Insert element for guiding a rope or cable, rope or cable guide roller and method for producing an insert element

Abstract

Insert element (1) for guiding a rope or cable, in particular for a cable car system, comprising a cover layer (2) with a first cover layer side (6) which is designed to come into contact with a rope or cable to be guided, and a second cover layer side (7) opposite the first cover layer side (6), and an indicator element (3) arranged on and / or in the cover layer (2), and wherein the indicator element (3) is designed to indicate a wear condition of the insert element (1), wherein the indicator element can become visible due to wear of the cover layer (2), so that a wear condition can be determined from the outside by looking at the first cover layer side (6), wherein the insert element (1) comprises a plurality of indicator elements (3) which are arranged distributed in a radial direction (20) of the insert element (1), and wherein each indicator element (3) has different properties.

Description

[0001] The present invention relates to an insert element for guiding a rope or cable, a rope or cable guide roller and a method for producing the insert element.

[0002] Insert elements, sometimes also called linings, are used for rope pulleys or deflection sheaves in cable cars, be it an aerial or rail cable car or a drag lift. The insert elements have the task of supporting and guiding a rope or cable. Furthermore, insert elements also have a sound-dampening and vibration-damping effect. Because such elements are used in sensitive systems such as cable cars, wear on such insert elements must be regularly monitored in order to replace an insert element in good time before it fails. Such monitoring is usually achieved by trained personnel visually inspecting the insert elements. The shape of the insert element is measured using a caliper or vernier caliper and compared with an initial condition.Based on a deviation in the shape of the insert element from its initial state, a wear condition can be determined. Due to the often difficult-to-reach insert elements (for example, on the supports of a cable car), monitoring the insert elements is labor-intensive, difficult, and time-consuming, and therefore expensive.

[0003] DE 3329024 A1 shows a pulley or sheave for guiding a rope. The pulley comprises a roller element and a counter element. The roller element and the counter element are connected by screws. The roller element and the counter element form a groove into which a wear strip can be inserted. The wear strip has a surface portion that can come into contact with a rope. Once the wear strip is worn, it can be replaced without special tools by simply loosening the screws.

[0004] EP 2669901 A1 discloses a cable with a wear indicator formed by an indicator device for the cable's wear status. The cable is characterized in that the outer sheath comprises a first layer forming the outer surface of the cable and a second layer adjacent to the first layer, which is continuously of a color different from the first layer.

[0005] US 6207902 B1 shows an electrical wiring system that provides a visible indication of wear before an electrical hazard arises in cable applications with high wear and tear. It uses high-contrast color between the extruded insulator and the outer jacket material in the cable. When the cable's outer jacket is worn, the underlying insulator becomes visible in a contrasting color to the outer jacket, indicating a hazardous condition.

[0006] Therefore, it is an object of the present invention to simplify monitoring of an insert element.

[0007] This object is achieved with an insert element having the features of claim 1, with a rope or cable guide roller having the features of claim 12, and with a method for producing the insert element having the features of claim 13. Preferred embodiments are specified in the dependent claims.

[0008] According to one aspect of the invention, an insert element for guiding a rope or cable, in particular for a cable car system, is provided, comprising a cover layer with a first cover layer side which is designed to come into contact with a rope or cable to be guided, and a second cover layer side opposite the first cover layer side, and an indicator element which is arranged on and / or in the cover layer, and wherein the indicator element is designed to indicate a wear state of the insert element.

[0009] According to one aspect of the present invention, the insert element can also be used in cable pulleys for lifts, elevators, cranes, etc., essentially anywhere where a cable or rope is guided, runs along, or is deflected. The invention also relates to so-called wear bands, which can be provided as closable bands instead of one-piece, closed cable pulley insert elements. For example, such wear bands can protect a rope or cable from direct contact with a building or other structures.

[0010] According to one aspect of the invention, insert elements, linings, or linings for rope pulleys protect the rope or cable on the one hand, and the rope pulley itself, or rather the usually metallic pulley disks that form it, on the other. Furthermore, the bearings of the rope pulley and the supporting structure can also be protected. Furthermore, insert elements can also increase comfort when guiding the rope through a pulley by ensuring mechanically and acoustically quiet running. For this purpose, the insert element can be made of a softer and / or more elastic material than the pulley on which the insert element may be provided. Accordingly, the insert element can be manufactured as a one-piece ring, for example, from an elastomer or rubber. The insert element can be realized with or without flexible textile fabric or flexible wire mesh inserts.For high loads, the insert element can be made of a plastic that may include polyurethane as the base polymer and may belong to the category of thermoplastics or thermosets.

[0011] In contrast to the prior art, with the insert element according to the invention, it is not necessary for a person to be in the immediate vicinity of the insert element to check the state of wear. Rather, it is sufficient for the insert element to be inspected from a distance, since the indicator element makes it easy to determine the state of wear of the insert element. For example, when used in cable car systems, it may be sufficient to inspect an insert element from the ground, for example using binoculars, and thus immediately obtain information about the state of wear. This can significantly reduce the time required for the inspection, so that, for example, the state of wear of an insert element can be checked as the vehicle drives past during operation.Thus, the previously known time-consuming and risky work of checking the insole elements can be reduced or avoided, while simultaneously ensuring that the wear status can be objectively determined independently of the person performing the inspection through the indicator element. This ensures that the insole element is always replaced at the same time. In contrast, a purely visual and individual inspection by one person does not guarantee that multiple insole elements will be assessed equally objectively. Consequently, by using the insole element according to one aspect of the present invention, replacement intervals for the insole elements can be standardized.

