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

Abstract

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

Description

[Technical Field]

[0001] The invention relates to an insert element for guiding a rope or cable, a rope or cable guiding roller and a method for manufacturing the insert element. [Background technology]

[0002] Insert elements, sometimes called linings, are used on rope pulleys or deflection pulleys in ropeways, whether they are aerial ropeways, rail ropeways, or drag lifts. The purpose of the insert elements is to support and guide the rope or cable. Furthermore, the insert elements also have sound-absorbing and vibration-damping effects. Due to the installation of such elements in sensitive systems such as ropeways, the wear of such insert elements must be monitored regularly so that they can be replaced in time before failure occurs. Such monitoring is usually performed by trained personnel who inspect the insert elements. The shape of the insert element is measured using a gauge or caliper and compared with its initial state. Based on the deviation of the insert element's shape from its initial state, the wear state can be inferred. Because insert elements are often difficult to access (e.g., located on cable car supports), monitoring the insert elements is labor-intensive, difficult, time-consuming, and therefore expensive. Summary of the Invention [Problem to be solved by the invention]

[0003] SUMMARY OF THE INVENTION It is therefore an object of the present invention to simplify the monitoring of insert elements. [Means for solving the problem]

[0004] This problem is solved by an insert element having the features of claim 1, a rope or cable guide roller having the features of claim 13 and a method for manufacturing an insert element having the features of claim 14. Preferred embodiments are set out in the dependent claims.

[0005] According to one aspect of the present invention, there is provided an insert element for guiding ropes or cables, in particular for cable car installations, comprising a surface layer having a first surface layer side designed to be in contact with the rope or cable to be guided and a second surface layer side opposite the first surface layer side, and an indicator element arranged on and / or in the surface layer, the indicator element being designed to indicate the wear state of the insert element.

[0006] According to one aspect of the present invention, the insert element can also be used in pulleys of lifts, elevators, cranes, etc. Basically, anywhere a cable or rope is guided, run, or deflected. The present invention also relates to so-called wear strips, which can be provided as lockable strips rather than as one-piece closed rope pulley insert elements. For example, such wear bands can protect the rope or cable from direct contact with a building or other structure. The rope or cable can also be a load-bearing structure. In particular, the cable or cord can be a non-current-carrying (i.e., power-carrying) element. Such a dual function would be counterproductive, since a cable used for power supply should not be used to carry a load at the same time. Nevertheless, a test current or the like can be conducted through the cable or rope.

[0007] According to one aspect of the present invention, an insert element, lining, or lining for a rope pulley protects the rope or cable, on the one hand, and the rope pulley itself, or rather the pulley bundle that forms it, which is usually made of metal, on the other hand. It can also protect the bearings of the rope pulley and the supporting structure. Furthermore, the insert element can also provide increased comfort by ensuring a mechanically and acoustically quiet running of the rope through the pulley. For this purpose, the insert element can be made of a softer and / or more elastic material than the pulley in which it is provided. Thus, the insert element can be made, for example, from an elastomer or rubber as a one-piece ring. The insert element can be realized with or without a flexible woven fabric or flexible wire mesh insert. For high loads, the insert element can be made of plastic, which can include polyurethane as a base polymer and belong to the thermoplastic or thermosetting resin category.

[0008] In contrast to the prior art, the use of the insert element of the present invention eliminates the need for a person to be in close proximity to the insert element to check its wear state. Instead, it is sufficient to inspect the insert element from a distance, since the wear state of the insert element can be easily recognized using the indicator element. For example, when used in a cableway system, it may be sufficient to inspect the insert element from the ground, for example, using binoculars, thereby immediately obtaining information about its wear state. This significantly reduces the inspection time, and the wear state of the insert element can be inspected, for example, as it passes by during a driving session. In this way, the previously known time-consuming and dangerous insert element inspection work can be reduced or avoided, while at the same time ensuring that the wear state can be objectively determined, independent of the person performing the inspection, thanks to the objective indication provided by the indicator element. This ensures that insert elements are always replaced simultaneously. In contrast, individual manual, purely visual inspection does not guarantee that several insert elements are objectively evaluated simultaneously. As a result, the use of the insert element of one aspect of the present invention allows for standardization of the replacement intervals of insert elements.

[0009] The insert element can be a separate part and designed to be fixed to the roller. The roller, in turn, can be rotatably held on a structure such as a support. For example, a pulley can be rotatably attached to a structure by means of plain or rolling bearings. A rope or cable can be placed on the insert element and supported and / or guided by the insert element. A cable guiding direction can specify the direction in which the guided cable extends. The insert element can also be designed to protect the cable from lateral displacements transverse to the cable guiding direction. For this purpose, the insert element can have a lower strength than the pulley. In other words, the insert element can be made of an elastic material that at least partially surrounds the guided cable. To improve guiding performance, the insert element can at least partially adapt to the shape of the rope to be guided.

[0010] Preferably, the insert element is designed as a single piece. In other words, the insert element cannot be disassembled into its component parts in a non-destructive manner. This can ensure high stability and easy manufacture of the insert element. In particular, in the case of a single-piece or one-piece insert element, a defined arrangement is guaranteed (e.g., during centralized production of the insert elements) so that, even with several insert elements, the indicator element always has the same relative position, e.g., with respect to the surface layer. This can ensure consistent determination of the wear of the insert element.

