Excessive wear on suspension means in lifts, particularly in machineroom-less (MRL) systems, has become a growing concern in recent years. A key factor influencing wear is the load distribution within the rope set. According to Prof. Feyrer’s well-known studies at the University of Stuttgart, the lifespan of the entire rope set can be reduced by up to 40% if a single rope deviates by just 15% from the average load within the set.

While standards such as North America’s Safety Code for Elevators and Escalators, ASME A17.1/B44, are trying to impose limits on static rope tension differences, the dynamic load behaviour during lift operation is often even more critical. Factors such as worn traction sheaves, misaligned deflection/diverter pulleys, or twisted ropes can lead to significant variations in rope tension, which directly equate to load. A detailed analysis of the load progression during the travel allows for a precise identification of such irregularities, enabling targeted implementation of corrective measures, optimising system performance and extending the lifespan of the suspension means and drive sheaves.

This paper presents real-world measurements of rope tensions and demonstrates how simple calculations and considerations can help derive effective measures to improve the performance and longevity of lift systems.