[0012] The insert element can be a separate part and designed to be secured in a roller. The roller, in turn, can be rotatably held on a structure such as a support. For example, the roller can be rotatably mounted on the structure by means of a plain bearing or roller bearing. A rope or cable can be placed on the insert element and supported and / or guided thereby. A rope guide direction can designate the direction of extension of the rope to be guided. The insert element can also be designed to protect the rope against transverse displacement transverse to the rope guide direction. For this purpose, the insert element can have a lower strength than the roller. In other words, the insert element can be formed from an elastic material that at least partially surrounds the rope to be guided.In order to improve the guiding properties, the insert element can at least partially adapt to the shape of the rope to be guided.

[0013] The cover layer can be a volume layer that extends in all three spatial directions. In particular, in a cross-section transverse to the cable guide direction, the cover layer can have a first cover layer side and a second opposite cover layer side. A surface of the cover layer on the first cover layer side and a surface of the cover layer on the second cover layer side can be many times larger than the side surfaces of the cover layer. The first cover layer side can have a shape such that the rope or cable can be reliably guided through the insert element. For this purpose, the first cover layer side can, for example, have a shape that is complementary to the rope or cable to be guided. Preferably, the first cover layer side has a shape such that the rope is at least partially accommodated in the cover layer.For this purpose, the cover layer can, for example, be recessed on the first cover layer side and / or have an area that is made of a different (e.g. softer) material.

[0014] The indicator element can be influenced and / or changed by operation (i.e. by contact between the rope and the cover layer and / or the indicator layer) in such a way that a state of wear of the insert element, in particular of the cover layer, by means of which the indicator element (for example a state of the indicator element) can be indicated. The indicator element can for example be a further layer which is arranged for example on the second cover layer side of the cover layer. Wear of the cover layer then makes the indicator element visible so that it can be quickly and easily determined from the outside, looking at the first cover layer side, that the cover layer or the insert element has a certain state of wear. For this purpose, the indicator element can for example have a different color from the cover layer. For example, the cover layer can be black and the indicator element white.This ensures that the high contrast allows for quick and easy detection of the indicator layer reaching the surface of the insert element.

[0015] According to a further aspect of the present invention, the indicator element can be a strip that is provided on the first cover layer side of the cover layer at least in the region in which the cable is guided through the cover layer. For example, the indicator element can be a strip-like element that is located transversely to the cable guide direction and / or along the cable guide direction in or on the first cover layer side. In this case, too, the indicator element can have a different color than the cover layer. During operation, the cover layer and the indicator element can be abraded. The indicator element can have a thinner material than the cover layer, so that upon abrasion the indicator element will eventually disappear (i.e., will no longer be visible), so that when looking at the first cover layer side, it can be seen whether the indicator element is still present there or not.Furthermore, the indicator element or elements can have a shape that points away from the first cover layer side and tapers or widens. The visible indicator element can be thicker or thinner depending on the wear. The indicator element can thus indicate whether and / or to what extent the cover layer is worn. Particularly in the embodiment in which the indicator element extends transversely to the rope guide direction, it is easy to identify in which area of the first cover layer side particularly great abrasion has occurred due to the rope or cable. This also makes it possible to draw conclusions about an operating condition (e.g., an off-center guide of the rope, uneven loading of the insert element, etc.). This allows operation to be further optimized and safety to be increased.

[0016] Preferably, a plurality of indicator elements can be provided in or on the cover layer. For example, a plurality of indicator elements can be provided as layers parallel to the first cover layer side in a successive manner. Each indicator layer can have a different color. It is conceivable that the indicator element closest to the first cover layer side is, for example, green, the following indicator element is orange, and the indicator element following it is red. Therefore, in the present embodiment, the insert element can have a total of three indicator elements, each of which is designed as a separate layer. During operation, the cover layer is then at least partially worn away first, so that the first (green) indicator element becomes visible.The indicator element can thus indicate that the cover layer is already worn, but that further operation of the insert element is still possible (due to the green color of the first indicator element). If the first indicator element is also worn, the second indicator element (yellow layer) appears and shows that the insert element will soon be worn and needs to be replaced. As soon as the red indicator element becomes visible, the indicator element shows that the insert element now needs to be replaced. Analogously, the insert element can have a variety of different layers as indicator elements, so that close monitoring of the insert element is possible. Furthermore, it is conceivable for the indicator element to extend variably relative to the first cover layer side. In this way, a visible pattern can be realized on the first cover layer side when the cover layer becomes worn.The pattern can change depending on the wear condition. For example, the indicator element can extend in a wave-like pattern relative to the first surface layer. The variable arrangement of the indicator element can ensure that wear conditions can only be detected by trained personnel and / or image recognition systems, and not by passengers or visitors. This can prevent untrained persons from misinterpreting the indicator element.

[0017] The above-mentioned insole element reduces the potential danger for personnel who have to inspect the insole elements and reduces the effort required to determine wear on the insole element. For example, the insole element can be inspected from a certain distance during a service trip.

[0018] Preferably, the indicator element covers the first cover layer side and / or the second cover layer side at least partially or in sections.

