WO2016189478A1

WO2016189478A1 - Roller for cableways

Info

Publication number: WO2016189478A1
Application number: PCT/IB2016/053066
Authority: WO
Inventors: Massimo CALDERARA
Original assignee: Funiproject - S.R.L.
Priority date: 2015-05-25
Filing date: 2016-05-25
Publication date: 2016-12-01

Abstract

A roller (1) for cableways, comprising a wheel on the peripheral region (3) of which there is at least part of a supporting race (2) for a cable, characterized in that at least said wheel is made of composite material.

Description

ROLLER FOR CABLEWAYS

The present invention relates to a roller for aerial or bottom-supported cableways, usable in particular in roller batteries, saddles, cable supports and carriages.

In aerial cableways or ropeways such as gondolas, chairlifts, ski-lifts, ropeway conveyors and the like, the hauling cables, which optionally also have a load-bearing function, are guided and supported by means of roller batteries arranged on supports placed along the line. More generally, aerial and bottom-supported cableways use rollers to support, guide and/or divert moving cables.

The main elements of roller batteries are rollers, on which the cables rest and roll. The rolling of the roller about its own central axis allows the advancement of the cable, opposing a reduced and limited resistance due to the rolling friction of the bearings and during transients due to the inertial mass of the roller itself.

Currentlv commercially available rollers are constituted usually by a disk-like body made of steel or aluminum, an external locking ring made of steel or aluminum, and a rubber ring accommodated between respective peripheral side walls of the disk-like body and of the locking ring, on which the hauling cable rests. Inside the disk-like body there is further a bushing for accommodating a pivot of the roller battery, ball bearings of the radial type and an elastic safety ring for locking the rubber ring and the locking ring. Covers for protecting the bearings may also be provided.

A drawback of rollers of the known type is their relative heavy weight, which makes them difficult to install on roller batteries that are typically located at a height of several meters.

Moreover, rollers of the known type are difficult to handle.

The aim of the present invention is to provide a roller for aerial cableways that is capable of improving the background art in one or more of the aspects indicated abov e. Within this aim, an object of the invention is to provide a roller for aerial cableways the overall weight of which is lower than that of steel or aluminum rollers of the known type.

Another object of the invention is to provide a roller for aerial cableways that has improved handling with respect to the background art.

Moreover, an object of the present invention is to overcome the known drawbacks in a manner that is alternative to any existing solutions.

Another object of the invention is to provide a roller for aerial cableways that is highly reliable, relatively easy to provide and at competitive costs.

This aim, as well as these and other objects that will become better apparent hereinafter, are achieved by a roller for cableways according to claim 1 , optionally having the characteristics of one or more of the dependent claims, and by the roller battery, by the support, by the carriage, by the vehicle and by the cableway according to the corresponding claims.

Further characteristics and advantages of the invention will become better apparent from the description of preferred hut not exclusive embodiments of the roller for cableways according to the invention, illustrated by way of nonlimiting example in the accompanying drawings, wherein:

Figure 1 is a perspective view of a roller according to a first embodiment of the invention;

Figure 2 is a sectional view, taken along a radial plane, of the roller of Figure 1 ;

Figure 3 is an exploded view of the roller of Figure 1 ;

Figure 4 is a side view of the roller of Figure 1 ;

Figure 5 is a view of a tower for aerial cableways comprising a roller battery according to the invention;

Figure 6 is a perspective view of a roller according to a second embodiment of the invention; Figure 7 is an exploded view of the roller of the preceding figure; Figure 8 is a sectional view, taken along a radial plane, of the roller of Figure 6;

Figures 9- 12 show the steps of the arrangement of prepreg laminas on a mold in order to obtain a first shell of the roller according to the second embodiment of the invention.