[0011] The surface layer can be a volumetric layer extending in all three spatial directions. In particular, in a cross section transverse to the cable guiding direction, the surface layer can have a first surface layer side and an opposite second surface layer side. The surface of the surface layer on the first surface layer side and the surface of the surface layer on the second surface layer side can be several times larger than the side of the surface layer. The first side of the surface layer can have a shape that allows the rope or cable to be reliably guided through the insert element. For this purpose, the first surface layer side can have, for example, a shape that is complementary to the rope or cable to be guided. Preferably, the first surface layer side has a shape that allows the rope to be at least partially housed within the surface layer. For this purpose, the surface layer can, for example, be recessed on the first surface layer side or have areas made of a different (e.g., softer) material.

[0012] The indicator element can be influenced and / or changed by operation (i.e., by contact between the rope and the surface layer and / or indicator layer) in such a way that the wear state of the insert element, in particular the surface layer, can be indicated by the indicator element (e.g., the state of the indicator element). For example, the indicator element can be an additional layer, for example, arranged on the second surface layer side of the surface layer. In that case, the indicator element becomes visible as a result of wear of the surface layer, making it possible to quickly and easily determine that the surface layer or the insert element is in a certain state of wear when looking from the outside at the first surface layer side. In the case of a ring-shaped core element, for example, the wear state can be determined by looking radially outward from the core element (i.e., at the contact side between the core element and the rope or cable). For this purpose, the indicator element can, for example, have a different color from the surface layer. For example, the surface layer can be black and the indicator element white. This ensures a high contrast, making it quick and easy to recognize that the indicator layer has come into contact with the surface of the core element.

[0013] According to a further aspect of the invention, the indicator element can be a strip provided on the first surface layer side of the surface layer, at least in the area where the rope is guided through the surface layer. For example, the indicator element can be a strip-like element located in or on the first side of the surface layer, transverse to and / or along the direction in which the rope is guided. Again, the indicator element can have a different color than the surface layer. During operation, the surface layer and the indicator element can wear away. In this case, the indicator element can have a material thickness smaller than the surface layer, and at some point during wear, the indicator element disappears (i.e., is no longer visible), allowing a view from the first surface layer side to determine whether the indicator element is still present. Furthermore, the indicator element can have a shape that narrows or widens with distance from the first surface layer side. Thus, the visible indicator element can thicken or thin depending on the wear. Thus, the indicator element can indicate whether the surface layer is worn and / or to what extent. In particular, in embodiments in which the indicator elements extend transversely to the rope guiding direction, it is easy to see which areas of the first surface layer are subject to particularly high wear by the ropes or cables, and in this way it is also possible to draw conclusions regarding operational conditions (e.g., deviations in the rope guiding, uneven loading on the core elements, etc.), which can result in further optimisation of operation and increased safety.

[0014] Preferably, several indicator elements can be provided in or on the surface layer. For example, several indicator elements can be provided as layers parallel to the first surface layer side, stacked on top of each other. Each indicator layer can have a different color. For example, the indicator element closest to the first surface layer side can be green, the next indicator element orange, and the next indicator element red. Thus, in this embodiment, the insert element can have a total of three indicator elements, each designed as a separate layer. In this case, during operation, the surface layer first at least partially wears off, and the first (green) indicator element becomes visible. In this way, the indicator element can indicate that the surface layer is already worn, but further operation of the insert element is still possible (due to the green color of the first indicator element). If the first indicator element also wears off, the second indicator element (yellow layer) appears, indicating that the insert element is soon worn and must be replaced. As soon as the red indicator element becomes visible, the indicator element indicates that the insert element must now be replaced. Similarly, the insert element can have many different layers as indicator elements, allowing for close monitoring of the insert element. It is also conceivable that the indicator element has a variable extension relative to the first surface layer side. In this way, a visible pattern can be created on the first side of the surface layer as the surface layer wears. The pattern can change depending on the sealing condition. For example, the indicator element can have a wavy extension relative to the first side of the surface layer. The variable positioning of the indicator element means that only specialized personnel and / or image recognition systems can detect the wear state, not passengers or visitors. This prevents amateurs from misinterpreting the indicator element.

[0015] On the one hand, the insert element reduces the potential danger for personnel who have to inspect the insert element, and on the other hand, reduces the effort involved in determining the wear of the insert element, for example, by allowing the insert element to be checked from a certain distance during the course of operation.

[0016] Preferably, the indicator element at least partially or sectionally covers the first surface layer side and / or the second surface layer side.

[0017] If the indicator element is designed as a volume layer, it can cover the surface layer at least in the area where the rope or cable comes into contact with the surface layer. In other words, in this case, the indicator element can be arranged on the first surface layer side. Alternatively or additionally, the indicator layer can be provided on the second surface layer side (i.e., the side of the surface layer opposite the rope or cable) and extend to the second surface layer side. In this case, the indicator layer only appears when the surface layer is worn. Alternatively or additionally, the indicator layer can also partially cover the first side and / or the second side of the surface layer. In this case, the indicator element can be arranged as a strip element (e.g., transversely or along the rope guide direction). The indicator element can therefore be arranged depending on the application of the insert element. For example, a partial arrangement of the indicator element can be advantageous if the cable or rope comes into contact with the surface layer in a known area. On the other hand, if it is not clear in advance where the wear will occur, a flat arrangement of the indicator element can be provided. The latter can apply, for example, to large-area insert elements. This means that the insert element can always be provided appropriately for its intended use. It is also conceivable to provide the indicator element in the surface layer, for example at half the material thickness of the surface layer. This means that the wear state can be indicated, for example, when the insert element is half worn. As a result, reliable monitoring of the expected service life of the insert element can be provided.