[0019] In the case where the indicator element is designed as a volume layer, the indicator element can cover the cover layer at least in the area in which the rope or cable comes into contact with the cover layer. In other words, the indicator element can be arranged on the first cover layer side in this case. Alternatively or additionally, the indicator layer can be provided on the second cover layer side (i.e. on the side of the cover layer facing away from the rope or cable) and extend over the second cover layer side. In this case, the indicator layer only becomes visible when the cover layer is worn. Alternatively or additionally, the indicator layer can also partially cover the first cover layer side and / or the second cover layer side. In this case, the indicator element can be arranged as strip elements (for example transversely to or along the rope guide direction).The indicator element can therefore be arranged depending on the use of the insert element. For example, a section-by-section arrangement of the indicator element can be advantageous in a case where the cable or rope comes into contact with the cover layer in a previously known area. In contrast, a planar arrangement of the indicator element can be provided in a case where it is not clear in advance where wear will occur. The latter can be the case, for example, with large-area insert elements. This means that the insert element can always be adequately provided according to the intended use. It is also conceivable to arrange the indicator element within the cover layer. For example, at half the material thickness of the cover layer. This means that a wear condition can be indicated where the insert element is half worn.Consequently, reliable monitoring of the expected service life of the insert element can be provided.

[0020] Preferably, the cover layer comprises SBR, NR, NBR, EPDM, CSM, BR and / or FKM.

[0021] Thus, the cover layer can have sufficient elasticity to ensure secure guidance of the cable or rope, while also providing the necessary sound and vibration dampening effects. 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 (fluororubber) are easy to process, allowing the cover layer to be easily manufactured in a suitable shape. In particular, the insert element can be a vulcanized product. Furthermore, the above-mentioned materials are inexpensive and therefore make the insert element manufacturing process efficient. Furthermore, the cover layer can comprise a mixture of the above materials. The above materials or mixtures thereof can each represent the base polymer and can be enhanced by additives such as carbon black, etc.This allows the desired properties (such as color) required for the intended use of the insert element to be easily achieved.

[0022] Preferably, the indicator element comprises PE, PP, TPE, PA and / or PETP.

[0023] Using the above materials, the indicator element can have suitable properties to, on the one hand, suitably indicate the state of wear and, on the other hand, have sufficient strength to, for example, guide the rope or cable safely and suitably in the event of contact with it and still indicate the state of wear of the insert element. In other words, the indicator layer can comprise PE (polyethylene), PP (polypropylene), TPE (thermoplastic elastomers), PA (polyamides) and / or PETP (polyethylene terephthalate). Furthermore, the indicator element can also comprise mixtures of the above materials. The above materials could represent only the base polymer and include other additives, such as carbon black, etc. Consequently, the indicator element can also be suitably adapted to the respective area of application of the insert element and have sufficient strength and resilience for long-term operation.

[0024] Preferably, the indicator element and the cover layer have different properties, such as in particular hardness, density, tear strength, elongation at break, abrasion, rebound resilience, compression set, tear resistance, glass transition temperature, electrical conductivity and / or swelling.

[0025] The cover layer preferably has a Shore A hardness greater than 81. In contrast, the indicator element can have a Shore A hardness of less than 80. It has been found that in the above-mentioned range, particularly high energy efficiency (particularly with regard to the deformation of the insert element) can be achieved when the insert element is used in a guide pulley for a cable car system. The fact that the indicator element has a lower hardness than the cover layer ensures that the indicator element is eroded more quickly than the cover layer upon contact with the rope or cable, so that any wear can be clearly and easily detected even from a certain distance. The hardness can be determined, for example, according to DIN 53505, DIN EN ISO 868, or analogously.

[0026] The density of the indicator element is preferably lower than the density of the cover layer. Preferably, the density of the indicator element is less than 1.25 g / cm 3 and the density of the cover layer is preferably greater than 1.25 g / cm 3 This ensures that the wear condition of the insert element can be clearly indicated. The density can preferably be determined according to EN ISO 1183-1. The cover layer preferably has a density in the range of 1.26 g / cm 3 up to 1.28 g / cm 3 This ensures that the weight of the insert element is within a suitable range, especially for use in conjunction with a pulley for a cable car system. This allows for particularly efficient operation of the pulley.

[0027] The tear strength can indicate the maximum mechanical tensile stress that a material can withstand before it fails (e.g., tears). Preferably, the cover layer has a tear strength of greater than 15 N / mm 2 In contrast, the indicator element can have a tear strength of less than 15 N / mm 2 In this range, it can be ensured that the cover layer has sufficient resistance to failure. This ensures the required safety when guiding a rope or cable. In contrast, a lower tear resistance is sufficient for the indicator element, since it is only partially used to guide the rope or cable, if at all. The ranges shown above can form a particularly efficient insert element, since the indicator element can be equipped with a lower tear resistance and is therefore more cost-effective.

[0028] Elongation at break or elongation at fracture can be a characteristic value that indicates the permanent extension of a component relative to its initial length when the component is subjected to a force. In other words, elongation at break can indicate the deformability of a component. The elongation at break can preferably be determined according to the DIN 53504-S2 standard. The cover layer preferably 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 the safe operation of the insert element without the risk of premature failure, even if the indicator element is involved in guiding the rope or cable.

[0029] Abrasion (also referred to as abrasion or erosion) can refer to the loss of material from the surface of components. Abrasion can be caused by mechanical stress, such as friction, and / or environmental influences. When material is removed from the component, very small particles can usually be generated. In materials science, abrasion is also referred to as wear. Abrasion is preferably determined as a volume according to ISO 4649 - Method A. The surface layer preferably has an abrasion of greater than 160 mm. 3 In contrast, the indicator element has an abrasion of preferably less than 160 mm 3 Furthermore, the abrasion of the cover layer and the indicator element can be limited to a maximum of 200 mm 3This also ensures the long-term operation of the insert element. This is particularly important if the indicator element is located in the material of the cover layer. Furthermore, the upper abrasion limit prevents excessive material from being released into the environment.

