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

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 manufacturing the insert element.

[0002] Insert elements, sometimes also called linings, are used for pulleys or deflection sheaves in cable cars, whether aerial or rail-based, or ski lifts. The insert elements support and guide the rope or cable. Furthermore, they also provide sound and vibration damping. Because these elements are used in sensitive systems like cable cars, their wear must be regularly monitored to ensure timely replacement before failure. This monitoring is typically carried out by trained personnel visually inspecting the insert elements. The shape of the insert is measured with a caliper and compared to a reference point.Based on a deviation in the shape of the insert element from its initial state, a state of wear can be inferred. Due to the often difficult-to-access nature of the insert elements (for example, on the cable car pylons), monitoring them is labor-intensive, difficult, time-consuming, and therefore expensive.

[0003] WO 2020 / 239497 A1 shows a rope pulley comprising a rubber disc and two flange discs.

[0004] EP 3 620 340 A1 shows a running ring having a running surface with a roller groove designed to provide support for a rope.

[0005] US 2009 / 039326 A1, JPA 04-133972 U, JPH 04-133 970 U and GB 1 384 146 A show a rope pulley insert with a running surface which can guide a rope.

[0006] FR 2 952 338 A1 shows a wheel with an outer layer and an inner layer. A groove is formed in the outer layer, which can guide a rope.

[0007] Therefore, the object of the present invention is to simplify the monitoring of an insert element.

[0008] This problem is solved by an insert element having the features of claim 1, by a rope or cable guide roller having the features of claim 11, and by a method for manufacturing the insert element having the features of claim 12. Preferred embodiments are specified in the dependent claims.

[0009] According to one aspect of the invention, an insert element for guiding a rope or cable, in particular for a cableway system, is provided comprising a cover layer with a first cover layer side 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 arranged on and / or in the cover layer, wherein the indicator element is designed to indicate a wear condition of the insert element.

[0010] According to one aspect of the present invention, the insert element can also be used in pulleys for lifts, elevators, cranes, etc.—basically anywhere a cable or rope is guided, runs along, or is deflected. The invention also relates to so-called wear strips, which can be provided as lockable strips instead of one-piece, closed pulley insert elements. For example, such wear strips can protect a rope or cable from direct contact with a building or other structures. The rope or cable may be a load-bearing structure. In particular, the cable or rope may be a non-electrical (i.e., power supply) element. Such a dual function would be counterproductive, since a cable used for power supply should not simultaneously be used to carry a load.Nevertheless, test currents or the like can be passed through the cable or rope.

[0011] According to one aspect of the invention, insert elements, linings, or reinforcements for pulleys protect both the rope or cable and the pulley itself, or rather the pulley discs that form it, which are usually metallic. Furthermore, the pulley's bearings and the supporting structure can also be protected. Insert elements can also improve the smooth running of the rope through a pulley by ensuring mechanically and acoustically quiet operation. For this purpose, the insert element can be made of a softer and / or more elastic material than the pulley on which it is mounted. Accordingly, the insert element can be manufactured as a single ring, for example, from an elastomer or rubber. The insert element can be implemented with or without flexible textile or wire mesh inserts.For high loads, the insert element can be made of a plastic that may include polyurethane as a base polymer and may belong to the category of thermoplastics or thermosets.

[0012] In contrast to the prior art, with the insole element according to the invention, it is not necessary for a person to be in close proximity to the insole element to check its wear condition. Rather, it is sufficient to inspect the insole element from a distance, since the indicator element makes it easy to determine its wear condition. For example, when used in cable car systems, it may be sufficient to inspect an insole element from the ground, for example using binoculars, and thus obtain immediate information about its wear condition. This significantly reduces the inspection time, so that, for example, the wear condition of an insole element can be checked while passing by during a service run.This reduces or eliminates the previously known time-consuming and risky work of inspecting the insole elements, while simultaneously ensuring that the wear condition can be objectively determined by the indicator element, independent of the person performing the inspection. This guarantees that the insole element is always replaced at the same time. In contrast, purely visual and individual inspection by one person does not ensure that multiple insole elements are assessed objectively in the same way. Consequently, by using the insole element according to one aspect of the present invention, the replacement intervals for the insole elements can be standardized.

[0013] The insert element can be a separate component designed to be fixed within a pulley. The pulley, in turn, can be rotatably mounted on a structure such as a support. For example, the pulley can be rotatably mounted on the structure by means of a plain bearing or roller bearing. A rope or cable can be laid on the insert element and supported and / or guided by it. The rope guidance direction can refer to the direction of travel of the rope being guided. The insert element can also be designed to prevent the rope from shifting laterally perpendicular to the rope guidance 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 rope being guided.To improve guiding properties, the insert element can adapt, at least partially, to the shape of the rope being guided.

