igus solutions in Doppelmayr bike clips

Lubrication-free and weatherproof bearing technology for moving applications on chair lifts

The Doppelmayr Group in collaboration with igus in a new project

The Doppelmayr Group , world market leader in cable car construction, develops innovative bicycle transport systems such as the bike clip, which ensure easy handling and maximum operational safety.

These systems enable mountain bikers in bike parks to transport their bikes up the mountain comfortably and efficiently without losing power or time. This allows riders to concentrate fully on the technically demanding downhill sections with jumps, drops and steep turns.

Maintenance-free igus plastic bearings are a central component of the moving assemblies of the bike clip and ensure smooth and reliable operation.

Requirement, challenge and solution

A chair lift fitted with bike clips that securely hold mountain bikes heads up to the summit station. View from the chair lift, past the bike clip attachment, towards the valley.

Requirement

In addition to classic passenger transport systems, Doppelmayr is increasingly focussing on additional functions such as bicycle transport systems. Robust and weather-resistant assemblies are particularly important in alpine regions where bicycles have to be transported comfortably by cable car.

The company needed movable bearing and guide elements for use in bike clips in chair lifts. They needed components that were maintenance-free, weather resistance, capable of a long service life and be able to withstand constant running properties under continuous mechanical loads.

Chair lift with assembled bike clips in the station. Mountain bikes are hooked in.

Challenge

External loads are a key problem in this environment. Components are subject to intensive mechanical stress and have to withstand a variety of environmental influences such as dirt, moisture, temperature changes and UV radiation. The aim of the project was therefore to develop a maintenance-free and durable solution for the moving assemblies within the bike clips. Maintenance intervals should be minimised and system downtimes avoided - without compromising on operational safety or handling.

Product photo of the Doppelmayr bike clip with labelled igus bearing points.

Soultion

The engineers at Doppelmayr rely on lubrication and maintenance-free solutions from igus to optimise the moving components of the bike clips. The decision in favour of igus was based on a broad portfolio of low-friction and corrosion-free tribopolymers that were developed for use in permanently moving applications and changing weather conditions.

The bike clips, which were designed for chair lifts, enable the convenient transport of up to four bikes per chair. While passengers can hook up their bikes themselves and remove them again later, the robust bearings in the moving assemblies ensure reliable operation.

Thanks to their self-lubricating specifications, the plastic bearings are completely maintenance-free, which considerably simplifies operation. They are also resistant to dirt, moisture and temperature fluctuations. They offer consistent running performances and guarantee reliable continuous operation despite the demanding use in alpine areas. The function also remains constant over the long downtimes during the winter months.

We came to the conclusion that the products from igus best fulfil our requirements due to their friction specifications and durability. Another decisive factor is that igus can manufacture customised parts at a very competitive price. igus customer service understood our needs immediately and manufactured the components quickly so that we could meet our launch date - fantastic!