[0030] Rebound resilience can be used to assess the elastic behavior of elastomers under impact stress. The cover layer preferably has a rebound resilience of at least 40%. In contrast, the indicator element preferably has a rebound resilience of less than 40%. The rebound resilience is preferably determined according to the DIN 53512 standard. Furthermore, the cover layer and the indicator element can have a rebound resilience of at least 25%. This ensures that the rope or cable is securely guided on the insert element without bouncing off it, thus enabling secure guidance of the rope.

[0031] Compression set is a measure of how elastomers behave under prolonged, constant compression deformation and subsequent relaxation. Compression set is preferably determined over 24 hours at 70°C and 20% deformation according to ISO 815 Type B. Preferably, the cover 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 secure guidance of the rope even under prolonged loading of the insert element. Furthermore, it can be ensured that the indicator element reliably indicates the wear status of the insert element. A particularly durable insert element can be provided in the above range.

[0032] Volume resistivity can be a measure of how well a component conducts electrical current. Volume resistivity is calculated by multiplying the measured volume resistivity by the measuring area divided by the sample length. Volume resistivity is preferably determined according to IEC 62631-3-2. Preferably, the top layer has a volume resistivity of less than 6.7*10 13 Ohm*cm. In contrast, the indicator layer preferably has a volume resistivity of at least 5 times 10 14 Ohm*cm. This ensures that the indicator element is electrically non-conductive. This is advantageous when, for example, a conductive cover layer is used (for example, with a volume resistivity of 1.9 times 10 5Ohm*cm). In this case, detection is possible when the rope is only in contact with the insert element via the indicator element, and thus the electrical resistance increases significantly. In other words, a voltage can be applied to a rope or cable to be guided, which voltage can be measured on a conductive cover layer. As soon as the cover layer is worn and the rope or cable is only in contact with the insert element via the indicator element, an increased resistance can be detected. This means that it can be concluded that the cover layer is worn. Alternatively, this design can also be the other way around, so that the cover layer is non-conductive and the indicator element creates an electrically conductive connection between a detector element (e.g. sensor element) and the rope to be guided.In this case too, it can be detected (in this case by establishing an electrical connection) that the top layer is worn.

[0033] The tear resistance can be determined, for example, according to ÖNORM C 9446:2007 02 01. The tear resistance can be the maximum force required to create a tear in the material and is related to the thickness of the material. The ratio of the tear resistance of the cover layer to the tear resistance of the indicator element can preferably be in a 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 cover layer, even when the cover layer is already largely worn. This ensures that the indicator element reliably indicates the wear status even when the cover layer is advanced. Furthermore, the rope or cable can be securely supported by the indicator element even when the cover layer is advanced.

[0034] The glass transition temperature can preferably be determined according to the ISO 11357-2 standard. The cover layer preferably 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 represent a temperature above which a polymer transitions from a rubbery to viscous state. In other words, if the glass transition temperature is exceeded, the cover layer can suddenly change its properties, which are necessary for guiding a cable. Therefore, it is advantageous if the cover layer has a sufficiently high glass transition temperature to ensure that the cable is safely guided through the insert element, even during continuous operation.In contrast, the indicator element can have a lower glass transition temperature, since, particularly in cases where the indicator element is only partially or partially attached to the cover layer, the indicator element is not primarily responsible for guiding the cable. Consequently, efficient interaction between the cover layer and the indicator element can be achieved. Furthermore, due to the above-determined glass transition temperature of the cover layer, the single-layer element can also be used with rapidly rotating rollers (i.e., with higher heat generation during operation).

[0035] The indicator element comprises a fabric, at least one thread, fluorescent material, colored liquid, in particular ink, and / or a film.

[0036] The fabric can, for example, be a textile fabric comprising at least two thread systems and provided over the entire surface of the cover layer or on the cover layer. If the cover layer is worn to the extent that the fabric is visible from the outside, this can indicate the state of wear of the insert element. The fabric can also be made from wires, cord, or other elements, for example. The fabric preferably also has a stabilizing effect, so that radial forces acting on the insert element can be absorbed by the fabric. This allows the insert element to be made thinner, which can save production costs. Furthermore, the insert element can also be used for small rolls.

[0037] The at least one thread can be arranged in or on the cover layer in such a way that when the cover layer wears, the thread becomes visible (i.e., is visible from the outside). This allows conclusions to be drawn about the state of wear of the insert element. The thread can be arranged in a straight or curved manner in the cover layer. Preferably, the thread can have a distinctive color (for example, a lighter color than the cover layer) so that it is easily recognizable even from a greater distance.

[0038] The fluorescent material can be used to detect the state of wear of the insole element. Furthermore, the fluorescent material can have the additional property of emitting light after the material has been excited. Photons can be emitted when light is emitted. For example, an insole element to be examined can be irradiated with a light source so that any fluorescent material visible on the surface emits corresponding light. This allows an insole element to be checked for its state of wear even in the dark. This can simplify the maintenance of an insole element. The fluorescent material can be applied to or in the indicator element in the form of paint or varnish. 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 in conjunction with the indicator element.

