The present disclosure relates to a pulley system. More particularly, the present disclosure relates to a pulley system including one or more sheaves configured for use as part of a continuously variable transmission of outdoor power equipment, such as a snow thrower, a portable generator, a rotary tiller, or another form of outdoor power equipment.
One embodiment of the invention relates to a pulley system configured for use as part of a continuously variable transmission of outdoor power equipment. The pulley system includes a sheave having a hub formed from a first material, a first annular wall formed from a second material, wherein the first annular wall includes a guide surface and is fastened to the hub, and a second annular wall including a guide surface, wherein the guide surface of the first annular wall faces the guide surface of the second annular wall to provide a track configured to receive a belt.
Another embodiment of the invention relates to a method of manufacturing a pulley system including the steps of spin-forming metal to form an annular wall of a sheave, pressing powdered metal to form a hub of the sheave, and fastening together the annular wall and the hub.
Another embodiment of the invention relates to outdoor power equipment including an engine having a crankshaft having a power takeoff, a tool having a driveshaft and configured to be powered by the engine, and a pulley system coupling the engine and the tool. The pulley system includes a first sheave having a first hub including an aperture configured to receive the power takeoff, a first annular wall fastened to the first hub, wherein the first annular wall includes a guide surface, and a second annular wall including a guide surface, wherein the second annular wall is fastened to the power takeoff of the crankshaft of the engine, and wherein the guide surface of the first annular wall faces the guide surface of the second annular wall to provide a first track configured to receive a belt.
Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.
The invention will become more fully understood from the following detailed description, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like elements, in which:
The skilled artisan will understand that the drawings primarily are for illustrative purposes and are not intended to limit the scope of the inventive subject matter described herein.
Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.
Referring to
Referring to
In some embodiments, the pulley system 224 is integrated with the engine 210, as shown in
According to an exemplary embodiment, the primary sheave 228 is coupled to the power takeoff 212 of the crankshaft 220. The primary sheave 228 includes two annular walls 232, 234 that are configured to move closer together or further apart from one another in order to adjust the width of a track 236 between the two annular walls 232, 234. Adjustment of the width of the track 236 causes a belt 238 joining the primary sheave 228 to the secondary sheave 226 to move closer or further from the axis of rotation of the primary sheave 228, and to thereby change the gear ratio of the pulley system 224. In some embodiments, one of the annular walls 232, 234 is fixed to a hub 240 that is configured to move axially with respect to the power takeoff 212 of the crankshaft 220. A spring 242 biases the annular walls 232, 234 together and tension in the belt 238 may overcome the bias of the spring 242.
In some embodiments, tension in the belt 238 is controlled by the secondary sheave 226. In other embodiments, a separate tensioning arm may be used to control tension in the belt. In some embodiments, the secondary sheave is coupled to the power takeoff of the crankshaft of the engine, and the primary sheave is coupled to the tool. In still other contemplated embodiments, one or both of the sheaves have fixed track widths and the annular walls of the sheaves are not configured to move relative to one another. In some such cases, the sheaves may serve as sheaves of a traditional pulley system, as opposed to a continuously variable transmission.
According to an exemplary embodiment, the secondary sheave 226 is coupled to a driven shaft (e.g., driveshaft 230) that may be coupled to a tool, such as a driveshaft of an auger on a snow thrower, a lawn mower blade, tines of a rotary tiller, or another tool. Similar to the primary sheave 228, the secondary sheave 226 includes a first annular wall 244, a second annular wall 246, and a hub 248. One of the annular walls 244, 246 is fixed to the hub 248, and the hub 248 is configured to move along the driveshaft 230 of the tool to change the track width 250 of the primary sheave 226.
A spring 252 biases the first and second annular walls 244, 246 together, and a change in torque on the driveshaft 230 causes rollers 254 coupled to the second annular wall 246 to rotate with respect to a spiral groove 256 that guides movement of the first and second annular walls 244, 246 closer together or further apart. Movement of the annular walls 244, 246 changes tension in the belt 238, which is communicated to the primary sheave 228.