[0014] Preferably, the insert element is formed in one piece. In other words, the insert element cannot be disassembled into its components without damage. This ensures high stability and simple manufacturing of the insert element. In particular, a defined positioning (for example, during central manufacturing of the insert element) is ensured with a one-piece or integral insert element, so that the indicator element always has the same relative position to, for example, the cover layer, regardless of the number of insert elements. This ensures consistent wear measurement of the insert element.

[0015] The cover layer can be a solid layer extending in all three spatial directions. In particular, in a cross-section perpendicular to the cable guidance direction, the cover layer can have a first cover layer side and a second, opposite cover layer side. The surface area of ​​the cover layer on the first and the surface area of ​​the cover layer on the second cover layer side can be many times larger than the lateral surfaces of the cover layer. The first cover layer side can have a shape such that the cable or rope 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 cable or rope being guided. Preferably, the first cover layer side has a shape such that the cable is at least partially contained within the cover layer.For example, the top layer on the first side of the top layer may be recessed and / or have an area made of a different (e.g. softer) material.

[0016] The indicator element can be influenced and / or altered by operation (i.e., by contact between the rope and the cover layer and / or the indicator layer) in such a way that a wear condition of the insert element, in particular the cover layer, can be indicated by the indicator element (for example, a condition of the indicator element). The indicator element can, for example, be an additional layer, such as one arranged on the second side of the cover layer. Wear of the cover layer can then make the indicator element visible, so that from the outside, looking at the first side of the cover layer, it can be quickly and easily determined that the cover layer or the insert element has a certain wear condition. Thus, with an annular insert element, a view of the outside in the radial direction of the insert element (i.e.,The wear condition can be determined on the contact side between the insert element and the rope or cable. For this purpose, the indicator element can, for example, have a different color than the cover layer. For instance, the cover layer can be black and the indicator element white. This ensures that the high contrast allows for quick and easy detection of when the indicator layer has reached the surface of the insert element.

[0017] According to a further aspect of the present invention, the indicator element can be a strip provided on the first surface of the covering layer, at least in the area where the rope passes through the covering layer. For example, the indicator element can be a strip-like element located transversely to the rope guidance direction and / or along the rope guidance direction in or on the first surface of the covering layer. In this case as well, the indicator element can have a different color than the covering layer. During operation, the covering layer and the indicator element can be worn away. The indicator element can have a thinner material than the covering layer, so that with abrasion, the indicator element eventually disappears (i.e., is no longer visible), allowing it to be determined by looking at the first surface of the covering layer whether the indicator element is still present or not.Furthermore, the indicator element(s) can have a shape that tapers or widens away from the first surface layer. Thus, the visible indicator element can be thicker or thinner depending on the wear. The indicator element can therefore show whether and / or to what extent the surface layer is worn. In particular, in the embodiment where the indicator element extends transversely to the cable guidance direction, it is easy to identify in which area of ​​the first surface layer there has been particularly extensive abrasion by the cable. This also allows conclusions to be drawn about an operating condition (for example, off-center cable guidance, uneven loading of the insert element, etc.). This enables further optimization of operation and increased safety.

[0018] Preferably, several indicator elements can be provided in or on the cover layer. For example, several indicator elements can be arranged as layers parallel to the first cover layer in a sequential manner. Each indicator layer can have a different color. It is conceivable that the indicator element closest to the first cover layer is, for example, green, the next indicator element is orange, and the next indicator element is red. Therefore, in the present embodiment, the insert element can have a total of three indicator elements, each 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 show that the top layer is already worn, but further operation of the insert element is still possible (indicated by the green color of the first indicator element). If the first indicator element is also worn, the second indicator element (yellow layer) becomes visible, indicating that the insert element will soon be worn and needs to be replaced. As soon as the red indicator element becomes visible, it indicates that the insert element now needs to be replaced. Similarly, the insert element can have multiple layers as indicator elements, allowing for close monitoring of the insert element. Furthermore, it is conceivable that the indicator element extends variably relative to the first top layer. This allows a visible pattern to be created on the first top layer as it wears down.The pattern can change depending on the degree of wear. For example, the indicator element can extend in a wave-like pattern relative to the first surface layer. This variable arrangement of the indicator element ensures that wear can only be detected by trained personnel and / or image recognition systems, and not by passengers or visitors. This prevents untrained individuals from misinterpreting the indicator element.