With reference to the cited figures, the cable guiding roller according to the invention, designated generally by the reference numeral 1 , 1 1 1 depending on the embodiment considered, comprises a wheel 3, 1 13, on the peripheral region of which there is at least part of a supporting race 2, 1 12 for a cable, in particular for a hauling cable if the roller is used in a roller battery of an aerial cableway, or for a load-bearing cable if the roller 1 is used in a carriage of a vehicle of the aerial cableway.

The wheel 3, 1 13 of the roller 1 , in particular, is formed by a central hub and by an annular element 32, 132 that has at least one side wall 3 1 , 13 1 of the race 2, 1 12. According to the invention, at least the wheel 3, 1 13 is made of composite material.

The wheel according to the invention can also comprise the second side wall of the race 2, 1 12 if the wheel is provided in one piece. In this case, the entire wheel is made of composite material.

However, in the illustrated preferred embodiments, the second side wall 41 , 141 of the race 2, 1 12 is defined by a locking ring 4, 1 14, which has substantially the same maximum diameter as the wheel 3, 1 13 and is fixed on the wheel 3, 1 13.

The fixing of the locking ring 4, 1 14 on the wheel 3, 1 13 can occur by keying, for example by using an elastic safety ring 42, 142 that is retained by a first annular hollow 33, 133 of the annular element 32, 132 and on which a second annular hollow 43, provided on the internal circumference of the locking ring or on a front surface of the locking ring 4, 1 14, engages.

Furthermore, the roller 1 , 1 1 1 can comprise a bushing for accommodating a pivot of the roller battery on which the roller according to the invention is mounted, and ball bearings of the radial type, for example the bearings designated by 71 and 72 in the first embodiment. There can be also covers for protecting such bearings, not shown.

In the illustrated embodiments, the wheel 3, 1 13 is made entirely of composite material and preferably the locking ring 4, 1 14 also is entirely made of composite material.

The composite material used to provide the wheel 3, 1 13 and optionally also the locking ring 4, 1 14 of the roller 1 , 1 1 1 according to the invention comprises a matrix made of thermoplastic or thermosetting resin reinforced with long and/or short fibers. The expression "short fibers" is understood to reference a fiber that has a length/diameter ratio of less than

100, whereas the expression "long fiber" is understood to reference a fiber with a length/diameter ratio of more than 100.

The fibers are preferably made of a material selected from the group that consists of glass, evlar, carbon, basalt and boron.

The resin used as a matrix is a polymeric resin, selected preferably from the group that consists of epoxy resins, bismaleimide resins (BMI) and polyester resins.

The wheel according to the invention can be obtained as shown more clearly in Figures 7- 12. Such wheel can be formed by a first shell 23 1 and by a second shell 232, which substantially have the shape of a surface of revolution, about the axis M of the hub of the wheel 1 13, with a generatrix that is substantially U-shaped. The legs of the U-shape are substantially parallel to the axis M of the hub and define respectively a substantially cylindrical internal surface that corresponds to the seat of the hub and of the bearings 71 -72 and a substantially cylindrical external surface that substantially corresponds to the annular element 132 of the wheel 1 13.

The U-shaped generatrix of the first shell 23 1 advantageously has a tab that is substantially planar and transverse to the axis M of the hub which, in the corresponding surface of revolution constituted by the first shell 23 1 , defines the first side wall 13 1 of the wheel 1 13.

Both shells 23 1 and 232 are preferably constituted entirely by composite material, in particular a bidirectional lamination, which can be obtained by superimposing plies of fabric of bidirectional fibers (with 0°/90° orientation) pre-impregnated with resin (epoxy or bismaleimide - BMI) and with a fiber concentration of at least 60%.

As an alternative, the bidirectional lamination can be obtained by superimposing plies of unidirectional fibers with a fiber concentration of at least 60% and pre-impregnated with resin (epoxy or bismaleimide - BMI) so that the fibers are oriented with an angular offset of 90° between one layer and the layer located directly above and/or below in the lamination.

In both cases, the fiber is advantageously carbon fiber, preferably with grade T600 or higher mechanical characteristics, i.e., with a breaking load of at least approximately 4136 MPa and an elastic modulus of at least 230 GPa.