[0039] The colored liquid can, for example, be arranged in capsules in the cover layer. If the cover layer is worn or abrasion-resistant, these capsules can be damaged, causing the liquid to reach the surface of the insert element. This makes it easy to recognize that a certain level of wear of the insert element has been reached. In this embodiment, it is advantageous that even in the case of minor abrasions, the liquid is distributed over a large area of the surface of the insert element, making it easy and straightforward to recognize that a certain level of wear has been reached, even in the case of minor damage to the cover layer. The capsule containing the liquid can be arranged in the cover layer at a certain distance in the radial direction from the first side of the cover layer.Furthermore, differently colored liquids can be provided depending on a position in the insert element (for example, depending on a distance from the first cover layer side). Thus, the extent of wear on the insert element can be determined by the different colors appearing on the surface of the insert element.

[0040] The foil can be a plastic foil or an aluminum foil arranged parallel to the first side of the cover layer in the insert element. When the cover layer wears, the foil can partially or completely become visible, thus indicating the wear status of the insert element. It is also conceivable to mix aluminum powder into the cover layer, which becomes visible when the cover layer wears. This allows the indicator element to be implemented particularly easily.

[0041] Preferably, the insert element comprises at least one conductivity sensor designed to detect a voltage applied to a rope or cable guided through the insert element.

[0042] This design can be implemented in two ways: Firstly, the cover layer can be an insulating material, as is the case with aerial cable cars, for example. In this case, the cable guided through the insert element is used to transport a signal (for example, a telephone signal). If the insert elements were not insulated, this signal would be disrupted and would not reach the receiver in a suitable form. In contrast, the indicator element can be designed to be conductive. If the cover layer is abraded to the extent that the cable guided through the insert element comes into contact with the indicator element, an electrical circuit can be closed and the signal conducted through the cable can be detected by the sensor on the insert element. This means that it is also possible to determine whether an insert element is worn or not using remote monitoring.Furthermore, this system can also detect the exact position of the worn insert element in a larger system. Alternatively, the cover layer can be designed to be conductive and the indicator element can be provided in the cover layer or on the second side of the cover layer and has an insulating property. If the cover layer is abrasive, tension can be transferred from the cable guided through the insert element to the insert element as long as the cover layer has a certain thickness. If the cover layer is worn and the abrasion is so great that the cable is in contact with the indicator element (e.g. with the indicator layer), the cable is insulated and tension can no longer be measured. In this case, too, it can be detected that the insert element is worn.

[0043] Preferably, the indicator element comprises at least one metal rod and / or one wire.

[0044] The metal rod can, for example, be located transversely to the cable guide direction in the cover layer. If the cover layer is abraded or worn to such an extent that the wire reaches the surface (i.e. the first side of the cover layer), it can be determined that the cover layer is worn. This offers the advantage that further abrasion is no longer possible due to the metal rod or is at least greatly reduced because the metal rod is significantly stronger than the cover layer. For this purpose, the metal rod can be arranged in a predetermined position (i.e. at a predetermined distance from the first side of the cover layer) in the cover layer at which it is desired that the insert element is replaced. In this way, a wear limit for the insert element can be easily defined, which nevertheless allows continued operation of the insert element.

[0045] Analogously, a wire can be arranged in or on the cover layer and thus act in a similar way to the metal rod. Furthermore, various separate wires can be arranged in different positions within the cover layer. For example, each wire can be a different distance from the first side of the cover layer. The wires can, for example, differ in color. If the cover layer is abraded to the extent that a wire comes to the surface of the cover layer, the wire can be detected and a wear condition indicated. During further operation, the wire (unlike the metal rod) can be worn further, i.e. removed from the insert element (until the next wire appears). Different wear conditions can be indicated by different colors of the different wires. It is also conceivable to apply a voltage to each wire and measure this voltage separately for each wire.If the applied voltage can be measured, it can be assumed that the insert element is still intact. If, on the other hand, no voltage can be measured for one or more wires, it can be assumed that these wires have already been removed from the insert element due to a reduced material thickness of the cover layer. Since the distance between the individual wires and to the first side of the cover layer is known, an abrasion depth or wear condition can be precisely defined according to the intervals at which the wires are provided in the insert element. Furthermore, this wear condition can also be determined by remote maintenance and / or automatically. This makes detailed monitoring of a system, which for example comprises a large number of system elements, easily possible. It is also conceivable to provide such an automated system for monitoring the wear condition of at least one insert element.For example, the monitoring system can automatically issue an alarm when a predetermined wear level is reached. This ensures that a worn insole element is detected and replaced in a timely manner.

[0046] The insert element comprises a plurality of indicator elements which are arranged distributed in a radial direction of the insert element, and wherein each indicator element has different properties.

[0047] The radial direction of the insert element can refer to an insert element that has a ring-like shape. Nevertheless, the insert element can also be a flat body. In any case, the radial direction can be a direction that is orthogonal to the first cover layer side and extends to the second cover layer side. The provision of multiple indicator elements behaves like the provision of different wires with different distances from the first cover layer side in the above embodiment. In other words, different wear states can also be realized with other indicator elements by providing the indicator elements with different distances from the first cover layer side.

[0048] Preferably, a ratio of the material thickness of the cover layer and the material thickness of the indicator element in a radial direction of the insert element is in a range of 0.01 to 0.7, preferably in a range of 0.07 to 0.5, more preferably in a range of 0.1 to 0.3.