[0019] The insert element described above reduces both the potential hazards for personnel who have to inspect the insert elements and the effort required to determine the wear of the insert element. For example, the insert element can be checked from a certain distance during a test drive.

[0020] Preferably, the indicator element covers the first surface layer and / or the second surface layer at least partially or section by section.

[0021] In the case where the indicator element is designed as a solid layer, it can cover the cover layer at least in the area where the rope or cable comes into contact with it. In other words, the indicator element can be located on the first side of the cover layer. Alternatively or additionally, the indicator layer can be located on the second side of the cover layer (i.e., the side of the cover layer facing away from the rope or cable) and extend across it. In this case, the indicator layer only becomes visible when the cover layer is worn. Alternatively or additionally, the indicator layer can also cover sections of the first and / or second side of the cover layer. In this case, the indicator element can be arranged as strip elements (for example, perpendicular to or along the rope's direction of travel).Thus, the indicator element can be arranged depending on the application of the insert element. For example, a section-by-section arrangement of the indicator element may be advantageous in a case where the cable or rope comes into contact with the cover layer at a known area. Conversely, a surface-wide arrangement of the indicator element may be appropriate 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. Therefore, the insert element can always be positioned appropriately for the intended application. Furthermore, it is conceivable to place the indicator element within the cover layer, for example, at half the thickness of the cover layer. This allows, for instance, the indication of a wear condition where the insert element is half worn.Consequently, reliable monitoring of the remaining expected service life of the insert element can be provided.

[0022] The top layer includes SBR, NR, NBR, EPDM, CSM, BR and / or FKM.

[0023] Thus, the outer layer can exhibit sufficient elasticity to ensure both secure cable or rope guidance and the necessary sound and vibration damping effects. Furthermore, the materials SBR (styrene-butadiene rubber), NR (natural rubber), NBR (acrylonitrile butadiene rubber), EPDM (ethylene propylene diene monomer rubber), CSM (Hypalon), BR (polybutadiene rubber), and / or FKM (fluorocarbon rubber) are readily processable, allowing for easy production of the outer layer in a suitable shape. In particular, the core element can be a vulcanization product. Moreover, the aforementioned materials are inexpensive, thus making the manufacturing process of the core element efficient. The outer layer can also comprise a mixture of the above materials. The above materials or mixtures thereof can each constitute the base polymer and can be enhanced with additives such as carbon black, etc.can be expanded. This makes it easy to achieve the desired properties (such as color) required for the intended use of the insert element.

[0024] The indicator element includes PE, PP, TPE, PA and / or PETP.

[0025] Using the materials mentioned above, the indicator element can possess suitable properties to both accurately indicate the wear condition and demonstrate sufficient strength to guide the rope or cable safely and effectively in the event of contact, while still indicating the 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 consist of mixtures of the above materials. In this case, the above materials could represent only the base polymer and include additional additives such as carbon black. Consequently, the indicator element can be appropriately adapted to the specific application of the insert element and possess sufficient strength and resistance for continuous operation.

[0026] Preferably, the indicator element and the cover layer have different properties, such as in particular hardness, density, tensile strength, elongation at break, abrasion, rebound elasticity, compression set, tear resistance, glass transition temperature, electrical conductivity and / or swelling.

[0027] The top layer has a Shore A hardness greater than 81 Shore A. In contrast, the indicator element has a Shore A hardness of less than 80 Shore A. It was found that particularly high energy efficiency (especially with regard to the deformation of the insert element) can be achieved in the aforementioned range when using the insert element in a guide roller for a cable car system. Because the indicator element has a lower hardness compared to the top layer, it can be ensured that the indicator element erodes more quickly than the top layer upon contact with the rope or cable, so that a wear condition is clearly and easily recognizable even from a distance. The hardness can be determined, for example, according to DIN 53505, DIN EN ISO 868, or an analogous standard.

[0028] 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 / cm³ and the density of the cover layer is preferably greater than 1.25 g / cm³. 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. Preferably, the cover 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 within a suitable range for use, particularly in conjunction with a roller for a cable car system. In this case, particularly efficient operation of the roller is possible.

[0029] Tensile strength indicates the maximum mechanical tensile stress a material can withstand before it fails (e.g., tears). Preferably, the outer layer has a tensile strength greater than 15 N / mm². In contrast, the indicator element can have a tensile strength of less than 15 N / mm². Within this range, it can be ensured that the outer layer has sufficient resistance to failure. Thus, the required safety for guiding a rope or cable can be guaranteed. A lower tensile strength is sufficient for the indicator element, as it is only partially used, if at all, for guiding the rope or cable. The areas described above allow for the formation of a particularly efficient insert element, since the indicator element can have a lower tensile strength and is therefore more cost-effective.

