Auto-return zip line trolley system

An auto-return zip line trolley provides a vehicle that rides a suspended cable between a low point and a high point. The vehicle is urged along the cable by a remote-controlled drive wheel. A motor drives the drive wheel to roll along the cable, when engaged. When a load is applied to the vehicle, a spring-loaded sheave subassembly urges the cable away from the drive wheel, such that the vehicle rides freely from a high point to a low point on the cable. When the load is removed from the vehicle, the spring-loaded sheave subassembly urges the cable into engagement with the drive wheel to enable motor-powered propulsion of the vehicle from the low point to the high point of cable. A receiver inside the housing is in operational communication with the motor. A transmitter transmits a control signal to the receiver for regulating power and speed of the motor.

FIELD OF THE INVENTION

The present invention relates generally to an auto-return zip line trolley assembly. More so, the present invention relates to a vehicle that rides a suspended cable and is powered by a remote-controlled drive wheel that disengages the cable when a load is carried, such that the vehicle rides freely from a high point to a low point on the cable; and the drive wheel re-engages the cable when the load is removed to enable motor-powered propulsion of the vehicle from the low point to the high point of the cable.

BACKGROUND OF THE INVENTION

Generally, a zip line consists of a trolley movably suspended on a cable that is erected over an inclined area. It is designed to enable a user to be propelled by gravity to travel from the top to the bottom of the inclined cable by holding on to, or attaching to, the freely moving trolley. Zip-lines come in many forms, most often used as a means of entertainment. They may be short and low, intended for child's play as found on some playgrounds. Longer and higher rides have become popular amusement rides and vacation activities. After the rider reaches the bottom end of the zip line cable the trolley must be returned to the top.

The trolley return has been accomplished by several means. In simple low to the ground installations the return can be done by simply pushing the trolley back to the top of the cable on foot. The return has also been carried out with a line leading from the trolley to the uphill end of the line. In other installations the trolley is removed from the zip line and transported in some manner back to the top of the ride. It is known in the art that returning a zip line trolley to the starting, or elevated, point along a cable is the most challenging and most time-consuming part of a zip line's operation. Generally, a trolley is disconnected at the end, carried back up to the high point, and reconnected to the cable. Otherwise, the trolley is pulled to the elevated position of the cable using a drag line or separate retrieval device.

Other proposals have involved zipline trolleys. The problem with these trolleys is that they do not automatically return to the high point. Also, the trolleys do not have the capacity to be controlled remotely. Even though the above cited zipline trolleys meet some of the needs of the market, a zip line trolley assembly having a vehicle that rides a suspended cable and is powered by a remote-controlled drive wheel that disengages the cable when a load is carried, such that the vehicle rides freely from a high point to a low point on the cable; and the drive wheel re-engages the cable when the load is removed to enable motor-powered propulsion of the vehicle from the low point to the high point of the cable, is still desired.

SUMMARY

Illustrative embodiments of the disclosure are generally directed to an auto-return zip line trolley. The auto-return zip line trolley assembly provides a vehicle that rides a suspended cable between a low point and a high point. The vehicle is urged along the cable by a remote-controlled drive wheel. A motor drives the drive wheel to roll along the cable, when engaged. When a load is applied to the vehicle, a spring-loaded sheave subassembly urges the cable away from the drive wheel, such that the vehicle rides freely from a high point to a low point on the cable. When the load is removed from the vehicle, the spring-loaded sheave subassembly urges the cable into engagement with the drive wheel to enable motor-powered propulsion of the vehicle from the low point to the high point of the cable.

In one aspect, the auto-return zip line trolley assembly, comprises:a vehicle having:a housing comprising multiple sidewalls, the sidewalls defining an interior cavity, a front end, and a rear end, the housing further defining a slot extending along the longitudinal of the sidewalls, the slot being sized and dimensioned to enable introduction of a cable extending between a high point and a low point into the interior cavity;a drive wheel disposed inside the interior cavity of the housing, the drive wheel selectively engaged with the cable;a motor operatively connected to the drive wheel, the motor configured to rotatably drive the drive wheel;whereby the drive wheel drives the housing along the cable when engaged with the cable;a spring-loaded sheave subassembly disposed inside the interior cavity of the housing,the spring-loaded sheave subassembly comprising a front sheave, the front sheave configured to engage the cable, the front sheave further being configured to pivot between an engage position for urging the cable into engagement with the drive wheel, and a disengage position for urging the cable into disengagement from the drive wheel,the front sheave subassembly further comprising a fulcrum about which the front sheave pivots between the engage position and the disengage position,the front sheave subassembly further comprising a spring, the spring having a spring tension sufficient to bias the front sheave to pivot to the engage position;whereby in the engage position, the motor rotates the drive wheel to urge the housing along the cable;whereby, a load applied to the housing having a weight greater than the spring tension urges the front sheave to pivot to the disengage position; andwhereby in the disengage position, the cable disengages from the drive wheel, causing the housing to freely ride along the cable.

