element 1 according to a further embodiment of the invention. The embodiment shown in Figure 5 essentially corresponds to the embodiment shown in Figure 2, with the difference that the indicator element 3 is formed not as an indicator layer, but as a number of capsules containing a colored liquid. The capsules 3 are arranged at different depths in the surface layer 2. In other words, the capsules 3 are arranged at different positions in the radial direction 20 of the insert element 1. In this case, if the surface layer 2 is worn by a cable or rope, the capsules are damaged and liquid can leak to the first surface layer side 6. The colored liquid can indicate that a certain wear state of the insert element 1 has been reached.

Figure 6 is a schematic cross-sectional view of a further embodiment of the invention. The embodiment shown in Figure 6 essentially corresponds to the embodiment shown in Figure 3, with the difference that the indicator element 3 comprises a wire arranged in the insert element 1 and extending in the cable guiding direction 10. The wire 3 is arranged at different distances from the first surface layer side 6 of the surface layer 2, so that the wire 3 emerging at the surface of the first surface layer side 6 can indicate different wear states of the insert element 1. In a further embodiment, a voltage can be applied to the wire 3 and measured by a sensor. Damage to the wire 3 (e.g. due to wear) can change the voltage. In particular, each wire can be monitored individually. This means that remote diagnostics can be used to detect the extent to which the insert element is worn.

The rope guiding direction can also be referred to as the circumferential direction of the round insert element. In a further embodiment not shown, the indicator element is formed as a structure on the surface of the surface layer (i.e. on the first surface layer side 6). For example, the indicator element 3 is a recess in the rope guiding area 5, and if the recess is no longer present, it can be concluded that a certain state of wear has occurred. In a further embodiment not shown, the insert element includes, in addition to the surface layer and the indicator element, a fabric layer designed to absorb radial forces.

REFERENCE NUMERALS 1 insert element 2 surface layer 3 indicator element 4 shoulder section 5 rope guiding section 6 first surface layer side 7 second surface layer side 8 recess 10 cable guiding direction 20 radial direction 30 axial direction

Claims (15)

An insert element (1) for guiding a rope or cable, in particular for a cableway installation, comprising:
a surface layer (2) having a first surface layer side (6) designed to come into contact with the rope or cable to be guided and a second surface layer side (7) opposite to the first surface layer side (6);
and an indicator element (3) arranged on and/or in said surface layer (2), said indicator element (3) being designed to indicate a wear state of said insert (1). The insert element (1) according to claim 1, which is integrally formed. An insert element (1) according to any one of the preceding claims, in which the indicator element (3) at least partially or partially covers the first surface layer side (6) and/or the second surface layer side (7). An insert element (1) according to any one of the preceding claims, wherein the surface layer (2) comprises SBR, NR, NBR, EPDM, CSM, BR and/or FKM. The insert element (1) according to any one of the preceding claims, wherein the indicator element (3) comprises PE, PP, TPE, PA and/or PETP. The insert element (1) according to any one of the preceding claims, wherein the indicator element (3) and the surface layer (2) have different properties, in particular hardness, density, tear resistance, elongation at break, wear, rebound resilience, compression set, tear propagation resistance, glass transition temperature, electrical conductivity and/or swelling degree. The insert element (1) according to any one of the preceding claims, wherein the indicator element (3) comprises a fabric, at least one thread, a fluorescent material, a coloring liquid, in particular an ink and/or a foil. The insert element (1) according to any one of the preceding claims, further comprising at least one conductivity sensor adapted to detect a voltage applied to a rope or cable passed through the insert element (1). An insert element (1) according to any one of the preceding claims, wherein the indicator element (3) comprises at least one metal rod and/or wire. The insert element (1) according to any one of the preceding claims, comprising a plurality of indicator elements (3) distributed in the radial direction (20) of the insert element (1), each indicator element (3) having different properties. The insert element (1) according to any one of the preceding claims, wherein the ratio of the material thickness of the indicator element (3) to the material thickness of the surface layer (2) in the radial direction (20) of the insert element (1) is in the range of 0.01 to 0.7, preferably in the range of 0.07 to 0.5, more preferably in the range of 0.1 to 0.3. The insert element (1) according to any one of the preceding claims, further comprising a fabric layer designed to absorb radial forces, the ratio of the material thickness of the fabric layer to the material thickness of the surface layer (2) in the radial direction (20) of the insert element (1) being in the range of 0.8 to 9, preferably in the range of 1 to 8, more preferably in the range of 2 to 7. said surface layer (2) having on its first surface layer side (6) in a cross section transverse to the rope or cable guiding direction a guiding area (5) and two shoulder areas (4) adjacent to said guiding area,
the guide region (5) has a recess (8) which is deepened by a recess distance with respect to at least one of the shoulder regions (4);
The insert element (1) according to any one of the preceding claims, wherein the ratio of the recess spacing to the width of the shoulder regions (4) in a cross section transverse to the rope or cable guiding direction (10) is in the range of 0.2 to 5, preferably in the range of 0.4 to 3, more preferably in the range of 0.7 to 2.5. An insert element (1) comprising a surface layer (2) having a first surface layer side (6) designed to be in contact with the rope or cable to be guided and a second surface layer side (7) opposite to said first surface layer side (6), and an indicator element (3) arranged on and/or in said surface layer (2) designed to indicate a wear state of the insert element (1); and a rope or cable guide pulley comprising a bearing area for a rotatable mounting of said rope or cable guide pulley. A method for manufacturing an insert element (1) for guiding a rope or cable, in particular according to any one of claims 1 to 13, comprising:
Providing an indicator element (3),
The method includes the steps of applying the indicator element (3) in or on a surface layer (2), and vulcanizing the indicator element (3) and the surface layer (2), wherein the indicator element (3) is capable of indicating a wear state of the insert element (1).

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