[0018] Preferably, the surface layer comprises SBR, NR, NBR, EPDM, CSM, BR and / or FKM.

[0019] This means that the surface layer can have sufficient elasticity to ensure that the cable or rope is guided reliably and that the required soundproofing and vibration-damping effects are achieved. Furthermore, the materials SBR (styrene butadiene rubber), NR (natural rubber), NBR (acrylonitrile butadiene rubber), EPDM (ethylene propylene diene rubber), CSM (Hypalon), BR (polybutadiene rubber), and / or FKM (fluoro rubber) are easy to process, allowing the surface layer to be easily manufactured into the appropriate shape. In particular, the insert element can be a vulcanized product. Additionally, the aforementioned materials are inexpensive, thus making the manufacturing process of the insert element efficient. Furthermore, the surface layer can comprise a mixture of the above materials. Each of the above materials or their blends can constitute a base polymer and can be expanded with additives such as carbon black. In this way, the desired properties (e.g., color) required for the intended use of the insert element can be easily achieved.

[0020] Preferably, the indicator element comprises PE, PP, TPE, PA and / or PETP.

[0021] The use of such materials allows the indicator element to have suitable properties, on the one hand, to indicate the wear state well and, on the other hand, to have sufficient strength to safely guide, for example, a rope or cable and still indicate the wear state of the insert element even when it comes into contact with it. In other words, the indicator layer can contain PE (polyethylene), PP (polypropylene), TPE (thermoplastic elastomer), PA (polyamide) and / or PETP (polyethylene terephthalate). Furthermore, the indicator element can also contain a mixture of the above materials. The above materials simply represent base polymers and can also contain further additives, such as carbon black. As a result, the indicator element can also be well adapted to the respective application area of ​​the insert element and have sufficient strength and durability for long-term operation.

[0022] Preferably, the indicator element and the surface layer have different properties, such as hardness, density, tensile strength, elongation at break, abrasion, rebound resilience, compression set, tear propagation resistance, glass transition temperature, electrical conductivity and / or degree of swelling, among others.

[0023] The surface layer preferably has a Shore A hardness greater than 81 Shore A. In contrast, the indicator element can have a Shore A hardness less than 80 Shore A. It has been found that particularly high energy efficiency (especially with regard to deformation of the insert element) can be achieved within the above-mentioned range when using insert elements in guide rollers for cable car systems. The fact that the indicator element has a lower hardness than the surface layer ensures that the indicator element erodes faster than the surface layer when in contact with the rope or cable, making the wear state clearly and easily recognizable even from a certain distance. Hardness can be measured, for example, according to DIN 53505, DIN EN ISO 868, etc.

[0024] The density of the indicator element is preferably lower than the density of the surface layer. Preferably, the density of the indicator element is 1.25 g / cm 3and the density of the surface layer is preferably less than 1.25 g / cm 3 This ensures that the wear state of the insert element can be clearly indicated. The density can preferably be measured according to the EN ISO 1183-1 standard. Preferably, the surface layer has a density of 1.26 g / cm 3 ~1.28g / cm 3 This ensures that the weight of the insert element remains within a suitable range, particularly when used with pulleys for cableway systems, allowing for particularly efficient operation of the pulleys.

[0025] Tensile strength may refer to the maximum mechanical tensile stress that a material can withstand before failing (e.g., breaking). Preferably, the surface layer has a strength of 15 N / mm 2 In contrast, the indicator element has a tensile strength of 15 N / mm 2 The area indicated above can be used to form a particularly efficient insert element, since the indicator element only needs to have a lower tear resistance and is therefore cheaper.

[0026] The elongation at break can be a characteristic value that indicates the permanent elongation of a component relative to its initial length when the component is loaded with a force. In other words, the elongation at break can indicate the component's deformation capacity. Preferably, the elongation at break can be measured according to the DIN 53504-S2 standard. Preferably, the surface layer has an elongation at break of at least 120%. In contrast, the indicator element has an elongation at break of at least 200%. This ensures that the safe operation of the insert element is guaranteed without the risk of premature breakage, even when the indicator element is involved in guiding a rope or cable.

[0027] Abrasion (also known as abrasion or erosion) can refer to the loss of material on the surface of a component. Abrasion can be caused by mechanical stresses such as friction or environmental influences. When material is removed from a component, very small particles can usually be generated. In material science, abrasion can also be referred to as wear. Preferably, abrasion is measured as a volume according to the ISO 4649-Method A standard. Preferably, the surface layer is less than 160 mm 3 In contrast, the indicator element preferably has a wear-out of 160 mm. 3 Furthermore, the wear of the surface layer and indicator element is limited to a maximum of 200 mm. 3 This can also ensure permanent operation of the insert element. This is particularly advantageous when the indicator element is located in the material of the surface layer. Furthermore, the upper limit of wear can prevent excessive material from entering the environment.