[0049] It was discovered that optimal interaction between the cover layer and the indicator element occurs in a first region. This is particularly true when the indicator element is designed as an indicator layer. The first region is particularly advantageous with regard to the occurrence of stresses between the two layers, since the ratio of both layer thicknesses to each other is such that no stress peaks occur at the interface between the cover layer and the indicator layer. This ensures the durability of the insert element.

[0050] In the second area mentioned, there is the advantage that even when several indicator elements are provided (in the second ratio given above, the material thickness of all existing indicator layers is added together), sufficient cohesion of all individual layers is ensured.

[0051] Furthermore, it was found that in the last defined area, the wear condition of the insert element is indicated by the wear indicator long enough for maintenance personnel to be aware of it. Thus, the wear condition of the insert element can be reliably indicated over a sufficient period of time and can also be reliably detected.

[0052] Preferably, the insert element comprises a fabric layer which is designed to absorb radial forces, wherein a ratio of the material thickness of the cover layer and the material thickness of the fabric layer in a radial direction of the insert element is in a range of 0.8 to 9, preferably in a range of 1 to 8, more preferably in a range of 2 to 6.

[0053] The first area mentioned above offers 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 a large radial force acts on the insert element. Even in such a case, safe operation can be achieved.

[0054] In the second area mentioned above, the fabric layer is as thick as the cover layer or thinner. This offers the advantage of providing an overall thinner insert element and allowing sufficient abrasion reserves to be realized through the cover layer. At the same time, the insert element offers sufficient resistance to absorb radial forces.

[0055] It has been found that the latter range represents an optimum, particularly for the operation of cable car systems. This allows the radial forces occurring in cable car systems to be adequately absorbed while still providing a sufficiently thin insert element, enabling efficient operation.

[0056] Preferably, the cover layer has, on its first cover layer side, a cross section transverse to a rope or cable guiding direction, a guide region and two protective regions adjacent to the guide region, wherein the guide region has a recess which is recessed by a recess spacing relative to at least one of the shoulder regions, and wherein a ratio of a width of both shoulder regions in the cross section transverse to the rope or cable guiding direction and the recess spacing is in a range from 0.2 to 5, preferably in a range from 0.4 to 3, more preferably in a range from 0.7 to 2.5.

[0057] The first cover layer side can thus be structured in such a way that the rope can be guided through the cover layer in a defined manner. The recess is preferably round and has the recess spacing as a radius. This allows the first cover layer side to be designed to complement a cable or rope to be guided, thereby improving guidance. The specified ratios indicate a ratio of the depth of the recess to a width of the insert element transverse to the rope guide direction. The first ratio offers the advantage that all types of rope or cable are compatible with the insert element without any problems. For example, even very thick ropes can be suitably guided through the insert element. Furthermore, the area of application of the insert element in the first area defined above is very wide, so that the insert element can be used in a variety of applications.The second area defined above offers the advantage that even in applications where forces are applied to the insert element transverse to the radial direction of the insert element and to the rope guide direction, the insert element has sufficient strength or resistance to such acting forces due to the shoulder areas, so that long-term operation is possible. In other words, the force acting on the shoulder areas depends on the depth that the rope sinks into the recess of the insert element. Thus, the second area defined above offers optimal lateral stiffness while simultaneously guiding the rope efficiently. The last area defined above offers the advantage that optimal lateral guidance properties for the rope or calve are provided by the insert element, whereby the insert element can be realized with minimal material use.

[0058] According to a further aspect of the present invention, a rope or cable guide roller is provided, comprising an insert element comprising a cover layer with a first cover layer side which is designed to come into contact with a rope or cable to be guided, and a second cover layer side opposite the first cover layer side, and an indicator element which is arranged on and / or in the cover layer side, and wherein the indicator element is designed to indicate a wear condition of the insert element, and a bearing region for rotatably supporting the rope or cable guide roller.

[0059] Such a roller can be used, for example, in cable cars, elevators, cranes, etc., to deflect and / or guide a rope or cable. The insert element can also be designed according to one of the above insert elements.

[0060] According to a further aspect of the present invention, a method for producing an insert element for guiding a rope or cable, in particular according to one of the above aspects, is provided, the method comprising the steps of: Providing an indicator element, Applying the indicator element in or on a cover layer, and vulcanizing the indicator element and the cover layer, wherein the indicator element can indicate a wear condition of the insert element.

[0061] Furthermore, the method can comprise a step of cutting or milling a groove into the first cover layer side of the cover layer. The groove can extend in the cable guide direction. The indicator element (for example a differently colored band) can be inserted into the recess and then vulcanized together with the cover layer. The indicator element can thus be firmly bonded to the cover layer. The indicator element is preferably arranged at the deepest point of the recess in the cover layer. The recess can be designed such that, at the start of operation of the insert element, the rope or cable to be guided does not touch the deepest point of the recess. Only when the cover layer wears or is abraded can the cable or rope come into contact with the deepest point of the recess and abrade the indicator element.If the indicator element is no longer visible, a certain level of wear can be defined. For example, if the indicator element is no longer visible, the insert element can be replaced.

[0062] The design variants and advantages mentioned above in connection with the device also apply analogously to the method, and vice versa. Individual features of individual embodiments can be combined to form new embodiments. The advantages of the individual features then also apply to the new embodiment. Preferred embodiments are described in detail below with reference to the figures. They show: Fig. 1 is a schematic and perspective view of an insert element according to an embodiment of the present invention, Fig. 2 a cross-section of the Fig. 1 shown insert element transverse to a cable guide direction, Fig. 3 is a schematic plan view of an insert element according to another embodiment of the present invention, Fig. 4 is a schematic plan view of an insert element according to a further embodiment of the present invention, Fig. 5 a schematic cross-section of an insert element of a further embodiment according to the present invention, and Fig. 6 a schematic cross section of an insert element according to another embodiment of the present invention.