In another aspect, the front sheave is configured to engage a lower end of the cable.

In another aspect, the front sheave pivots upwardly to urge the cable to the disengage position.

In another aspect, the front sheave pivots downwardly to urge the cable to the engaged position.

In another aspect, the front sheave subassembly further comprises a lever configured to join the front sheave to the spring.

In another aspect, the front sheave disposed at or near the front end of the housing in a spaced-apart and colinear relationship to the rear sheave.

In another aspect, the assembly further comprises a rear sheave disposed inside the interior cavity of the housing, the rear sheave further being disposed at or near the rear end of the housing, the rear sheave configured to constantly engage the cable for enhancing stability of the vehicle along the cable.

In another aspect, the assembly further comprises a tension control member operatively attached to the drive wheel, the tension control member configured to regulate contact pressure between the drive wheel and the cable.

In another aspect, the tension control member comprises a dial.

In another aspect, the assembly further comprises a rechargeable battery operatively connected to the motor, the rechargeable battery configured to provide electrical power to the motor.

In another aspect, the assembly further comprises a receiver disposed inside the interior cavity of the housing, the receiver being in operational communication with the motor.

In another aspect, the assembly further comprises a transmitter configured to transmit a control signal to the receiver, the control signal operable to regulate powering on and off the motor, the control signal further being operable to regulate speed of the motor.

In another aspect, the cable comprises a suspended zip line.

In another aspect, the motor is an electrical motor.

In another aspect, the motor comprises an electronic speed controller.

In another aspect, the drive wheel comprises a rubber material.

In another aspect, the assembly further comprises a pair of handles on each side of the housing.

In another aspect, the assembly further comprises a clip-in point configured to enable attachment with the load.

In another aspect, the load includes at least one of the following: a seat, a harness, and a rider.

In another aspect, the assembly further comprises a guard rail affixed to the top of the housing for at least partially covering the front and rear sheaves.

One objective of the present invention is to automate the return of a trolley along a zip line through a motorized drive wheel that disengages to roll freely downhill and engages for motorized propulsion of the vehicle uphill.

Another objective is to provide faster operation of the vehicle for immediate return uphill after the rider detaches from the vehicle.

Yet another objective is to provide a smoother ride along suspended cables, because drag lines are prone to tangling and snagging during operation.

Another objective is to provide a safer operation by avoiding a tangled drag line that is a hazard to participants, i.e., entanglement, sudden stops. And the permanent fixing of the vehicle on the cable reduces equipment changes and room for operator error.

Another objective is to provide a zip line vehicle that is useful in carrying a rider over-water installation, where the sudden release of the participant tends to bounce and spin the vehicle, tangling any drag line attached and derailing the vehicle wheels.

Another objective is to enable adjustment of the tension between drive wheel and cable to accommodate variously sized and diameter suspended cables/zip lines.

Another objective is to remotely control the motorized ascension of the vehicle.

Another objective is to provide an inexpensive to operate auto-return zip line vehicle assembly.

DETAILED DESCRIPTION OF THE INVENTION

An auto-return zip line trolley assembly100is referenced inFIGS.1-6. The auto-return zip line trolley assembly100, hereafter “assembly100” enables automated, remote-controlled travel of a vehicle102, such as a zipline trolley, between a high point108aand a low point108bof a cable106. Such a vehicle102is configured to safely carry a load110, such as a rider via a handlebar, a harness, or seat, atop a suspended zipline cable106from one end of the zipline to the other. The vehicle102can have, incorporated therein, a drive wheel408and multiple sheaves. The present disclosure automates engagement and disengagement of the drive wheel408with the cable106, to selectively enable either free rolling, or motorized driving of the vehicle102, depending on whether a load110is attached thereto, and whether the vehicle102is at the low point108bor the high point108aof the cable106.

For example,FIG.1illustrates a perspective view of the assembly100traveling along a suspended cable between a high point and a low point. As illustrated, the vehicle102rolls freely from the high point108ato the low point108bwith a load110attached. This is possible because gravity provides the impetus for driving the vehicle102along the cable106. The same vehicle102is shown travelling uphill under motor power, from the low point108bto the high point108awhen the load110is removed. In this operational embodiment, a motor-powered drive wheel408engages the cable106to drive the vehicle102against the force of gravity and while carrying the load110. The mechanisms that enable such automated operation of the vehicle102are disclosed below.