For example, in the case of bidirectional prepregs made of carbon fiber and epoxy resin, each ply can have a thickness of approximately 0.65 mm, a surface weight of 600 g/m², a maximum resin content of 40%, a fiber density of at least 1.8 g/m³, a resin density of 1 .23 g/cm³, an elastic modulus of at least 55 GPa, a breaking load of at least 700 MPa, a compression modulus of at least 50 GPa, and a compressive strength of at least 600 MPa.

Such prepreg plies can be provided, or precut, as laminas having the shape of a circular sector and arranged on the convex surface of an annular mold that has a substantially complementary shape with respect to the shell that one wishes to obtain.

In the illustrated case, the annular mold 33 1 is the one used to obtain the first shell 23 1.

For example, the bidirectional prepreg plies can be laminas 332a with an angular aperture of 60°, which are applied by arranging them mutually adjacent and edge-to-edge around the mold 33 1 so as to form a first layer. Each subsequent layer can be obtained again by arranging laterally adjacent and edge-to-edge laminas 332b with an angular aperture of 60° but by applying them to the lower layer offset with a certain center angle other than 0°, 60° and multiples of 60°, for example offset by 20°, with respect to the laminas 332a of the lower layer.

A similar lamination process is followed in order to obtain the second shell 232 by using a corresponding mold (not shown).

The laminas 332a-332b are applied so that the fibers are directed substantially with an angle of 0° and 90° with respect to the radial direction of the respective shell 23 1 -232 that one wishes to form, or with an angle of substantially +45° and -45° with respect to such radial direction.

Advantageously, the laminas 332a-332b are provided with holes for the passage of screws that will be used to keep the two molds with the pre- preg shells joined in the subsequent steps until the end of thermosetting.

After the forming of the two shells 23 1 and 232 by superimposing laminas of prepreg, the two molds with the prepreg shells applied thereto are in fact superimposed coaxially so as to be able to apply additional plies around the radially innermost face of the shells 23 1 and 232, in order to obtain a substantially cylindrical bushing 234, which, after thermosetting, will be shaped with appropriate supporting steps 238 for the ball bearings of the radial type 71 and 72 to be applied in the hub.

Likewise, again with the molds superimposed, other plies can be applied to the radially outermost face of the shells 231 and 232 so as to obtain an outer tubular sheath 233, which has an L-shaped cross-section and also covers the axially innermost face of the side wall 13 1 of the wheel 1 13. Advantageously, the axially innermost last layer of the side walls 13 1 , 141 , can be made of evlar, in particular in the edge region of the side walls that protrudes beyond a rubber ring 1 15 of the wheel 1 13, a region in which there might be accidental contact with the cable 6 or with the clamp for coupling to a hauling cable.

The shells 23 1 and 232 can have a thickness comprised between 8 mm and 15 mm, for example 9.75 mm if the 0.65-mm plies described above are used.

The structure of shells and sheaths of prepreg cited above is subsequently placed in an oven for thermosetting.

As an option, a mechanical support filler 235-236, for example a polyurethane foam, may be inserted preliminarily in the gaps between the shells 23 1 and 232 and the tubular sheaths 233 and 234, in order to avoid a deformation of the shells during the subsequent thermosetting.

After thermosetting and removal of the molds, it is possible to proceed with a milling of the resulting wheel structure, in order to obtain through openings 237 and corresponding spokes 1 18 and also obtain the steps 238 for the bearings 71 -72. The milling to obtain the through openings 237 is performed advantageously starting from the holes left in the shells 23 1 -232 by the screws applied previously in order to keep the two shells mutually fastened during thermosetting and then removed before milling.