[0063] Fig. Figure 1 is a schematic and perspective view of an insert element 1 according to an embodiment of the present invention. The insert element 1 according to the present embodiment has a ring-like shape and is shown in Fig. 1 only shown in sections. The insert element 1 has a cover layer 2. The cover layer 2 has a first cover layer side 6, which represents an outer side of the cover layer 2 (i.e. facing the environment), and a second cover layer side 7, which represents an inner side of the cover layer side 2. An indicator layer is provided on the second cover layer side 7 as an indicator element 3. Furthermore, the cover layer 2 has a cable guide region 5 and two shoulder regions 4 on its first cover layer side 6. The two shoulder regions 4 enclose the cable guide region 5 in their center. A rope or cable to be guided (not shown in the figures) lies in the rope guide region 5 so that the rope or cable comes into contact with the cover layer 2. The rope guide region 5 has a recess 8, which is recessed radially inwards relative to the shoulder regions 4.The rope is guided through the insert element 1 in a rope guide direction 10 (in . Fig. 1 from right to left or from left to right). In other words, the rope can move in the rope guide direction 10. The insert element 1 can also move (i.e. rotate) in accordance with the movement of the rope. For example, a pulley on which the insert element 1 is arranged can rotate. The guiding of the rope can cause the cover layer 2 to wear down, particularly since the relative speed between the rope and the insert element is not zero. This wear causes abrasion, which causes the cover layer 2 to lose material. If the cover layer 2 has been worn down to the extent that the indicator layer 3 becomes visible (i.e. can be seen from the outside when looking at the insert element from above), the state of wear of the insert element can be determined from the outside. It can therefore be determined that the insert element 1 needs to be replaced.

[0064] Fig. 2 is a section through the Fig. 1 shown insert element 1 transverse to the cable guide direction 10. In Fig. 2, the cable guide direction runs into and out of the plane of the sheet. In Fig. 2, the recess 8 in the cable guide area 5 can be seen. Furthermore, it can be seen that the recess 8 has a radius that defines the recess. Furthermore, in Fig. 2, the radial direction 20 and an axial direction 30 are shown. The indicator layer 3 of the present embodiment is integrally bonded to the cover layer 2 by vulcanization. This ensures that there is sufficient cohesion between the cover layer 2 and the indicator layer 3.

[0065] Fig. 3 is a plan view of an insert element 1 according to a further embodiment of the present invention. In this embodiment, the cover layer 2 also has two shoulder regions 4 and a cable guide region 5. However, in the present embodiment, the indicator element is not arranged as an indicator layer on the second cover layer side 7 of the cover layer 2, but as strip-like elements that extend in the axial direction parallel to one another and transversely to the cable guide direction 10. The indicator elements 3 extend both in the shoulder regions 4 and in the cable guide region. Thus, wear can be indicated across the entire width of the insert element 1. In the present embodiment, the indicator elements 3 are located on the surface of the insert element 1 (ieon the first cover layer side 6), so that if the indicator elements 3 are no longer present, it can be concluded that a certain wear condition of the insert element 1 has occurred.

[0066] In a further embodiment not shown, in addition to the surface-mounted indicator elements 3, further indicator elements are arranged within the cover layer 2. The indicator elements 3 differ in their color. More precisely, the indicator elements 3 arranged on the surface of the cover layer 2 (i.e., on the first cover layer side 6) differ from the indicator elements 3 arranged within the cover layer 2. Thus, the extent of wear of the insert element 1 can be easily and readily identified through different color coding.

[0067] Fig. Figure 4 shows a plan view of an insert element 1 according to a further embodiment of the present invention. The present embodiment largely corresponds to that shown in Fig. 3, with the difference that the indicator elements 3 now run in the cable guide direction 10. In the present embodiment, an indicator element is arranged at the deepest point of the recess 8 in the cable guide region 5 and an indicator element 3 is arranged in each of the shoulder regions 4. Thus, a periodically occurring uneven load on the insert element 1 due to uneven wear of the indicator elements 3 can also be detected.

[0068] Fig. Figure 5 is a cross-section through an insert element 1 according to a further embodiment of the present invention. Fig. 5 essentially corresponds to the embodiment shown in Fig. 2, with the difference that the indicator element 3 is not formed as an indicator layer, but as a plurality of capsules containing a colored liquid. The capsules 3 are arranged at different depths within the cover layer 2. In other words, the capsules 3 are arranged at different positions in the radial direction 20 of the insert element 1. If the cover layer 2 is worn by a cable or rope, the capsules can be damaged and the liquid can escape to the first cover layer side 6. The colored liquid can indicate that a certain wear state of the insert element 1 has been reached.

[0069] Fig. Figure 6 is a schematic cross-section of another embodiment of the present invention. Fig. 6 essentially corresponds to the embodiment shown in Fig.3, with the difference that the indicator element 3 comprises wires running in the cable guide direction 10, which are arranged within the insert element 1. The wires 3 are arranged at different distances from the first cover layer side 6 of the cover layer 2 and can thus indicate different states of wear of the insert element 1 by the wires 3 emerging from the surface on the first cover layer side 6. In a further embodiment, a voltage can be applied to the wires 3 and measured by a sensor. Damage to a wire 3 (for example due to wear) can change the voltage. In particular, each wire can be monitored individually. Thus, remote diagnosis can determine how worn the insert element is.

