Pulley

This invention relates generally to pulleys or sheaves and more particularly concerns a pulley or sheave comprising relatively few parts which can be simply and inexpensively manufactured and assembled.

Pulleys or sheaves assembled from hubs and one or more sheet metal parts are disclosed in U.S. Pat. Nos. 3,069,919; 3,094,881; 3,381,540; 3,722,310; 4,002,081 and 4,037,486. These pulleys generally require a plurality of bending, forming, brazing and staking operations for assembling the parts.

Accordingly, it is an object of the present invention to provide a new and improved pulley comprising relatively few parts which are simpler and less expensive both in their manufacture and in the assembly thereof than prior art pulleys.

The foregoing, as well as other objects and advantages of this invention will become apparent upon consideration of the following detailed description and the accompanying drawings, wherein like reference numerals are used throughout to designate like elements and components.

FIG. 1 is a perspective view of a pulley embodying the present invention;

FIG. 2 is an enlarged elevational view of the central portion of the pulley of FIG. 1;

FIG. 3 is an exploded perspective view of the central portion of the pulley of FIGS. 1 and 2;

FIG. 4 is a sectional view of the pulley taken substantially in the plane of line 4--4 in FIG. 2;

FIG. 5 is a sectional view of the pulley taken substantially in the plane of line 5--5 in FIG. 2;

FIG. 6 is a partially exploded perspective view of the central portion of a second embodiment of a pulley of the present invention;

FIG. 7 is a perspective view of the embodiment of FIG. 6 in assembled form;

FIG. 8 is a partially exploded perspective view of a central portion of yet another embodiment of a pulley according to this invention;

FIG. 9 is a perspective view of the embodiment of FIG. 8 in its assembled form;

FIG. 10 is a sectional view taken substantially in the plane of line 10--10 of FIG. 9; and

FIG. 11 is a sectional view taken substantially in the plane of line 11--11 of FIG. 7.

Turning now specifically to the drawings, and in particular to FIGS 1 through 5 thereof, there is shown a pulley 10 embodying the present invention. More specifically, the pulley 10 comprises an assembly of component parts and can be considered to include a generally cylindrical axially elongate hub 12 and first and second sheet metal members 14 and 16. The sheet metal members 14 and 16 are generally annular in form and each include a central opening 15 for receiving a portion of the hub 12, and an outwardly flared margin 18, 20. The sheet metal members 14 and 16 are held in opposing assembled relation by a plurality of weldments 22 disposed generally around concentric annular abutting portions 24 thereof. The outwardly flared margins 18 and 20 are thus oppositely projected to define a groove for accommodating a belt therebetween.

The assembled sheet metal members 14 and 16, in the illustrated embodiment, include annular, axially outwardly extending or non-abutting web portions 25, radially inwardly of the annular abutting portions 24, and second annular abutting portions 26 radially inside of the portions 25, generally surrounding the central openings 15 thereof. It will be appreciated that the described configuration of the web portions 25 and of the portions 24 and 26 provides strength and rigidity to the assembled sheet metal members 14, 16. It will further be appreciated that the sheet metal members, 14 and 16, as described, may be simply and economically formed by conventional sheet metal forming operations. The members 14 and 16 are then easily assembled by being placed in opposing relation, the weldments 22 being applied thereto in a single, relatively simple operation.

Referring now specifically to FIGS. 2 and 3, it will be seen that the hub 12 comprises a generally cylindrical, elongate hub having a central opening 28 for accommodating a shaft. As best seen in FIG. 3, a shoulder 30 is formed on the hub 12, defining a shoulder portion 32 of decreased diameter extending axially over a fractional part of the axial length of the hub 12. A plurality of axially extending upset grooves 34 are disposed radially about the hub 12 axially trailing the shoulder 30. The grooves 34 define a corresponding plurality of axially extending lands 36 therebetween, also disposed radially about the hub 12, and axially trailing the shoulder 30. The upset grooves 34 terminate in a corresponding plurality of radially outwardly extending tabs 38 about a common circumference of the hub 12. It will be appreciated that the foregoing lands 36 and grooves 34 and outwardly extending tabs 38 are relatively easily and inexpensively formed in a conventional upset groove-forming operation.