[0030] Elongation at break, or elongation at break, is a characteristic value that indicates the permanent elongation of a component relative to its initial length when the component is subjected to a force. In other words, elongation at break can indicate a component's deformability. Preferably, the elongation at break can be determined according to DIN 53504-S2. Preferably, the cover 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 the reliable operation of the insert element without the risk of premature failure, even when the indicator element is involved in guiding the rope or cable.

[0031] Abrasion (also known as wear or erosion) refers to material loss on the surface of components. Abrasion can be caused by mechanical stress, such as friction, and / or by environmental influences. The removal of material from the component often produces very small particles. In materials science, abrasion can also be referred to as wear. Preferably, abrasion is determined by volume according to ISO 4649 - Method A. Preferably, the top layer exhibits an abrasion greater than 160 mm³. In contrast, the indicator element preferably exhibits an abrasion less than 160 mm³. Furthermore, the abrasion of the top layer and the indicator element can be limited to a maximum of 200 mm³. This ensures the continuous operation of the insert element. This is particularly advantageous when the indicator element is embedded within the top layer material.Furthermore, the upper limit on abrasion can prevent excessive material from entering the environment.

[0032] Rebound elasticity can be used to assess the elastic behavior of elastomers under impact. Preferably, the top layer has a rebound elasticity of at least 40%. In contrast, the indicator element preferably has a rebound elasticity of less than 40%. Preferably, the rebound elasticity is determined according to DIN 53512. Furthermore, the top layer and the indicator element can each have a rebound elasticity of at least 25%. This ensures that the rope or cable is guided securely on the insert element without slipping off, thus enabling reliable rope guidance.

[0033] Compression set is a measure of how elastomers behave under prolonged, constant compression and subsequent relaxation. Preferably, the compression set is determined over 24 hours at 70°C and 20% deformation according to ISO 815 Type B. The top layer preferably exhibits a compression set of less than 20%, while the indicator element exhibits a compression set of at least 20%. This ensures reliable cable guidance even under prolonged stress on the insert element. Furthermore, it ensures that the indicator element reliably signals the wear of the insert element. A particularly durable insert element can be provided within the above parameters.

[0034] The volume resistance can be a measure of how well a component conducts electric current. The specific volume resistance is calculated by multiplying the measured volume resistance by the measuring area and dividing by the sample length. Preferably, the specific volume resistance is determined according to the standard IEC 62631-3-2. Preferably, the top layer has a specific volume resistance of less than 6.7 × 10¹³ Ω·cm. In contrast, the indicator layer preferably has a specific volume resistance of at least 5 × 10¹⁴ Ω·cm. This ensures that the indicator element is electrically non-conductive. This is advantageous, for example, when a conductive top layer is used (e.g., with a specific volume resistance of 1.9 × 10⁵ Ω·cm).In this case, it can be detected 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, which can be measured at a conductive outer layer. As soon as the outer layer wears out and the rope or cable is only in contact with the insert element via the indicator element, an increased resistance can be detected. This indicates that the outer layer is worn. Alternatively, this design can also be reversed, so that the outer layer is non-conductive and the indicator element establishes an electrically conductive connection between a detector element (e.g., a sensor element) and the rope.In this case too, it can be detected (in this case by establishing an electrical connection) that the top layer is worn.

[0035] 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 material's thickness. The ratio of the tear resistance of the cover layer to the tear resistance of the indicator element is preferably in the range of 0.7 to 1.9. It has been found that within 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 state even with advanced wear of the cover layer. Furthermore, the rope or cable can be securely supported by the indicator element even with advanced wear of the cover layer.

[0036] The glass transition temperature can preferably be determined according to ISO 11357-2. Preferably, the top 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 is the temperature at which a polymer transitions to a rubbery to viscous state. In other words, if the glass transition temperature is exceeded, the top layer can abruptly change its properties necessary for guiding a rope. Therefore, it is advantageous if the top layer has a sufficiently high glass transition temperature to ensure that the rope is guided reliably through the insert element, even during continuous operation.In contrast, the indicator element can have a lower glass transition temperature, since, particularly when the indicator element is only partially or partially integrated into the cover layer, it is not primarily responsible for guiding the rope. Consequently, efficient interaction between the cover layer and the indicator element can be achieved. Furthermore, the glass transition temperature of the cover layer, as determined above, allows the insert element to be used even with rapidly rotating rollers (i.e., with higher heat generation during operation).