The side walls 3 1 , 13 1 and 41 , 141 of the race 2, 1 12 axially retain a rubber ring 5, 1 15 that is fitted on the annular element 32, 132, the outer surface of which is contoured so as to define the concavity of the race 2, 1 12 on which a cable 6 rests which is hauling, load-bearing or hauling and load- bearing during use. The rubber ring 5, 1 15 is fitted first onto the ring 32, 132, on which the locking ring 4, 1 14, by pressing it against the rubber ring 5, 1 1 5, and the elastic safety ring 42, 142 are then fitted.

According to another aspect of the invention, the wheel 3, 1 13 preferably comprises a plurality of spokes 8, 1 18 that connect the annular element 32, 132 to the hub of the wheel 3, 1 13. The spokes 8, 1 18 are preferably of a radial type and are provided in one piece with the hub and the annular element 32, 132. The absence of material in the region between the spokes 8, 1 18 allows, in addition to an overall weight reduction of the roller 1 , 1 1 1 for an equal amount of material (whether composite or not), also an improved handling, which allows the person who mounts the roller 1 , 1 1 1 on a roller battery 100 to grip the wheel 3, 1 13 more conveniently and safely. The spokes 8, 1 18 further allow easy harnessing and consequent easy assembly and disassembly, during maintenance, of rollers arranged in an elevated position on a support.

A possible roller battery 100 for aerial cableways that uses the roller 1 or 1 1 1 according to the invention is shown in Figure 5. Such roller battery 100 comprises a battery of said rollers 1 , 1 1 1 , which can be pivoted directly on a fixed support 102 of the roller battery 100 or, as in the illustrated case, can be pivoted in pairs on the ends of a first rocker 103, which in turn can be pivoted on the support 102 or, as in the illustrated case, can be pivoted on an end of a second rocker 104 that is pivoted on the support 102. In this last case, a third rocker 105 is pivoted on the other end of the second rocker 104 and two other rollers 1 or 1 1 1 according to the invention are pivoted to the ends of the third rocker.

The fixed support 102 of the roller battery 100 is, or is fixed to, the crossmember of a support 106 of the aerial cableway, for example a pylon or a lattice tower.

The illustrated roller battery 100 is a supporting roller battery, particularly of the rocker type, but it is possible to provide retention roller batteries, double-action roller batteries, saddles, cable supports, pre-station roller batteries, vertical/horizontal redirection roller batteries, or station carriages that use rollers 1 according to the invention.

In practice it has been found that the roller according to the invention fully achieves the intended aim. The main advantage offered by the innovation resides in the overall weight reduction of the roller, which is achieved by passing from steel to composite material but also by passing from a roller with a solid body to a spoked roller.

In particular, the spokes are useful also to facilitate the grip and optional harnessing of the roller, making it certainly easier to handle. As regards transport costs, they are inevitably reduced due to the lower consumption of fuel for an equal transported volume.

By lightening the rollers, the roller batteries also weigh less and can be lifted and mounted more easily on the crossmembers of the supports during the step of initial assembly of the system, entailing a saving in time, means and costs.

Furthermore, a roller that is lighter for equal dimensions allows to save time in the execution of in-line maintenance operations. These operations for assembly and disassembly of the rollers in line are currently performed by a minimum of two to a maximum of three workers, who climb together on a maintenance carriage that is attached to the cable and are conveyed to the roller battery that is the subject of maintenance. These operations are required almost every year to change the most highly worn rubber gaskets. The light weight of the roller according to the invention also allows a significant reduction in the risk of injury due to cuts, abrasions, crushing, bruising, fractures, falls from heights, hernias), which are always possible when maneuvering such heavy objects in less than ideal balance conditions. In practice, the maneuvers for disassembly/assembly and handling of the rollers are extremely facilitated, with possible reductions also of personnel. The maintenance maneuvers could in theory also be performed by a single person.

Further advantages reside in that the rollers according to the invention have a rotating mass/rotational inertia and a friction/internal resistance to rotation that are lower than the values of known rollers. This entails a reduced use of power for the overall movement of the loads in line and accordingly a reduced consumption of electric power required by the motors of the electric drive.

Finally, the use of composite materials allows to provide high-value finishes with paint work in various colors, the insertion of logos and of artistic compositions.