[0070] The cable guide direction can also be referred to as the circumferential direction in the case of round insert elements. In a further embodiment (not shown), the indicator element is formed as a structure on the surface of the cover layer (i.e., on the first cover layer side 6). For example, the indicator element 3 is a depression in a cable guide region 5, and if the depression is no longer present, it can be concluded that a certain wear condition has occurred. In a further embodiment (not shown), the insert element comprises, in addition to the cover layer and the indicator element, a fabric layer designed to absorb radial forces. List of reference symbols: 1 insert element 2 Top layer 3 Indicator element 4 Shoulder area 5 Rope guide area 6 first top layer side 7 second top layer side 8 Deepening 10 Cable guide direction 20 Radial direction 30 Axial direction

Claims

[1] Insert element (1) for guiding a rope or cable, in particular for a cable car system, comprising a cover layer (2) with a first cover layer side (6) which is designed to come into contact with a rope or cable to be guided, and a second cover layer side (7) opposite the first cover layer side (6), and an indicator element (3) arranged on and / or in the cover layer (2), and wherein the indicator element (3) is designed to indicate a wear condition of the insert element (1), wherein the indicator element can become visible due to wear of the cover layer (2), so that a wear condition can be determined from the outside by looking at the first cover layer side (6), wherein the insert element (1) comprises a plurality of indicator elements (3) which are arranged distributed in a radial direction (20) of the insert element (1), and wherein each indicator element (3) has different properties. [2] Insert element (1) according to claim 1, wherein the indicator element (3) covers the first cover layer side (6) and / or the second cover layer side (7) at least partially or in sections. [3] Insert element (1) according to one of the preceding claims, wherein the cover layer (2) comprises SBR, NR, NBR, EPDM, CSM, BR and / or FKM. [4] Insert element (1) according to one of the preceding claims, wherein the indicator element (3) comprises PE, PP, TPE, PA and / or PETP. [5] Insert element (1) according to one of the preceding claims, wherein the indicator element (3) and the cover layer (2) have different properties, such as in particular hardness, density, tear strength, elongation at break, abrasion, rebound resilience, compression set, tear resistance, glass transition temperature, electrical conductivity and / or swelling. [6] Insert element (1) according to one of the preceding claims, wherein the indicator element (3) comprises a fabric, at least one thread, fluorescent material, colored liquid, in particular ink and / or a film. [7] Insert element (1) according to one of the preceding claims, further comprising at least one conductivity sensor configured to detect a voltage applied to a rope or cable guided through the insert element (1). [8] Insert element (1) according to one of the preceding claims, wherein the indicator element (3) comprises at least one metal rod and / or wire. [9] Insert element (1) according to one of the preceding claims, wherein a ratio of the material thickness of the cover layer (2) and the material thickness of the indicator element (3) in a radial direction (20) of the insert element (1) is in a range of 0.01 to 0.7, preferably in a range of 0.07 to 0.5, more preferably in a range of 0.1 to 0.

3. [10] Insert element (1) according to one of the preceding claims, further comprising a fabric layer which is designed to absorb radial forces, wherein a ratio of the material thickness of the cover layer (2) and the material thickness of the fabric layer in a radial direction (20) of the insert element (1) is in a range of 0.8 to 9, preferably in a range of 1 to 8, more preferably in a range of 2 to 7. [11] Insert element (1) according to one of the preceding claims, wherein the cover layer (2) has on its first cover layer side (6) in a cross section transverse to a rope or cable guide direction a guide region (5) and two shoulder regions (4) adjacent to the guide region, wherein the guide region (5) has a recess (8) which is recessed by a recess distance relative to at least one of the shoulder regions (4), and wherein a ratio of a width of both shoulder regions (4) in the cross section transverse to the rope or cable guiding direction (10) and the recess spacing is in a range of 0.2 to 5, preferably in a range of 0.4 to 3, more preferably in a range of 0.7 to 2.

5. [12] Rope or cable guide roller comprising an insert element (1) comprising a cover layer (2) with a first cover layer side (6) designed to come into contact with a rope or cable to be guided, and a second cover layer side (7) opposite the first cover layer side (6), and an indicator element (3) arranged on and / or in the cover layer (2), and wherein the indicator element (3) is designed to indicate a wear condition of the insert element (1), wherein wear of the cover layer (2) can make the indicator element visible, so that a wear condition can be determined from the outside by looking at the first cover layer side (6), wherein the insert element (1) comprises a plurality of indicator elements (3) arranged distributed in a radial direction (20) of the insert element (1), and wherein each indicator element (3) has different properties, and a bearing area for the rotatable storage of the rope or cable guide roller. [13] Method for producing an insert element (1) for guiding a rope or cable, in particular according to one of claims 1 to 11, the method comprising: Providing a plurality of indicator elements (3), each indicator element (3) having different properties, Applying the indicator elements (3) in or on a cover layer (2) so that they are distributed in a radial direction (20) of the insert element (1), and Vulcanizing the indicator element (3) and the cover layer (2), wherein the indicator element (3) can indicate a state of wear of the insert element (1), wherein the indicator element can become visible due to wear of the cover layer (2), so that a state of wear can be determined from the outside by looking at the cover layer.

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