AsFIG.2illustrates, the vehicle102comprises a housing104that forms a protective shell around the mechanical and electrical components of the assembly100. The housing104comprises multiple sidewalls200, which can include panels that form a generally rectangular, elongated shape. In other embodiments, the housing104can have a bullet shaped configuration for aerodynamic traversing up and down the cable106. In other embodiments, the sidewalls200can take additional shapes, including cubicle, pyramid, and irregular shapes. In other embodiments, the sidewalls200define an interior cavity into which the mechanical and electrical components reside (SeeFIG.4A). The housing104has a front end208a, and an opposing rear end208b. Because the housing104is simply moving linearly along a cable106, the forward and rearward orientation is relative.

As referenced inFIG.3, the housing104also defines a slot202that extends along the longitudinal of the sidewalls200. The slot202is sized and dimensioned to enable introduction of a cable106in a central region of the interior cavity. The cable106can extend between a high point108aand a low point108b. In other embodiments, the slot202may orient upwardly, such that the cable106slides downwardly into the interior cavity. In some embodiments, the cable106is a suspended zip line, as is used in a mountain lift.

In some embodiments, the assembly further comprises a guard rail affixed to the top of the housing104for at least partially covering the front and rear sheave206s. The guard rail protects the sheaves from physical damage and serves to help align the housing104with the cable106. The guard rails214may include a pair of parallel, flat plates projecting from both sides of the slot202in the housing104. In one possible embodiment, the assembly100further comprises a pair of handles216a-bon each side of the housing104. The handles216a-benable the load110, such as a rider, to attach to the housing104while free rolling downhill, from the high point108ato the low point108b.

AsFIG.2illustrates, other anchoring mechanisms can be located, however, on the housing104, to enable tying or clipping the load110directly to the housing104. For example, the assembly100also utilizes a clip-in point218at each side of the housing104. The clip-in point218is configured to enable attachment with a seat, a harness, and the pair of handles216a-b. The clip-in point may be a screw or bolt that fastens the seat, harness, or handles216a-bto the housing104.

Looking now atFIG.4A, the assembly100also includes a drive wheel408that is operational inside the interior cavity of the housing104. The drive wheel408selectively engages a lower end of the cable106. In one non-limiting embodiment, the drive wheel408comprises a rubber material to enhance traction with the cable106. In this configuration, the drive wheel408may be a disc with rubber layers to enhance traction with the cable106. Any friction enhancing material may however be used in construction of the drive wheel408. Thus, as the drive wheel408rotates, the housing104is urged to move in the same direction as the rotation of the drive wheel408. Conversely, when the drive wheel408and cable106are disengaged, the vehicle102moves freely along the cable106, from the high point108ato the low point108b.

In this manner, the drive wheel408rides the lower side of the cable106, creating traction therebetween. This enables the drive wheel408to propel the entire housing104along the cable106; even while the housing104carries a load110. It is significant to note that the uphill return of the load110on the housing104is distinct from the downhill load110. In any case, the housing104is configured to return a small load110, such as an empty bucket swing or disc seat, from the low point108bto the high point108aof the cable106.

The drive wheel408is regulated to selectively engage and disengage the cable106. When the housing104carries a load110, the weight of the load110causes the cable106to disengage from the drive wheel408(SeeFIG.4A). This allows the drive wheel408to roll freely from a high point108ato a low point108bon the cable106. Once at the low point108b, the load110is removed from the housing104, causing the drive wheel408to re-engage the cable106(SeeFIG.4B). The allows the motor-powered drive wheel408to urge the housing104towards the high point108aof the cable106.

As discussed above, once the drive wheel408engages with the cable106, a motor410propels the drive wheel408to drive the housing104from the low point108bto the high point108aalong the cable106. In one possible embodiment, the motor410is operatively connected to the drive wheel408to rotatably drive the drive wheel408. In some embodiments, the motor410is an electrical motor410. In other embodiments, the motor410comprises an electronic speed controller414; and thereby the speed that the housing104moves uphill along the cable106. In this manner, the drive wheel408drives the housing104along the cable106when engaged with the cable106; thereby automating the movement of the housing104along the cable106.

As referenced inFIG.4B, the assembly100includes a spring-loaded sheave subassembly400. The sheave subassembly400is the mechanism that enables selective engagement between the cable106and the drive wheel408. In some embodiments, the sheave subassembly400is operationally disposed inside the interior cavity of the housing104. In some embodiments, the spring-loaded sheave subassembly400comprises a front sheave204that is configured to engage a lower end of the cable106. This allows the front sheave204to selectively lift and lower the cable106into contact with the drive wheel408. In some embodiments, the front sheave204is disposed at or near the front end208aof the housing104.