[0028] Rebound resilience can be used to evaluate the elastic behavior of elastomers under impact stress. Preferably, the surface layer has a rebound resilience of at least 40%. In contrast, the indicator element preferably has a rebound resilience of less than 40%. Preferably, rebound resilience is measured according to the DIN 53512 standard. Furthermore, the surface layer and the indicator element can have a rebound resilience of at least 25%. This ensures that the rope or cable is reliably guided over the insert element without bouncing off the insert element, thus ensuring reliable guidance of the rope.

[0029] Compression set is a measure of how an elastomer behaves during long-term constant compression and subsequent relaxation. Preferably, compression set is measured according to ISO 815 Type B standard at 70°C and 20% strain for 24 hours. Preferably, the surface layer can have a compression set of less than 20%. In contrast, the indicator element can have a compression set of at least 20%. This ensures that the rope is reliably guided even when the insert element is subjected to long-term load. Furthermore, it can be ensured that the indicator element reliably indicates the wear state of the core element. The above-mentioned area can be provided with a particularly durable insert element.

[0030] Volume resistivity can be a measure of how well a component conducts electrical current. Volume resistivity is obtained by multiplying the measured volume resistivity by the measurement area and dividing it by the sample length. Preferably, the volume resistivity is measured according to the IEC 62631-3-2 standard. Preferably, the surface layer has a resistivity of 6.7 * 10 13 Ohms * In contrast, the indicator layer preferably has a volume resistivity of at least 5×10 14 Ohms * cm. This ensures that the indicator element is non-conductive. This can be achieved, for example, by providing a conductive surface layer (e.g., 1.9×10 5Ohms * This is advantageous when a guided rope or cable (having a volume resistivity of 0.01 Ω / cm) is used. In this case, it is possible to detect when the rope comes into contact with the insert element only via the indicator element, which results in a significant increase in electrical resistance. In other words, a voltage can be applied to the guided rope or cable and this voltage can be measured on the conductive surface layer. As soon as the surface layer wears and the rope or cable comes into contact with the insert element only via the indicator element, an increase in resistance can be detected. This makes it possible to draw the conclusion that the surface layer is worn. Alternatively, this configuration can be designed inversely, so that the surface layer is non-conductive and the indicator element establishes a conductive connection between the detector element (e.g., sensor element) and the guided cable. In this case, it is also possible to detect that the surface layer is worn (in this case, by establishing an electrical connection).

[0031] The tear propagation resistance can be measured, for example, according to ONORM C9446:2007 02 01. The tear propagation resistance can be the maximum force required to form a tear in a material and can be correlated to the thickness of the material. The ratio of the tear propagation resistance of the surface layer to the tear propagation resistance of the indicator element can preferably be in the range of 0.7 to 1.9. It has been found that this range allows the indicator element to be reliably retained in or on the surface layer even when the surface layer is already heavily worn. This ensures that the indicator element reliably indicates the wear state even when the surface layer is already in an advanced wear stage. Furthermore, the rope or cable can be reliably supported by the indicator element even when the surface layer is already in an advanced wear stage.

[0032] The glass transition temperature can be preferably measured according to the ISO 11357-2 standard. Preferably, the surface layer has a glass transition temperature of at least 70°C. In contrast, the indicator element can have a lower glass transition temperature. The glass transition temperature can be the temperature above which a polymer changes from a rubbery to a viscous state. In other words, above the glass transition temperature, the surface layer suddenly changes its properties, which are necessary for guiding the rope. Therefore, it is advantageous for the surface layer to have a glass transition temperature high enough to ensure safe guidance of the rope through the core element, even during continuous operation. In contrast, the indicator element, especially if it is only provided sectionwise or partially on the surface layer, can have a lower glass transition temperature because it does not primarily play a role in guiding the rope. As a result, efficient interaction between the surface layer and the indicator element can be achieved. Furthermore, thanks to the glass transition temperature of the surface layer measured above, the insert element can be used even with pulleys that rotate at high speeds (i.e., which generate more heat during operation).

[0033] Preferably, the indicator element comprises a fabric, at least one thread, a fluorescent material, a colored liquid, especially an ink and / or a film.

[0034] The fabric can be, for example, a surface woven fabric provided in or on the surface layer, including at least two thread systems. If the surface layer is worn to such an extent that the fabric is visible from the outside, the wear state of the insert element can be determined. The fabric can also be made of, for example, wire, cord, or other elements. Preferably, the fabric also has a stabilizing effect, such that radial forces acting on the insert element can be absorbed by the fabric. This allows the insert element to be thinner, which can save manufacturing costs. Furthermore, the insert element can also be used in small rolls.

[0035] The at least one thread can be arranged in or on the surface layer in such a way that the thread becomes exposed (i.e., becomes visible from the outside) when the surface layer is worn. This makes it possible to draw conclusions about the wear state of the insert element. The thread can be arranged straight or curved in the surface layer. Preferably, the thread can have a distinctive color (e.g., a lighter color than the surface layer) so that it can be easily identified from a greater distance.

[0036] Fluorescent materials can be used to detect the wear state of the insert element. Furthermore, fluorescent materials can have the additional property that they emit light after excitation. When light is emitted, photons can be emitted. For example, the insert element to be tested can be illuminated with a light source, so that the fluorescent material visible on the surface emits light accordingly. This means that the insert element can be checked for wear even in the dark. This can simplify the maintenance of the insert element. The fluorescent material can be applied in the form of a paint or lacquer on or in the indicator element. The light source used to excite the fluorescent material can be, for example, a UV light source. In principle, any fluorescent material is suitable for use with the indicator element.

