INSERT ELEMENT FOR GUIDING A ROPE OR CABLE, ROPE OR CABLE GUIDE ROLLER AND METHOD OF MANUFACTURING AN INSERT ELEMENT

Abstract

An insert element for guiding a rope or cable, in particular for a cableway installation. The insert element including a surface layer with a first surface layer side configured to come into contact with a 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, wherein the indicator element is configured to indicate a state of wear of the insert element. A pulley that includes the insert element and a method for manufacturing the insert element are further provided.

Claims

1.-15. (canceled)

16. An insert element for guiding a rope or cable for a cableway installation, comprising: a surface layer with a first surface layer side configured to come into contact with a 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, wherein the indicator element is configured to indicate a state of wear of the insert element.

17. The insert element according to claim 16, wherein the insert element is formed in one piece.

18. The insert element according to claim 16, wherein the indicator element covers the first surface layer side and/or the second surface layer side at least partially or in sections.

19. The insert element according to claim 16, wherein the surface layer comprises at least one of SBR, NR, NBR, EPDM, CSM, BR and FKM.

20. The insert element according to claim 16, wherein the indicator element comprises at least one of PE, PP, TPE, PA and PETP.

21. The insert element according to claim 16, wherein the indicator element and the surface comparatively layer have different properties, including a different hardness, density, tear resistance, elongation at break, abrasion, rebound elasticity, compression set, tear propagation resistance, glass transition temperature, electrical conductivity and swelling.

22. The insert element according to claim 16, wherein the indicator element comprises at least one of a fabric, at least one thread, a fluorescent material, a colored ink and a foil.

23. The insert element according to claim 16, further comprising: at least one conductivity sensor configured to detect a voltage applied to the rope or cable passed through the insert element.

24. The insert element according to claim 16, wherein the indicator element comprises at least one metal rod and/or wire.

25. The insert element according to claim 16, wherein the indicator element is one of a plurality of indicator elements distributed in a radial direction of the insert element, and each indicator element having different properties.

26. The insert element according to claim 16, wherein a ratio of a material thickness of the surface layer and a material thickness of the indicator element in a radial direction of the insert element is in a range from 0.01 to 0.7.

27. The insert element according to claim 26, wherein the ratio is in a range from 0.07 to 0.5.

28. The insert element according to claim 27, wherein the ratio is in a range from 0.1 to 0.3.

29. The insert element according to claim 16, further comprising: a fabric layer configured to absorb radial forces, wherein a ratio of a material thickness of the surface layer and a material thickness of the fabric layer in a radial direction of the insert element is in a range from 0.8 to 9.

30. The insert element according to claim 29, wherein the ratio is in a range of from 1 to 8.

31. The insert element according to claim 30, wherein the ratio is in a range of from 2 to 7.

32. The insert element according to claim 16, wherein the surface layer has a guide region and two shoulder regions adjacent to the guide region on the first surface layer side in a cross-section transverse to a rope or cable guide direction, wherein the guide region has a recess which is deepened by a recess spacing relative to at least one of the two shoulder regions, and wherein a ratio of a width of both shoulder regions in a cross-section transverse to the rope or cable guide direction and the recess spacing is in a range from 0.2 to 5.

33. The insert element according to claim 32, wherein the ratio is in a range of from 0.4 to 3.

34. The insert element according to claim 33, wherein the ratio is in a range of from 0.7 to 2.5.

35. A rope or cable guide pulley, comprising: an insert element comprising a surface layer with a first surface layer side, configured to come into contact with a rope or cable to be guided, and a second surface layer side opposite the first surface layer side; an indicator element arranged on and/or in the surface layer, wherein the indicator element is configured to indicate a state of wear of the insert element; and a bearing area for rotatable mounting of the rope or cable guide pulley.

36. A method of manufacturing an insert element for guiding a rope or cable according to claim 16, the method comprising: providing the indicator element; applying the indicator element in or on a surface layer; and vulcanization the indicator element and the surface layer; wherein the indicator element is configured to indicate a state of wear of the insert element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0063] The embodiment 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 with each other to form new embodiments. The advantages of the individual features then also apply to the new embodiment. In the following, embodiments to be preferred are described in detail with reference to the figures. They show:

[0064] FIG. 1 is a schematic and perspective view of an insert element according to an embodiment of the present invention;

[0065] FIG. 2 is a cross-section of the insert element shown in FIG. 1 transverse to a cable guide direction;

[0066] FIG. 3 is a schematic surface view of an insert element according to a further embodiment of the present invention;

[0067] FIG. 4 is a schematic surface view of an insert element according to a further embodiment of the present invention;

[0068] FIG. 5 is a schematic cross-section of an insert element of a further embodiment according to the present invention; and