[0037] Preferably, the indicator element comprises a fabric, at least one thread, fluorescent material, colored liquid, in particular ink, and / or a film.

[0038] The fabric can, for example, be a textile woven fabric comprising at least two yarn systems and applied across the entire surface of the top layer or attached to the top layer. If the top layer is worn to the point that the fabric is visible from the outside, the wear condition of the insert element can be determined. The fabric can also be made of wires, cord, or other elements. Preferably, the fabric also has a stabilizing effect, allowing radial forces acting on the insert element to be absorbed by the fabric. This allows the insert element to be made thinner, thus reducing production costs. Furthermore, the insert element can also be used in small rolls.

[0039] The at least one thread can be arranged in or on the cover layer in such a way that the thread becomes visible (i.e., visible from the outside) when the cover layer wears down. This allows conclusions to be drawn about the wear state of the insert element. The thread can be arranged straight or curved within 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 visible even from a distance.

[0040] The fluorescent material can be used to detect the wear condition of the insert element. Furthermore, the fluorescent material can have the additional property of emitting light upon excitation. This light emission can produce photons. For example, an insert element under inspection can be illuminated with a light source, causing any fluorescent material visible on its surface to emit light. This allows the wear condition of an insert element to be checked even in darkness. This simplifies the maintenance of the insert element. The fluorescent material can be applied to or within the indicator element in the form of paint or lacquer. 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.

[0041] The colored liquid can, for example, be arranged in capsules within the top layer. When the top layer wears down or abrasion occurs, these capsules can be damaged, allowing the liquid to reach the surface of the insert element. This makes it easy to recognize when a certain wear state of the insert element has been reached. In this embodiment, it is advantageous that even with minor abrasion, the liquid is distributed over a large area of ​​the insert element's surface, so that even with small damage to the top layer, it is easily and readily apparent that a certain wear state has been reached. The capsule containing the liquid can be arranged within the top layer at a specific radial distance from the first surface of the top layer.Furthermore, differently colored liquids can be provided depending on their position within the insert element (for example, depending on their distance from the first surface layer). Thus, the extent of wear on the insert element can be determined by observing the different colors appearing on its surface.

[0042] The foil can be a plastic or aluminum foil, positioned parallel to the first cover layer within the insert element. As the cover layer wears, the foil can become partially or completely visible, thus indicating the wear state of the insert element. Alternatively, aluminum powder can be mixed into the cover layer, which would become visible when the cover layer wears down. This allows for a particularly simple implementation of the indicator element.

[0043] Preferably, the insert element comprises at least one conductivity sensor configured to detect a voltage applied to a rope or cable passing through the insert element.

[0044] This embodiment can be implemented in two ways: Firstly, the outer layer can be an insulating material, as is the case, for example, with aerial tramways. Here, the cable guided through the insert element is used to transmit 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. Alternatively, the indicator element can be conductive. If the outer layer is worn away to the point that the cable guided through the insert element comes into contact with the indicator element, an electrical circuit can be closed, and the signal transmitted through the cable can be detected by the sensor on the insert element. Thus, it is possible to determine remotely whether an insert element is worn or not.Furthermore, this system can precisely detect the position of the worn insert element within a larger system. Additionally, the cover layer can be designed to be conductive, and the indicator element can be located within the cover layer or on the other side of the cover layer, possessing insulating properties. As long as the cover layer wears away, tension can be transferred from the rope running through the insert element to the insert element, provided the cover layer maintains a certain thickness. However, if the cover layer is worn and the abrasion is so extensive that the rope is in contact with the indicator element (e.g., with the indicator layer), the rope is insulated, and no further tension can be measured. In this case, too, the system can detect that the insert element is worn.

[0045] The metal rod can, for example, be positioned perpendicular to the cable's direction of travel within the surface layer. If the surface layer is worn down to the point where the wire reaches the surface (i.e., the first layer of the surface layer), it can be determined that the surface layer is worn. This offers the advantage that further abrasion by the metal rod is prevented or at least significantly reduced, as the metal rod has a considerably higher strength than the surface layer. Furthermore, the metal rod can be positioned in a predetermined location within the surface layer (i.e., at a predetermined distance from the first layer of the surface layer) at which the insert element is to be replaced. This allows for the simple definition of a wear limit for the insert element, while still permitting its continued use.