[0037] The colored liquid can be disposed in capsules, for example, in the surface layer. In the event of wear or abrasion of the surface layer, these capsules can be damaged, allowing the liquid to escape to the surface of the insert element. This facilitates the recognition that the insert element has reached a certain state of wear. Advantageously, in this embodiment, even in the event of minor wear, the liquid is dispersed over a wide area on the surface of the insert element, making it easy and simple to recognize that a certain state of wear has been reached, even in the event of minor damage to the surface layer. The liquid-containing capsules can be disposed in the surface layer at a certain radial distance from the first surface layer side. Furthermore, different colored liquids can be provided depending on the position in the insert element (e.g., depending on the distance from the first surface layer side). In this way, the various colors appearing on the surface of the insert element can be used to determine how worn the insert element has become.

[0038] The foil can be a plastic foil or an aluminum foil arranged parallel to the first surface layer side of the insert element. When the surface layer is worn, the foil can be partially or completely exposed, thereby indicating the wear state of the insert element. It is also conceivable to incorporate aluminum powder into the surface layer, so that when the surface layer is worn, the aluminum powder becomes visible. This makes the indicator element particularly easy to realize.

[0039] Preferably, the insert element includes at least one conductivity sensor designed to sense a voltage applied to a rope or cable passing through the insert element.

[0040] This embodiment can be realized in two ways. First, the surface layer can be an insulating material, as in the case of an aerial cableway, for example. In this case, the cable running through the insert element is used to carry a signal (e.g., a telephone signal). If the insert element were not insulated, this signal would be disrupted and would not reach the receiver in a proper form. In contrast, the indicator element can be designed to be conductive. If the surface layer is rubbed off to such an extent that the cable passing through the insert element comes into contact with the indicator element, a circuit is closed, and the signal conducted through the cable can be detected by a sensor on the insert element. This means that remote monitoring can be used to determine whether the insert element is worn. Furthermore, this system can also detect the exact location of a worn core element within a larger system. On the other hand, it is also possible for the surface layer to be designed to be conductive, and for the indicator element to be provided in or on the second side of the surface layer and have insulating properties. If the surface layer is worn, tension can be transmitted from the rope passing through the insert element to the insert element as long as the surface layer has a certain thickness. If the surface layer wears and the wear is so great that the rope comes into contact with the indicator element (e.g. with the indicator layer), the rope becomes insulated and tension can no longer be measured, again making it possible to detect that the core element is worn.

[0041] Preferably, the indicator element comprises at least one metal rod and / or wire.

[0042] For example, a metal rod can be positioned in the surface layer at a right angle to the direction in which the cable is guided. If the upper layer is worn or abraded to such an extent that the wire reaches the surface (i.e., the first side of the surface layer), it can be determined that the upper layer is worn. Since the metal rod has a significantly higher strength than the surface layer, this offers the advantage that further wear is impossible or at least greatly reduced by the metal rod. For this purpose, the metal rod can be placed in the surface layer at a predetermined position (i.e., at a predetermined distance from the first surface layer side) where it is desired to replace the insert element. In this way, the wear limit of the insert element can be determined in a simple manner, which still allows the insert element to continue operating.

[0043] Similarly, wires can be placed in or on the surface layer, thereby achieving the same effect as metal rods. Furthermore, different wires separated from one another can be placed at different positions within the surface layer. For example, each wire can have a different distance from the first side of the surface layer. For example, the wires can be different colors. If the surface layer is worn away to such an extent that the wire contacts the surface of the surface layer, the wire can be recognized and a worn state can be indicated. During further operation, the wire (as opposed to the metal rod) can further wear, i.e., become detached from the insert element (until the next wire appears). Different colors of different wires can indicate different wear states. It is also conceivable to apply a voltage to each wire and measure it separately for each wire. If the applied voltage can be measured, it can be assumed that the insert element is still intact. On the other hand, if the voltage cannot be measured for one or more wires, it can be assumed that these wires have already become detached from the insert element due to a decrease in the material thickness of the surface layer. Because the distances of the individual wires to each other and to the first surface layer side are known, the depth of wear or the wear state can be accurately determined according to the spacing at which the wires are provided in the insert element. Furthermore, this wear state can also be determined by remote and / or automated maintenance. This means, for example, that detailed monitoring of a system comprising a large number of system elements is easily possible. It is also conceivable to provide an automated system for monitoring the wear state of at least one insert element. The monitoring system can, for example, automatically issue an alarm when a predetermined wear state is reached. This can ensure that worn insert elements are detected and replaced in a timely manner.

[0044] Preferably, the insert element includes a plurality of indicator elements radially dispersed about the insert element, each indicator element having a different property.

[0045] The radial direction of the insert element can refer to an insert element having a ring-like shape. Nevertheless, the insert element can also be a flat object. In either case, the radial direction can be a direction perpendicular to the first overlay side and extending toward the second overlay side. Providing several indicator elements is similar to providing different wires at different distances from the first covering layer side in the above embodiment. In other words, providing indicator elements at different distances from the first surface layer side can also achieve different wear states with other indicator elements.