In this manner, the front sheave204pivots between an engage position that urges the cable106into engagement with the drive wheel408. In one embodiment, the front sheave204pivots downwardly to urge the cable106to the engage position. Conversely, the front sheave204pivots to a disengage position that urges the cable106to disengage from the drive wheel408. In one possible embodiment, the front sheave204pivots upwardly to urge the cable106to the disengage position.

To enable this mechanism, the front sheave204subassembly400includes a fulcrum402about which the front sheave204pivots between the engage position and the disengage position. The fulcrum402may include a bolt or screw. Furthermore, the front sheave204subassembly400comprises a spring406that is operatively connected to the front sheave204and works to bias the front sheave204to the engage position. As referenced inFIG.5, the front sheave204subassembly400further comprises a lever404that is configured to join the front sheave204to the spring406. The lever404may include a flat bar, having an L-shaped configuration.

In other embodiments, the spring406has a spring tension that is sufficient to bias the front sheave204to pivot to the engage position. In some embodiments, the spring comprises a compression spring, or an extension spring. Thus, in the engage position where the cable106and the drive wheel408are in contact, the motor rotates the drive wheel408to urge the housing104along the cable106. When the load110is removed from the housing104, the front sheave204is pivoted to the engage position.

Conversely, in the disengage position, the cable106disengages from the drive wheel408, causing the housing104to freely ride along the cable106. When the weight of the load110is sufficient, such as a rider or a ski chair, the weight of the load110overcomes the spring tension. In one non-limiting embodiment, the spring tension is in units of force divided by distance. In some embodiments, the load110includes at least one of the following: a seat, a harness, and a rider. It is possible, for example, for a rider to grip the handles216a-bwhile the vehicle102travels from the high point108ato the low end. In some embodiments, the housing104comprises a clip-in point to enable attachment with the load110(SeeFIG.2).

Looking again atFIG.6, the assembly100further comprises a rear sheave206that is disposed inside the interior cavity of the housing104. The rear sheave206positions at or near the rear end208bof the housing104, in a spaced-apart and colinear relationship to the front sheave204. In one embodiment, the front and rear sheave206sroll about an axle in both directions in a free-rolling manner. The rear sheave206is configured to constantly engage the cable106, rolling along the lower end of the cable106. This serves to enhance stability of the housing104traveling along the cable106. Thus, the front and rear sheave206scan simultaneously roll across the cable106, from the low point108bto the high point108a. And the rear sheave206alone rolls across the cable106, from the high point108ato the low point108b.

In some embodiments, the assembly further comprises a tension control member212that operatively attaches to the drive wheel408. The tension control member212is configured to regulate contact pressure between the drive wheel408and the cable106. This may be operable by urging the drive wheel408towards the cable106, and away from the cable106in increments. In alternative embodiments, the tension control member212is remote controlled. In one non-limiting embodiment, the tension control member212comprises a dial that can be rotated in a first direction to tighten the grip between the drive wheel408and the cable106, or a second direction to disengage the driver wheel from the cable106. This tension control member212allows the drive wheel408to accommodate variously sized and dimensioned cable106s.

In some embodiments, the assembly100further comprises a rechargeable battery210operatively connected to the motor. The rechargeable battery210is configured to provide electrical power to the motor. The rechargeable battery210is designed for quick connect and disconnect for optimal operation on a ski slope, for example. The rechargeable battery210can be recharged through an external power source, a solar panel, or another battery210.

AsFIG.4Ashows, the assembly100further comprises a receiver412disposed inside the interior cavity the housing104, the receiver412being in operational communication with the motor. The receiver412can be operable to receive radio signals, as is commonly used in radio control. To send signals to the receiver412, the assembly100comprises a transmitter112that is configured to transmit a control signal114to the receiver412. The control signal is operable to regulate powering on and off the motor. The control signal is also operable to regulate speed of the motor, through the electronic speed controller414. In alternative embodiments, the control signal may include, without limitation, infrared light, visible light, radio waves, or sound waves.

In operation, the vehicle102is controlled by a user-operated transmitter112and actuated by an internal motor and drive wheel408that is tensioned against the cable106for rotatable traction. Riding the cable106from the high point108ato the low point108b, the weight of the load110pivots the spring-loaded front sheave204to the disengage position, causing the drive wheel408to disengage from the cable106. The front and rear sheave206sroll freely, to enable the trolley to ride the cable106from the high point108ato the low point108bwhile carrying the load110.

Once the load110disengages from the vehicle102at the end of the ride, the spring-loaded front sheave204biases to the engage position, causing the drive wheel408to re-engage the cable106. Once in contact with the cable106, the drive wheel408can be operatively driven by the motor, such that the vehicle102is driven back to the high point108a. This utilization of the load110's weight to disengage the cable106from the drive wheel408is what allows the retrieval components to be integrated into the vehicle102itself.