Still with reference to FIGS. 2 and 3, it will be seen that the central openings 15 of the sheet metal members 14, 16, comprise generally circular openings including a radially castellated array of alternating slots and projections 40, 42. The slots and projections 40, 42 are complimentarily arranged for engaging the lands and grooves 36, 34, of the hub 12. In assembled relation, as best seen in FIGS. 1, 2 and 5, the shaft 12, upon insertion through the central opening 15 of the sheet metal members 14, 16, is flared over at a leading end part 44 thereof. In a preferred embodiment, the lands 36 of the hub 12 are also deformed somewhat upon engagement with the slots 40 of the sheet metal members 14 and 16, to form a press fit therewith.

Attention is now directed to FIGS. 4 and 5, from which it will be appreciated, together with the foregoing descriptions, that the hub 12 is held in radially assembled relation with the sheet metal members 14 and 16 through the cooperation of the lands and grooves 34, 36 with the slots and projections 40, 42. Moreover, it will be appreciated that this cooperation permits the transmission of a surprising amount of torque from the hub to the pulley perimeter for driving a belt or the like associated therewith. Similarly, the hub 12 is held in axially assembled relation with the sheet metal members 14, 16 by the cooperation of the flared over part 44 with the radially outwardly extending tabs 38. Thus, the lands and grooves 34, 36 of hub 12, the slots and projections 40, 42 of sheet metal members 14, 16, and the flared over part 44 and radially extending tabs 38 of the hub 12, together form holding means for holding the hub 12 and the sheet metal members 14, 16 in assembled relation.

Referring now to FIGS. 8 through 10, additional holding means comprising a generally annular ring or washer 46 is provided in an alternate embodiment of the pulley 10. In the embodiments of FIGS. 8 through 10, the sheet metal members 14, 16 and hub 12 are the same as described above. The annular washer 46 is interposed between the flared over part 44 of the hub 12 and the sheet metal members 14, 16, for providing additional strength and rigidity about the central opening 15.

Referring now to FIGS. 6, 7 and 11, another embodiment of holding means for holding the hub 12 and sheet metal members 14, 16 in assembled relation, is illustrated. The hub 12 and sheet metal members 14, 16, of FIGS. 6, 7, and 11 are substantially identical to those described above. However, the central openings 15a of the sheet metal members 14, 16 lack the slots and projections 40, 42 of the previous embodiments, being of a diameter generally equal to the diameter defined by the radially inner faces of the projections 42 of the previous embodiments. A retaining member comprises a generally annular welding plate 48, having a central opening 49 comprising a radially alternating array of slots and projections 50, 52 of substantially similar form to the slots and projections 40, 42 of the sheet metal members 14, 16 in the previous embodiments. Thus, in the present embodiment, the lands and grooves 36, 34 of the hub 12 engage the slots and projections 50, 52 of the welding plate 48. Preferably the leading faces of the lands 36 are deformed somewhat to form a press fit with the slots 50. The welding plate 48 includes a radial array of welding projections 54 on one face thereof, for weldable attachment to the annular abutting portion 26 of either of the sheet metal members 14 or 16. The diameter of the plate 48 is somewhat less than the outer diameter of the annular portion 26 whereby the plate 48 nests therein. As best seen in FIG. 7, the hub 12 is provided with a flared over portion 44 upon insertion through the central opening 15a, in similar fashion to the embodiment of FIGS. 1 through 5. It will be appreciated that the provision of the welding plate 48 provides, together with the flared over portion 44 of the hub 12, an alternate embodiment of holding means for holding the hub 12 and sheet metal members 14, 16 in assembled relation.

While specific embodiments of the present invention have been illustrated and described herein, it will be understood that the invention is not limited thereto. On the contrary, it is intended to cover all alternatives, modifications and equivalents may be included within the spirit and scope of the invention as defined by the appended claims.