[0046] Similarly, a wire can be positioned in or on the top layer, thus acting similarly to the metal rod. Furthermore, several separate wires can be arranged in different positions within the top layer. For example, each wire can have a different distance from the first edge of the top layer. The wires can also differ in color. If the top layer is worn away to the point where a wire reaches its surface, the wire can be detected, indicating wear. With continued operation, the wire (unlike the metal rod) can be further worn, i.e., moved away from the insert element (until the next wire is exposed). Different colors of the wires can indicate different wear states. It is also conceivable to apply a voltage to each wire and measure it separately.If the applied voltage can be measured, it can be assumed that the insert element is still intact. However, if no voltage can be measured for one or more wires, it can be assumed that these wires have already been worn away from the insert element by a reduction in the 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 positioned in the insert element. Furthermore, this wear condition can also be determined remotely and / or automatically. Thus, detailed monitoring of a system that, for example, comprises a large number of system components is readily possible. It is also conceivable to implement such an automated system for monitoring the wear condition of at least one insert element.The monitoring system can, for example, automatically issue an alarm when a predetermined wear level is reached. This ensures that a worn insert element is detected and replaced in a timely manner.

[0047] Preferably, the insert element comprises several indicator elements that are arranged distributed in a radial direction of the insert element, and wherein each indicator element has different properties.

[0048] The radial direction of the insert element can refer to an insert element that has a ring-like shape. However, the insert element can also be a flat body. In either case, the radial direction can be perpendicular to the first surface layer and extending to the second surface layer. Providing multiple indicator elements is analogous to providing different wires at varying distances from the first surface layer in the embodiment described above. In other words, different wear states can also be achieved with different indicator elements by providing the indicator elements at varying distances from the first surface layer.

[0049] Preferably, the ratio of the material thickness of the cover layer to 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.

[0050] It was found that in a first region, the interaction between the cover layer and the indicator element is optimal. This is particularly true when the indicator element is designed as an indicator layer. The first region is especially advantageous with regard to the occurrence of stresses between the two layers, as the thicknesses of both layers are such that no stress peaks occur at the interface between the cover layer and the indicator layer. Thus, the durability of the insert element can be ensured.

[0051] In the second area mentioned, the advantage is that even when several indicator elements are provided (in the second ratio given above, the material thickness of all existing indicator layers is added), sufficient cohesion of all individual layers is ensured.

[0052] Furthermore, it was found that in the last defined area, the wear condition of the insert element is indicated for a sufficient duration to allow maintenance personnel to take note of it. Thus, the wear condition of the insert element can be reliably displayed and detected over a sufficient period of time.

[0053] Preferably, the insert element comprises a fabric layer designed to absorb radial forces, wherein the ratio of the material thickness of the cover layer to 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.

[0054] 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 it. Even in such a case, safe operation can be achieved.

[0055] In the second area mentioned above, the fabric layer is as thick as the top layer or thinner. This offers the advantage of allowing for a thinner overall insert element, while the top layer provides sufficient abrasion resistance. At the same time, the insert element offers enough resistance to absorb radial forces.

[0056] It was found that the latter range represents an optimum, particularly in the operation of cable car systems. In this range, the radial forces occurring in cable car systems can be adequately absorbed, while still providing a sufficiently thin insert element to enable efficient operation.

[0057] Preferably, the cover layer has on its first cover layer side a guide area and two protective areas adjacent to the guide area in a cross-section transverse to a rope or cable guidance direction, wherein the guide area has a recess which is deeper than at least one of the shoulder areas by a recess spacing, and wherein the ratio of the width of both shoulder areas in the cross-section transverse to the rope or cable guidance direction 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.

[0058] Thus, the first surface layer can be structured in such a way that the cable can be guided through it in a defined manner. Preferably, the recess is round and has the recess spacing as its radius. This allows the first surface layer to be designed to perfectly match the shape of the cable or rope being guided, thereby improving guidance. The specified ratios indicate the ratio of the recess depth to the width of the insert element perpendicular to the cable guidance direction. The first ratio offers the advantage that all types of cables or ropes are compatible with the insert element without any problems. For example, even very thick cables can be guided through the insert element effectively. Furthermore, the range of applications for the insert element in the first area defined above is very broad, allowing it to be used in a wide variety of applications.In the second area defined above, the advantage lies in the fact that even in applications where forces are applied to the insert element perpendicular to its radial direction and the direction of rope guidance, the insert element possesses sufficient strength and resistance to such forces through its shoulder areas, thus enabling continuous operation. In other words, the force acting on the shoulder areas depends on the depth to which the rope is drawn into the recess of the insert element. Therefore, the second area defined above offers optimal lateral stiffness while simultaneously ensuring efficient rope guidance. The final area defined above offers the advantage that the insert element provides optimal lateral guidance for the rope or cable, and can be manufactured with minimal material usage.