Referring to
According to some exemplary embodiments, the secondary sheave 318 of the pulley system 312 is coupled to a driveshaft 324 of the powered tool along with a governor 326 (e.g., mechanical governor, electronic governor, rotational accelerometer, pneumatic governor in communication with a blower fan). The governor 326 provides feedback to a throttle system 328 of the engine 314, such as by way of an electronic control unit 330, which may adjust the speed of the engine 314 as a function of the rotation rate of the driveshaft 324, as opposed to the crankshaft 332. In some such embodiments, changes in torque experienced by the driveshaft 324 control the secondary sheave 318, which controls the gear ratio of the pulley system 312. In other embodiments, the only governor of the system is connected to the crankshaft, the secondary sheave is fastened to the crankshaft, one of the sheaves has a fixed track width and a tensioning arm is used to control tension in the belt, or other configurations of a pulley system may be used.
Referring now to
According to an exemplary embodiment, one of the first and second annular walls 518, 520, 522, 524 is fastened to the hub 514, 516 of the respective sheave 510, 512. The other of the first and second annular walls 518, 520, 522, 524 is fastened to a shaft 534, 536 (e.g., power takeoff, driveshaft, tube coupled to a power takeoff or driveshaft) that is inserted through an aperture 538, 540 in the respective hub 514, 516 such that the hub 514, 516 is configured to move axially along the shaft 534, 536. Movement of the hub 514, 516 along the shaft 534, 536 changes the track width of the respective sheave 510, 512.
Referring to
In some embodiments, the annular walls 518, 520, 522, 524 include an inner aperture 562, 564, 566, 568. The inner aperture 562, 564, 566, 568 is centered in the middle of the guide surface 526, 528, 530, 532 of the respective annular wall 518, 520, 522, 524 and is configured to receive either the hub 514, 516 or the shaft 534, 536, 634, 636. In some embodiments, the inner aperture 562, 564, 566, 568 includes a side wall that extends in the direction of the axis of rotation R and is configured to interface with the exterior surface of the hub 514, 516 or the shaft 534, 536, 634, 636. In other embodiments, the annular wall 518, 520, 522, 524 attaches to the lengthwise end of the hub 514, 516 or shaft 534, 536, 634, 636 instead of extending along the exterior surface of the hub 514, 516 or shaft 534, 536, 634, 636.
According to an exemplary embodiment, the guide surface 526, 528, 530, 532 extends away from the respective hub 514, 516 or shaft 534, 536, 634, 636 at an angle α that is wider than a right angle such that the opposing guide surfaces 526, 528, 530, 532 form sides of a V-shaped track when the annular walls 518, 520, 522, 524 of the respective sheaves 510, 512 are close to one another. Put another way, the guide surfaces 526, 528, 530, 532 define angled sides of a trapezoid where the wider base of the trapezoid is further from the axis of rotation R, as shown in
According to an exemplary embodiment, the annular walls 518, 520, 522, 524 further include an outer lip 554, 556, 558, 560 (e.g., outer diameter) or flange that is angled with respect to the guide surface 526, 528, 530, 532 and extends away from the other of the first or second annular wall 518, 520, 522, 524. Roll grooves may be pressed or stamped into the outer lip 554, 556, 558, 560 of the annular walls 518, 520, 522, 524 or elsewhere on the annular walls 518, 520, 522, 524 for increased strength and stiffening.
In some embodiments, the outer lip 560 is long enough to hold considerable mass, and serves as an inertia ring or flywheel. In some such embodiments, at least a quarter of the mass of the annular wall 524 is located in the outer lip 560, such as at least a third or at least half of the mass. In other embodiments, a cast ring may be pressed onto the annular wall, forming a T-shaped flange on the outer edge of the annular wall to serve as an inertia ring. Use of an inertia ring or flywheel is intended to dampen out load transitions in the pulley system.
In contemplated embodiments, the inertia ring, annular wall, and tube are integrally formed together via a casting, such as with a solid iron casting. In other contemplated embodiments, the inertia ring, annular wall, and tube may be integrally formed via metal spinning.
In some embodiments, one of the annular walls 518, 520 is fastened to the hub 514, 516 and the other of the annular walls 522, 524 includes a guide element, such as a roller 570, 572, bearing, extension, etc., that is sized to be received in a groove 574, 576 or slot on the outer surface of the hub 514, 516. The roller 570, 572 and groove 574, 576 constrain movement of the annular walls 518, 520, 522, 524 relative to one another. According to an exemplary embodiment, as shown in
Referring to
According to an exemplary embodiment, the hub 514, 516 and at least one of the annular walls 518, 520, 522, 524 are formed separately from one another and are subsequently fastened together. The different processes used to form the hub 514, 516 and annular walls 518, 520, 522, 524, such as powdered-metal pressing and metal spinning, may be particularly efficient for manufacturing the respective parts, especially when compared to the costly and intensive process of die casting and machining pulley sheaves formed as integral wall-and-hub structures. Die casting sheaves for a pulley system may require that a manufacturer invest in costly die cast tooling. In addition, the casting must be machined in order to improve the surface finish and reduce run-out. The added machining steps increase the costs of the parts in terms of labor and resources. Using the different methods of forming individual components of the sheaves 510, 512 and subsequently fastening them together may remove some of the costly process steps. However, in other contemplated embodiments die casting and machining may be used.