[0046] Preferably, the ratio of the material thickness of the surface layer of the insert element in the radial direction to the material thickness of the indicator element is in the range of 0.01 to 0.7, preferably in the range of 0.07 to 0.5, more preferably in the range of 0.1 to 0.3.

[0047] It has been found that in the first zone there is an optimal interaction between the surface layer and the indicator element. This is particularly true if the indicator element is designed as an indicator layer. The first-mentioned zone is particularly favorable with regard to the generation of stresses between the two layers, since the thicknesses of the two layers are in such a ratio to one another that no stress peaks occur at the interface between the surface layer and the indicator layer. This ensures the durability of the insert element.

[0048] In the second region mentioned above, the advantage is that even if several indicator elements are provided (in the second ratio specified above, the material thicknesses of all present indicator layers are added together), sufficient adhesion of all the individual layers is guaranteed.

[0049] Furthermore, it has been found that the wear state of the insert element is indicated by the last defined zone for a sufficient period of time so that the wear state of the insert element can be noticed by a maintenance worker, which means that the wear state of the insert element can be reliably indicated and reliably detected for a sufficient period of time.

[0050] Preferably, the insert element comprises a fabric layer designed to absorb radial forces, and the ratio of the material thickness of the surface layer to the material thickness of the fabric layer in the radial direction of the insert element is in the range of 0.8 to 9, preferably in the range of 1 to 8, more preferably in the range of 2 to 6.

[0051] The first section described above provides the advantage that the insert element can be used in a wide range of applications, for example, the insert element can also be used in systems where large radial forces act on the insert element, while still providing safe operation.

[0052] In the second region, the fabric layer is just as thick as the surface layer or thinner. The advantage here is that an overall thinner insert element can be provided, while still providing sufficient wear reserves through the surface layer. At the same time, the insert element provides sufficient resistance to absorb radial forces.

[0053] The latter zone has proven to be optimal, especially when operating a cable car system, as it allows the radial forces occurring in the cable car system to be sufficiently absorbed, while still providing insert elements that are thin enough to allow efficient operation.

[0054] Preferably, the surface layer has, on its first surface layer side, a cross section transverse to the cable or cable guiding direction, a guide area, and two protective areas adjacent to the guide area, and the guide area has a recess that is recessed by a recess distance relative to at least one of the shoulder areas, and the ratio of the width of both shoulder areas in the cross section transverse to the cable or cable guiding direction to the recess distance is in the range of 0.2 to 5, preferably in the range of 0.4 to 3, more preferably in the range of 0.7 to 2.5.

[0055] This means that the first side of the surface layer can be structured in such a way that the cable can be guided through it in a predetermined manner. Preferably, the recesses are circular, with the recess spacing as a radius. This allows the first side of the surface layer to be complementary to the cable or rope being guided, which improves the guidance. The specified ratio indicates the ratio of the recess depth to the insert element width transverse to the cable guidance direction. The first ratio offers the advantage that any type of rope or cable can be easily accommodated in the insert element. For example, even very thick ropes can be successfully guided through the insert element. Furthermore, the range of use of the insert element in the first region defined above is very large, allowing the insert element to be used in a variety of applications. The second region defined above has the advantage that even in applications where forces are applied to the insert element transverse to the radial direction of the insert element and the direction in which the rope is guided, the insert element has sufficient strength or resistance to such forces, allowing for permanent operation. In other words, the force acting on the shoulder region depends on the depth to which the rope sinks into the recess of the insert element. Thus, the second section defined above provides efficient rope guidance while at the same time offering optimal lateral stiffness. The last section defined above offers the advantage that optimal lateral guidance for the rope or calf is provided by the insert element, which can thereby be realized with minimal material usage.

[0056] According to a further aspect of the present invention, there is provided a rope or cable guide pulley including an insert member including a surface layer having a first surface layer side adapted to contact the rope or cable to be guided and a second surface layer side opposite the first surface layer side, and an indicator member disposed on and / or in the surface layer side, the indicator member adapted to indicate a wear state of the insert member, and a bearing portion for rotatably supporting the rope or cable guide pulley.

[0057] Such pulleys can be used, for example, to deflect and / or guide ropes or cables in cable cars, elevators, cranes, etc. The insert element can also be designed according to one of the insert elements described above.

[0058] According to a further aspect of the present invention there is provided a method of manufacturing a core member for guiding a rope or cable, in particular of any of the above aspects, comprising the steps of: providing an indicator element; applying an indicator element into or onto a surface layer; and vulcanizing the indicator element and the surface layer; wherein the indicator element is capable of indicating a wear state of the insert element.

[0059] Furthermore, the method can include a step of cutting or milling a groove in the first surface of the surface layer. The groove can extend in the cable guiding direction. An indicator element (e.g., a tape of a different color) can be inserted into the groove and then vulcanized together with the surface layer. In this way, the indicator element can be glued to the surface layer. Preferably, the indicator element is located at the deepest point of the recess in the surface layer. The recess can be designed in such a way that, at the start of operation of the insert element, the guided rope or cable does not touch the deepest point of the recess. The cable or rope can only touch the deepest point of the recess and wear down the indicator element as a result of wear or abrasion of the surface layer. A certain wear state can be determined if the indicator element is no longer visible. For example, the insert element can be replaced when the indicator element is no longer visible.