[0059] 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 configured 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 arranged on and / or in the cover layer side, wherein the indicator element is configured to indicate a wear condition of the insert element, and a bearing area for rotatably mounting the rope or cable guide roller.

[0060] Such a pulley 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 insert elements described above.

[0061] According to a further aspect of the present invention, a method for manufacturing an insert element for guiding a rope or cable, in particular according to one of the above aspects, is provided, wherein the method comprises the steps: 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.

[0062] Furthermore, the method can include a step of cutting or milling a groove into the first surface layer of the cover layer. The groove can extend in the direction of cable guidance. The indicator element (for example, a differently colored band) can be inserted into the groove and then vulcanized together with the cover layer. Thus, the indicator element can be bonded to the cover layer. Preferably, the indicator element is positioned at the deepest point of the groove in the cover layer. The groove can be designed such that, at the beginning of operation of the insert element, the cable or rope being guided does not touch the deepest point of the groove. Only through wear or abrasion of the cover layer can the cable or rope come into contact with the deepest point of the groove and rub off the indicator element.If the indicator element is no longer visible, it can be defined that a certain wear condition has been reached. For example, if the indicator element is no longer visible, the insert element can be replaced.

[0063] The design variants and advantages listed above in connection with the device also apply analogously to the method and vice versa. Individual features of individual embodiments can be combined to create 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. These show: Fig. 1 a schematic and perspective view of an insert element according to an embodiment of the present invention, Fig. 2 a cross-section of the in Fig. 1 the depicted insert element perpendicular to a cable guidance direction, Fig. 3 a schematic top view of an insert element according to a further embodiment of the present invention, Fig. 4 a schematic top 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 a further embodiment of the present invention.

[0064] Fig. 1 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 simplified to Fig. 1 The insert element 1 is shown only in sections. The cover layer 2 has a top layer 2. The top layer 2 has a first top layer side 6, which is an outer side of the top layer 2 (i.e., facing the environment), and a second top layer side 7, which is an inner side of the top layer side 2. An indicator layer is provided on the second top layer side 7 as an indicator element 3. Furthermore, the top layer 2 has a cable guide area 5 and two shoulder areas 4 on its first top layer side 6. The two shoulder areas 4 enclose the cable guide area 5 in their center. A cable or wire (not shown in the figures) lies in the cable guide area 5, so that the cable or wire comes into contact with the top layer 2. The cable guide area 5 has a recess 8 that is radially recessed inwards relative to the shoulder areas 4.The rope is guided through the insert element 1 in a rope guidance direction 10 (in . Fig. 1 from right to left or from left to right). In other words, the rope can move in the rope guidance direction 10. The insert element 1 can also move (i.e., rotate) according to the movement of the rope. For example, a pulley on which the insert element 1 is mounted can rotate. Due to the guidance of the rope, the cover layer 2 can wear down, especially since the relative velocity between the rope and the insert element is not zero. This wear causes abrasion, resulting in the cover layer 2 losing material. When the cover layer 2 is worn down to the point that the indicator layer 3 is exposed (i.e., visible from the outside when looking at the insert element from above), the wear condition of the insert element can be determined from the outside. Accordingly, it can be determined that the insert element 1 needs to be replaced.

[0065] Fig. 2 is a cross-section through the in Fig. 1 The illustrated insert element 1 is positioned transversely to the cable guidance direction 10. Fig. 2 The cable guidance direction therefore runs into and out of the plane of the blade. Fig. 2 The recess 8 is visible in the rope guide area 5. 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 bonded to the cover layer 2 by means of a co-vulcanization process. This ensures sufficient cohesion between the cover layer 2 and the indicator layer 3.

[0066] Fig. 3 Figure 1 is a top view of an insert element 1 according to a further embodiment of the present invention. In this embodiment as well, the cover layer 2 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 rather as strip-like elements that extend parallel to each other in the axial direction 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 (i.e.,on 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.

[0067] In another embodiment (not shown), in addition to the surface-mounted indicator elements 3, further indicator elements are arranged within the cover layer 2. These indicator elements 3 differ in color. More precisely, the indicator elements 3 located on the surface of the cover layer 2 (i.e., on the first side 6 of the cover layer) differ from the indicator elements 3 located within the cover layer 2. Thus, the extent of wear of the insert element 1 can be easily and readily determined by means of the different color codes.

[0068] Fig. 4 Figure 1 shows a top view of an insert element 1 according to a further embodiment of the present invention. The present embodiment largely corresponds to that described in Figure 1. Fig. 3 The embodiment shown differs in that the indicator elements 3 now run in the direction of the cable guide 10. In the present embodiment, one indicator element is arranged at the deepest point of the recess 8 in the cable guide area 5, and one indicator element 3 is located in each of the shoulder areas 4. Thus, even a periodically occurring uneven load on the insert element 1 can be detected by uneven wear of the indicator elements 3.