[0069] FIG. 6 is a schematic cross-section of an insert element according to a further embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0070] FIG. 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 only shown in sections in FIG. 1 for simplification. The insert element 1 has a surface layer 2. The surface layer 2 has a first surface layer side 6, which represents an outer side of the surface layer 2 (i.e. facing the environment), and a second surface layer side 7, which represents an inner side of the surface layer side 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 area 5 and two shoulder areas 4 on its first surface layer side 6. The two shoulder areas 4 enclose the rope guide area 5 in their center. A rope or cable to be guided (not shown in the figures) comes to rest in the rope guide area 5 so that the rope or cable comes into contact with the surface layer 2. The cable guide area 5 has a recess 8, which is recessed radially inwards in relation to the shoulder areas 4. The cable is guided through the insert element 1 in a cable guide direction 10 (in FIG. 1 from right to left or from left to right). In other words, the cable can move in the cable guide 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 arranged can rotate. Guiding the rope can cause the surface layer 2 to wear, particularly since a relative speed between the rope and the core element is not equal to zero. The wear causes abrasion, which causes the surface layer 2 to lose material. If the surface layer 2 is worn 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 state of wear of the core element can be recognized from the outside. Accordingly, it can be determined that the insert element 1 needs to be replaced.

[0071] FIG. 2 is a section through the insert element 1 shown in FIG. 1 at right angles to the cable guide direction 10. In FIG. 2, the cable guide direction therefore runs into and out of the sheet plane. In FIG. 2, the recess 8 can be seen in the cable guide area 5. It can also be seen that the indentation 8 has a radius that defines the indentation. Furthermore, the radial direction 20 and an axial direction 30 are shown in FIG. 2. The indicator layer 3 of the present embodiment is bonded to the surface layer 2 by vulcanization. This can ensure that there is sufficient cohesion between the surface layer 2 and the indicator layer 3.

[0072] FIG. 3 is a surface view of an insert element 1 according to a further embodiment of the present invention. In this embodiment, the surface layer 2 also has two shoulder regions 4 and a rope guide region 5. However, in the present embodiment, the indicator element is not arranged as an indicator layer on the second surface layer side 7 of the surface layer 2, but as strip-like elements which extend in the axial direction parallel to one another and transversely to the cable guide direction 10. The indicator elements 3 extend both in the shoulder areas 4 and in the rope guide area. This means that wear can be indicated over the entire width of the core element 1. In the present 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.

[0073] In another embodiment not shown, further indicator elements are arranged inside the surface layer 2 in addition to the indicator elements 3 attached to the surface. The indicator elements 3 differ in their color. More precisely, the indicator elements 3 that are arranged on the surface of the surface layer 2 (i.e. on the first surface layer side 6) differ from the indicator elements 3 that are arranged inside the surface layer 2. This means that different color coding can be used to easily and readily identify how far the wear of the insert element 1 has progressed.

[0074] FIG. 4 shows a surface view of an insert element 1 according to a further embodiment of the present invention. The present embodiment largely corresponds to the embodiment shown in FIG. 3, with the difference 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 in each of the shoulder areas 4. This means that a periodically occurring uneven load on the insert element 1 due to uneven wear of the indicator elements 3 can also be detected.

[0075] FIG. 5 is a cross-section through 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, with the difference that the indicator element 3 is not formed as an indicator layer, but as a plurality of capsules containing a colored liquid. The capsules 3 are arranged at different depths within the surface 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 surface layer 2 is now worn by a cable or rope, the capsules can be damaged and the liquid can escape to the first surface layer side 6. The colored liquid can indicate that a certain state of wear of the insert element 1 has been reached.

[0076] FIG. 6 is a schematic cross-section of a further embodiment of the present invention. The embodiment shown in FIG. 6 essentially corresponds to the embodiment shown in FIG. 3, with the difference that the indicator element 3 comprises wires extending in the cable guide direction 10, which are arranged inside the insert element 1. The wires 3 are arranged at different distances from the first surface layer side 6 of the surface layer 2 and can thus indicate different wear states of the insert element 1 by the wires 3 coming to the surface on the first surface layer side 6. In a further embodiment, a voltage can be applied to the wires 3 and measured by a sensor. Damage to a wire 3 (for example due to wear) can cause the voltage to change. In particular, each wire can be monitored individually and separately. This means that remote diagnosis can be used to detect the extent to which the insert element is worn.

[0077] The rope guide direction can also be referred to as the circumferential direction for round insert elements. 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 a rope guide area 5 and if the indentation is no longer present, it can be concluded that a certain wear condition has occurred. In a further embodiment not shown, the insert element comprises, in addition to the surface layer and the indicator element, a fabric layer designed to absorb radial forces.

Reference Sign List

[0078] 1 Insert element [0079] 2 Surface layer [0080] 3 Indicator element [0081] 4 Shoulder area [0082] 5 Rope guide area [0083] 6 First surface layer side [0084] 7 Second surface layer side [0085] 8 Deepening [0086] 10 Cable guide direction [0087] 20 Radial direction [0088] 30 Axial direction