Although the roller according to the invention has been conceived for roller batteries of cableways, the same roller can also be used in the vehicles of aerial cableways, in particular on the truck of the suspension of the cabin or of the seat that is used to glide on the load-bearing cable and to be coupled, by means of a suitable grip, to the hauling cable.

The roller thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims; all the details may further be replaced with other technically equivalent elements.

The disclosures of Italian utility model patent application no. 20201500001 7324 (UB201 5U038784), the priority of which is claimed in the present application, are included by reference.

Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.

Claims

1 . A roller for cableways, comprising a wheel on the peripheral region of which there is at least part of a supporting race for a cable, characterized in that at least said wheel is made of composite material.

2. The roller according to claim 1 , wherein said wheel comprises a hub and an annular element that has at least one side wall of said race.

3. The roller according to claim 2, wherein said roller comprises a locking ring that is fixed to said wheel and has substantially the same diameter as said wheel, wherein the peripheral region of said locking ring defines the second side wall of said race.

4. The roller according to one or more of the preceding claims, wherein said race comprises a rubber ring that is interposed between said side walls.

5. The roller according to claim 1 , wherein said wheel is provided in one piece and comprises, at its peripheral region, a pair of side walls of said race, between which a rubber ring is interposed.

6. The roller according to one or more of the preceding claims, wherein said composite material comprises a matrix made of thermoplastic or thermosetting resin reinforced with long and/or short fibers.

7. The roller according to claim 6, wherein said fibers are made of a material selected from the group that consists of glass, Kevlar, carbon, basalt and boron.

8. The roller according to claim 6 or 7, wherein said resin is a polymeric resin.

9. The roller according to claim 8, wherein said resin is selected from the group that consists of epoxy resins, bismaleimide resins and polyester resins.

10. The roller according to one or more of the preceding claims, wherein said composite material is a bidirectional lamination formed by plies that are superimposed so that the fibers of any two adjacent layers of the lamination have substantially mutually perpendicular directions or are directed along two directions that are mutually substantially perpendicular within the same ply.

1 1. The roller according to claim 10, wherein the plies are bidirectional fabrics with a concentration of carbon fiber of at least 60% and are impregnated with resin, wherein the carbon fiber has a breaking load of at least 4136 MPa and an elastic modulus of at least 230 GPa.

12. The roller according to one or more of the preceding claims, wherein said wheel comprises a plurality of spokes.

13. The roller according to the preamble of claim 1 , wherein said wheel comprises a plurality of spokes.

14. A roller battery for cableways, comprising a support and characterized in that it comprises at least one roller according to one or more of the preceding claims, pivoted directly or indirectly on said support.

15. The roller battery according to claim 14, characterized in that it comprises a battery of said rollers.

16. The roller battery according to claim 1 5, wherein said rollers are pivoted in pairs on the ends of a first rocker, which in turn is pivoted on said support.

17. The roller battery according to claim 16, wherein said first rocker is pivoted on an end of a second rocker that is pivoted on said support, a third rocker being pivoted on the other end of said second rocker, two other said rollers being pivoted to the ends of said third rocker.

18. The roller battery according to one or more of the preceding claims, wherein said roller battery is a supporting roller battery or a retention roller battery or a double-action roller battery.

19. A support for at least one hauling cable of a cableway, characterized in that it comprises at least one roller battery according to one or more of the preceding claims.

20. A carriage of a vehicle for aerial cableways, characterized in that it comprises at least one roller according to one or more of the preceding claims.

21 . A vehicle for aerial cableways provided with at least one hauling cable and at least one load-bearing cable, said vehicle comprising a cabin or a seat and a suspension of said cabin or seat, characterized in that it further comprises the carriage according to the preceding claim.

22. An aerial cableway comprising at least one hauling cable, characterized in that it comprises at least one support according to claim 19 and/or at least one vehicle according to claim 21 that is coupled to said hauling cable.