[0069] Fig. 5 is a cross-section through an insert element 1 according to a further embodiment of the present invention. The following corresponds to the Fig. 5 The embodiment shown is essentially the same as that described in Fig. 2 The illustrated embodiment differs in 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 leak out onto the first side 6 of the cover layer. The colored liquid indicates that a certain wear state of the insert element 1 has been reached.

[0070] Fig. 6 is a schematic cross-section of a further embodiment of the present invention. The following corresponds to the one shown in Fig. 6 The embodiment shown is essentially the same as that described in Fig. 3 The illustrated embodiment differs in that the indicator element 3 comprises wires running in the cable guidance direction 10, which are arranged within the insert element 1. The wires 3 are arranged at different distances from the first surface 6 of the cover layer 2 and can thus indicate different wear states of the insert element 1 by the wires 3 emerging at the surface 6 of the first surface. 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 thus be monitored individually. Remote diagnostics can therefore be used to determine the extent of wear of the insert element.

[0071] The cable guidance direction can also be referred to as the circumferential direction in the case of round insert elements. In another embodiment not shown, the indicator element is designed as a structure on the surface of the cover layer (i.e., on the first side of the cover layer 6). For example, the indicator element 3 is a depression in a cable guidance area 5, and the absence of the depression indicates that a certain wear condition has occurred. In yet another 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. Bezugszeichenliste:

[0072] 1 Insert element 2 Top layer 3 Indicator element 4 Shoulder area 5 Cable guide area 6 First top layer side 7 Second top layer side 8 Recess 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 cableway installation, comprising a top layer (2) with a first top layer side (6), which is designed to come into contact with a rope or cable to be guided, and a second top layer side (7) opposite the first top layer side (6), and an indicator element (3), which is arranged on and / or in the top layer (2), and wherein the indicator element (3) is designed to indicate a wear condition of the insert element (1), wherein the top layer (2) has a Shore A hardness of greater than 81 Shore and comprises SBR, NR, NBR, EPDM, CSM, BR and / or FKM, characterized in that the indicator element (3) has a Shore A hardness of less than 80 Shore and comprises PP, TPE, PA and / or PETP.

2. Insert element (1) according to claim 1, wherein the insert element is formed as one-piece.

3. Insert element (1) according to one of the preceding claims, 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.

4. Insert element (1) according to one of the preceding claims, wherein the indicator element (3) and the top layer (2) have different properties, such as in particular hardness, density, tear resistance, elongation at break, abrasion, rebound elasticity, compressive deformation rest, tear resistance, glass transition temperature, electrical conductivity and / or swelling.

5. Insert element (1) according to any 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.

6. 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).

7. Insert element (1) according to any one of the preceding claims, 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.

8. Insert element (1) according to one of the preceding claims, wherein a ratio of the material thickness of the top 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 from 0.01 to 0.7, preferably in a range from 0.07 to 0.5, more preferably in a range from 0.1 to 0.3.

9. 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 top layer (2) and the material thickness of the fabric layer in a radial direction (20) of the insert element (1) is in a range from 0.8 to 9, preferably in a range from 1 to 8, more preferably in a range from 2 to 7.

10. Insert element (1) according to one of the preceding claims, wherein the top layer (2) has a guide region (5) and two shoulder regions (4) adjacent to the guide region on its first top layer side (6) in a cross-section transverse to a cable or cable routing direction, wherein the guide region (5) has a depression (8) which is recessed by a depth clearance with respect 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 cable or cable routing direction (10) and of the width of the two shoulder regions (4) in the cross-section transverse to the cable or cable routing direction (10) to the width of the guide region (5) in the cross-section transverse to the cable or cable routing direction (10) is in the range of 0.5 to 9. cable routing direction (10) and the depth clearance is in a range from 0.2 to 5.0, preferably in a range from 0.4 to 3.0, more preferably in a range from 0.7 to 2.5.

11. Rope or cable guide pulley comprising an insert element (1) according to any one of the preceding claims, and a bearing portion for rotatably supporting the rope or cable guide pulley.

12. Method of manufacturing an insert element (1) for guiding a rope or cable according to any one of claims 1 to 10, the method comprising: providing the indicator element (3), applying the indicator element (3) in or on the top layer (2), and vulcanizing the indicator element (3) and the top layer (2), wherein the indicator element (3) can indicate a wear condition of the insert element (1).