According to an exemplary embodiment, one or both of the annular walls 518, 520, 522, 524 are formed via metal spinning (e.g., spin forming, spinning) where the metal (e.g., blank steel or aluminum) is rotated, such as on a lathe, and formed into an axially-symmetric annular wall. Spinning metal to form the annular walls 518, 520, 522, 524 is believed to provide improved concentricity to the resulting annular walls 518, 520, 522, 524, relative to other processes such as stamping or molding. Improved concentricity reduces wobble of the sheaves 510, 512 in the pulley system and correspondingly reduces noise and vibration-related wear of the outdoor power equipment.
In other embodiments, one or both of the annular walls 518, 520, 522, 524 are stamped from sheet metal, such as sheets of aluminum, steel, or other metals. Some such annular walls 518, 520, 522, 524 are formed from sheets of substantially uniform thickness. If stamped, the center part of the annular wall 518, 520, 522, 524 may be formed as a bubble that is subsequently pierced to form the aperture 562, 564, 566, 568 and then coined. Alternatively or in addition to stamping the annular walls 518, 520, 522, 524, gussets may be stamped into the inner bends 578, 580, 582, 584 opposite to the guide surface 526, 528, 530, 532 for reinforcement of the sheaves 510, 512 out of the way of the belt.
In still other embodiments, one or both of the annular walls 518, 520, 522, 524 are formed from molded plastic, such as injection molded low-density polyethylene, acrylonitrile butadiene styrene, polycarbonate/acrylonitrile butadiene styrene blend, polyetheretherketone, or other plastics. In some contemplated embodiments, a support frame (e.g., “backbone”) of metal may be stamped and then set and molded into a plastic-molded annular wall.
In some embodiments, the hub 514, 516 is formed from a process that is different than the process used to form one or both of the first and second annular walls 518, 520, 522, 524. According to an exemplary embodiment, the hub 514, 516 is formed from powdered metal that is compressed and heated to form a solid body. In other embodiments, the hub 514, 516 may be formed via metal spinning or injection molding of plastic. Features of the hub 514, 516, such as the grooves 574, 576 guiding the rollers 570, 572, may be reinforced with steel or another metal. In other embodiments, the hub 514, 516 is integrally formed with one or both of the annular walls 518, 520, 522, 524. In some embodiments the second annular hub 522, 524 and shaft 534, 536 are integrally formed together via metal spinning.
The hub 514, 516 may be formed from a first material and one or both of the annular walls 518, 520, 522, 524 may be formed from a second material. The first and second materials may be chemically different (e.g., steel versus aluminum, plastic versus metal), or the first and second materials may be chemically the same but different with regard to structure, such as a sheet of steel versus powdered steel. In some embodiments, the helix side of the sheave 512, such as the hub 516, is formed from plastic, while the shaft 536 is metal. In some such embodiments, a metal sleeve may be added to the helix groove 574 of a plastic hub for reinforcement and control of wear. In other embodiments, the hub 516 is formed from powdered metal.
According to an exemplary embodiment, the first annular wall 518, 520 is fastened to (e.g., fixed with respect to, welded to, riveted to, pressure fit to) the hub 514, 516. The second annular wall 520, 522 is fastened to a shaft 534, 536, 634, 636. In various alternate embodiments, the annular walls 518, 520, 522, 524 and the respective hubs 514, 516 or shafts 534, 536, 634, 636 may be spin welded together, pressed together, friction welded together, laser welded together, or otherwise fastened together. In still other embodiments, the hubs 514, 516 or shafts 534, 536, 634, 636 may include grooves or ridges for a spline coupling with the respective annular wall 518, 520, 522, 524.
The construction and arrangements of the pulley system, as shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.
This application claims the benefit of Application No. 61/538,714, filed Sep. 23, 2011, which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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61538714 | Sep 2011 | US |