[0060] The variations and advantages of the embodiments mentioned above in relation to the device also apply to the method, and vice versa. Individual features of the individual embodiments can also be combined with one another to form new embodiments. The advantages of the individual features also apply to the new embodiments. Preferred embodiments are described in detail below with reference to the drawings. [Brief explanation of the drawings]

[0061] [Figure 1] 1 is a schematic perspective view of an insert element according to one embodiment of the present invention; [Figure 2] 2 is a cross-sectional view of the insert element shown in FIG. 1 transverse to the rope guiding direction; [Figure 3] 4 is a schematic surface view of an insert element according to a further embodiment of the present invention; [Figure 4] 4 is a schematic surface view of an insert element according to a further embodiment of the present invention; [Figure 5] 3 is a schematic cross-sectional view of a further embodiment of an insert element according to the present invention; [Figure 6] 4 is a schematic cross-sectional view of an insert element according to a further embodiment of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0062] FIG. 1 is a schematic perspective view of an insert element 1 according to an embodiment of the present invention. The insert element 1 according to this embodiment has a ring-like shape, only a portion of which is shown in FIG. 1 for simplicity. The insert element 1 has a surface layer 2. The surface layer 2 has a first surface layer side 6 representing the outer side of the surface layer 2 (i.e., facing the environment) and a second surface layer side 7 representing the inner side of the surface layer 2. An indicator layer is provided on the second surface layer side 7 as an indicator element 3. Furthermore, the surface layer 2 has a cable guide section 5 and two shoulder sections 4 on its first surface layer side 6. The two shoulder sections 4 enclose the cable guide section 5 in their centers. A guided rope or cable (not shown) rests in the rope guide section 5 and comes into contact with the surface layer 2. The cable guide section 5 has a recess 8 recessed radially inward relative to the shoulder sections 4. The cable is guided through the insert element 1 in a cable guide direction 10 (from right to left or from left to right in FIG. 1 ). In other words, the cable can move in the cable guiding direction 10. The insert element 1 can also move (i.e. rotate) according to the movement of the rope. For example, the pulley on which the insert element 1 is arranged can rotate. In particular, the guiding of the rope can wear the surface layer 2, since the relative speed between the rope and the core element is not equal to zero. Wear causes abrasion, which causes the surface layer 2 to lose material. If the surface layer 2 wears down to such an extent that the indicator layer 3 appears (i.e. is visible from the outside in a surface view of the core element), the wear state of the core element can be observed from the outside. It can therefore be determined that the insert element 1 needs to be replaced.

[0063] Figure 2 is a cross-sectional view of the insert element 1 shown in Figure 1, taken at a right angle to the cable guiding direction 10. In Figure 2, the cable guiding direction therefore extends into and out of the plane of the paper. In Figure 2, a recess 8 can be seen in the cable guiding section 5. It can also be seen that the recess 8 has a radius that defines the recess. Furthermore, Figure 2 shows the radial direction 20 and the axial direction 30. The indicator layer 3 in this embodiment is bonded to the surface layer 2 by a vulcanization process. This can ensure that there is sufficient adhesion between the surface layer 2 and the indicator layer 3.

[0064] 3 is a surface view of an insert element 1 according to a further embodiment of the invention. In this embodiment, the surface layer 2 also has two shoulder regions 4 and one rope guide region 5. However, in this embodiment, the indicator elements are not arranged as indicator layers on the second surface layer side 7 of the surface layer 2, but rather as strip-like elements extending axially parallel to each other and transverse to the cable guiding direction 10. The indicator elements 3 extend in both the shoulder region 4 and the rope guide region. This means that wear can be indicated across the entire width of the core element 1. In this embodiment, the indicator elements 3 are located on the surface of the core element 1 (i.e. on the first surface layer side 6) so that if the indicator elements 3 are no longer present, it can be concluded that a certain state of wear of the core element 1 has occurred.

[0065] In another embodiment not shown, in addition to the indicator elements 3 attached to the surface, further indicator elements are arranged in the surface layer 2. The indicator elements 3 are of different colours. More precisely, the indicator elements 3 arranged on the surface of the surface layer 2 (i.e. on the first surface layer side 6) are different from the indicator elements 3 arranged in the surface layer 2. This means that using different colour coding it can be easily and quickly identified how far the insert element 1 has been worn.

[0066] Figure 4 shows a surface view of an insert element 1 according to a further embodiment of the invention. This embodiment largely corresponds to the embodiment shown in Figure 3, with the difference that in this case the indicator elements 3 extend in the cable guiding direction 10. In this embodiment, one indicator element is arranged at the deepest point of the recess 8 in the cable guiding section 5, and one indicator element 3 is arranged in each shoulder section 4. This means that even uneven loads that periodically occur on the insert element 1 due to uneven wear of the indicator elements 3 can be detected.

[0067] FIG. 5 is a cross-sectional view of an insert element 1 according to a further embodiment of the present invention. The embodiment shown in FIG. 5 essentially corresponds to the embodiment shown in FIG. 2, except that the indicator element 3 is formed not as an indicator layer but as multiple capsules containing a colored liquid. The capsules 3 are arranged at different depths within the surface layer 2. In other words, the capsules 3 are arranged at different positions in the radial direction 20 of the insert element 1. In this case, if the surface layer 2 is worn by a cable or rope, the capsules may be damaged and liquid may leak onto the first surface layer side 6. The colored liquid can indicate that the insert element 1 has reached a certain wear state.

[0068] FIG. 6 is a schematic cross-sectional view of a further embodiment of the present invention. The embodiment shown in FIG. 6 essentially corresponds to the embodiment shown in FIG. 3, except that the indicator element 3 comprises a wire arranged in the insert element 1 and extending in the cable guiding direction 10. The wire 3 is arranged at different distances from the first surface layer side 6 of the surface layer 2, and therefore, the wire 3 emerging at the surface of the first surface layer side 6 can indicate different wear states of the insert element 1. In a further embodiment, a voltage can be applied to the wire 3 and measured by a sensor. Damage to the wire 3 (e.g., due to wear) can change the voltage. In particular, each wire can be monitored individually. This means that remote diagnostics can be used to detect the extent to which the insert element is worn.

[0069] The rope guiding direction can also be referred to as the circumferential direction of the round insert element. In a further embodiment not shown, the indicator element is formed as a structure on the surface of the surface layer (i.e. on the first surface layer side 6). For example, the indicator element 3 is an indentation in the rope guiding area 5, and if the indentation is no longer present, it can be concluded that a certain state of wear has occurred. In a further embodiment not shown, the insert element comprises, in addition to the surface layer and the indicator element, a fabric layer designed to absorb radial forces. [Explanation of symbols]

[0070] 1 Insert element 2 Surface layer 3 Indicator Elements 4 shoulder area 5 Rope guide area 6 First surface layer side 7 Second surface layer side 8. Dent 10 Cable guide direction 20 Radial 30 axial direction

Claims

1. An insert element (1) for guiding ropes or cables for a cableway installation, comprising: a surface layer (2) having a first surface layer side (6) designed to come into contact with the rope or cable to be guided and a second surface layer side (7) opposite to the first surface layer side (6); an indicator element (3) disposed on and / or in said surface layer (2); wherein the indicator element (3) is designed to indicate the wear state of the insert element (1), the indicator element (3) comprises a fabric, at least one thread, a fluorescent material, a coloring liquid, an ink and / or a foil; the surface layer having a Shore A hardness greater than 81 Shore and the indicator element having a Shore A hardness less than 80 Shore. Insert element (1).

2. 2. The insert element (1) according to claim 1, which is integrally formed.

3. 2. The insert element (1) according to claim 1, wherein the indicator element (3) at least partially or sectionally covers the first surface layer side (6) and / or the second surface layer side (7).

4. The insert element (1) according to claim 1, wherein the surface layer (2) comprises SBR, NR, NBR, EPDM, CSM, BR and / or FKM.

5. The insert element (1) according to claim 1, wherein the indicator element (3) comprises PE, PP, TPE, PA and / or PETP.

6. 2. The insert element (1) according to claim 1, wherein the indicator element (3) and the surface layer (2) have different properties in terms of hardness, density, tear resistance, elongation at break, abrasion, rebound resilience, compression set, tear propagation resistance, glass transition temperature, electrical conductivity and / or swelling degree.

7. 2. The insert element (1) according to claim 1, further comprising at least one conductivity sensor adapted to detect a voltage applied to a rope or cable threaded through the insert element (1).

8. The insert element (1) according to claim 1, wherein the indicator element (3) comprises at least one metal rod and / or wire.

9. 2. The insert element (1) according to claim 1, comprising a plurality of indicator elements (3) distributed in a radial direction (20) of the insert element (1), each indicator element (3) having a different property.

10. The insert element (1) according to claim 1, wherein the ratio of the material thickness of the indicator element (3) to the material thickness of the surface layer (2) in the radial direction (20) of the insert element (1) is in the range of 0.01 to 0.

7.

11. 2. The insert element (1) according to claim 1, further comprising a fabric layer designed to absorb radial forces, wherein the ratio of the material thickness of the fabric layer to the material thickness of the surface layer (2) in the radial direction (20) of the insert element (1) is in the range of 0.8 to 9.

12. the surface layer (2) has, on its first surface layer side (6) in a cross section transverse to the rope or cable guiding direction, a guide area (5) and two shoulder areas (4) adjacent to the guide area, The guide area (5) has a recess (8) that is deepened by a recess distance relative to at least one of the shoulder areas (4), 2. The insert element (1) according to claim 1, wherein the ratio of the recess spacing to the width of the shoulder regions (4) in a cross section transverse to the rope or cable guiding direction (10) is in the range of 0.2 to 5.

13. an insert element (1) comprising a surface layer (2) having a first surface layer side (6) designed to come into contact with the rope or cable to be guided and a second surface layer side (7) opposite to the first surface layer side (6), and an indicator element (3) arranged on and / or in the surface layer (2) and designed to indicate the wear state of the insert element (1); bearing area for the rotatable mounting of said rope or cable guide pulley Including, the indicator element (3) comprises a fabric, at least one thread, a fluorescent material, a coloring liquid, an ink and / or a foil; 1. A rope or cable guide pulley, wherein the surface layer has a Shore A hardness greater than 81 Shore and the indicator element has a Shore A hardness less than 80 Shore.

14. A method for manufacturing an insert element (1) for guiding ropes or cables according to any one of claims 1 to 12, comprising the steps of: providing an indicator element (3), applying said indicator element (3) in or on the surface layer (2); and vulcanizing the indicator element (3) and the surface layer (2); wherein said indicator element (3) is capable of indicating a wear state of said insert element (1).

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