DESC:FIELD OF INVENTION

[001] The present invention concerns fan belt pulleys for automotive applications. In particular, the present invention concerns a low-cost, light-weight pulley assembly for an engine. More particularly, the present invention concerns a main drive pulley of an internal combustion engine, e.g. for a 3-cylinder tractor engine, and having a sheet metal pulley with a multi-function unitized cast iron (CI) adaptor.

BACKGROUND OF THE INVENTION

[002] In the automotive industry, there is a great demand for a pulley which is inexpensive to manufacture, yet which has adequate strength and a longer life even under hard conditions of use, such as in tractor engines, for example- for driving the engine fan from the fan belt.

[003] Until recently, most of the fan belt pulleys in use were cast pulleys, but now these are already being replaced by stamped pulleys with multipurpose adaptor because of their lower cost of manufacture.

OBJECTS OF THE INVENTION

[004] Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

[005] It is an object of the present invention to provide a light-weight and low-cost tractor of the main drive pulley assembly of an engine, having a light-weight pulley with a multi-function adaptor.

[006] Another object of the present invention is to provide a main drive pulley assembly of a 3-cyliner tractor engine, having a light-weight pulley with a multi-function cast iron adaptor to transmit relatively higher torques.

[007] A still another object of the present invention is to provide a main drive pulley assembly of a tractor engine, having a spun metal sheet pulley with a multi-function CI adaptor offering a good rigidity.

[008] A yet another object of the present invention is to provide a main drive pulley assembly of a 3-cylinder tractor engine, having a spun metal sheet pulley with a multi-function CI adaptor, offering substantial weight reduction.

[009] A further object of the present invention is to provide a main drive pulley assembly of a 3-cylinder tractor engine, having a spun metal sheet pulley with a cast and machined adaptor which is simple and easy to machine.

[010] These and other objects and advantages of the present invention will become more apparent from the following description, when read with the accompanying figures of drawing, which are however not intended to limit the scope of the present invention in any way.

SUMMARY OF THE INVENTION

[011] In accordance of a main drive pulley assembly of an engine, having a pulley with a multi-function adaptor, the pulley assembly comprises:

• a sheet metal pulley;
• a unitized cast iron (CI) adaptor; and
• a plurality of fasteners for assembling together the pulley and the unitized CI adaptor after machining thereof;

wherein the adaptor is casted and machined with a flange and a profiled balancing weight for balancing the forces of rotating and reciprocating components of the engine; the adaptor includes a unitized configuration including a pulley locator and multiple pulley positioners, an oil seal mounting arrangement, a blind keyway arrangement for positive locking and thereby to serve multiple functions by the unique casting and machining thereof.
[012] Typically, the pulley is made as a spun metal sheet light-weight pulley for containing the overall weight of the crankshaft pulley assembly within a range of 50 to 60% of the conventional fully cast pulley assembly.

[013] Typically, the unitized CI adaptor comprises a partially circular flange casted with a profiled balancing weight attached thereto, the balancing weight having one face thereof planar with one face of the flange and the other face thereof protruding out of the other face of the flange.

[014] Typically, the balancing weight comprises one or more holes on the face thereof facing the spun metal sheet pulley for balancing the mass thereof for static balancing of the rotating and reciprocating forces of the engine.

[015] Typically, the flange comprises six (6) holes as pulley positioners for assembling the unitized CI adaptor thereto.

[016] Typically, the unitized CI adaptor having a flange comprising an integrated hollow spacer protruding out of one side thereof for keeping the balancing weight away from the pulley hub and a hollow adaptor shaft extending away from the integrated hollow spacer from other side of the flange, the integrated hollow spacer and the adaptor shaft disposed around an center axis of the unitized CI adaptor.

[017] Typically, the integrated hollow spacer comprises a length smaller than the adaptor shaft and includes a through hole at the center thereof for mounting the crankshaft pulley assembly on the engine crankshaft.

[018] Typically, the integrated hollow spacer comprises a relief groove formed on the side thereof facing the adaptor shaft keyway machining therein.

[019] Typically, the hollow adapter shaft comprises an outer diameter hardened and machined and subsequently ground to a high surface finish to obtain an oil seal fitment area for mounting a front oil seal thereon.

[020] Typically, the hollow adapter shaft comprises a blind keyway machined only up to the relief groove on the integrated hollow spacer for positively locking of the crankshaft pulley assembly to the engine crankshaft by placing a woodruff key therein.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[021] The present invention will be briefly described with reference to the accompanying drawings, wherein:

[022] Figure 1 shows a perspective view the main drive or crankshaft pulley assembly of an IC engine, which consists of a spun sheet-metal pulley with a multi-function unitized cast iron adaptor (hereinafter simply referred to as CI adaptor) configured in accordance with the present invention connected via a crankshaft to the flywheel.

[023] Figures 2a-2b show perspective views of the main drive or crankshaft pulley assembly of Fig.1 consisting of a spun sheet-metal pulley with a unitized CI adaptor fitted to crankshaft 200 of an engine, e.g. a tractor engine.

[024] Figures 3a-3b show perspective views of the spun sheet metal pulley of main drive or crankshaft pulley assembly of Figs. 2a-2b.

[025] Figures 4a-4b show perspective views of the multi-function unitized CI adaptor of main drive or crankshaft pulley assembly of Figs. 2a-2b.

[026] Figure 5 shows a centrally sectioned perspective view of multi-function unitized CI adaptor of the crankshaft pulley assembly of Figs. 4a-4b.

[027] Figure 6 shows a centrally sectioned perspective view of the main drive or crankshaft pulley assembly shown in Figs. 2a-2b.

[028] Figure 7 shows a perspective view of the main drive or crankshaft pulley assembly shown in Figs. 2a-2b, cut along keyway in CI adaptor 120 thereof.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[029] In the following, the present invention will be described in more details with reference to the accompanying drawings without limiting the scope and ambit of the present invention in any way.

[030] Figure 1 shows a perspective view of the crankshaft pulley assembly 100 of a crankshaft pulley of an IC engine, which consists of a spun sheet-metal pulley 110 with a multi-function unitized CI adaptor 120 and configured in accordance with the present invention and connected via a crankshaft 200 to flywheel 300. This crankshaft pulley assembly 100 will be described in detail in the following with reference to other figures.

[031] Figure 2a shows a first perspective view from one side of crankshaft pulley assembly 100 of Fig.1 and made with a spun sheet-metal pulley 110 having a multi-function unitized CI adaptor 120 with an adaptor shaft. Here, pulley assembly 100 is indicated before its connection to crankshaft 200.

[032] Figure 2b shows a second perspective view from other side of the crankshaft pulley assembly 100 of Fig.1 with spun sheet-metal pulley 110 fitted on multi-function unitized CI adaptor 120 provided with a pulley locator.

[033] Figure 3a shows a first perspective view of the spun sheet metal pulley 110 of crankshaft pulley assembly 100 shown in Figs. 2a-2b. Here, spun sheet metal pulley 110 is shown from its side fitted with multi-function, unitized CI adaptor 120. The pulley 110 has a flange 111 with belt groove 112, pulley hub 114, pulley center hole 115 for locating pulley locator 134 of adaptor 120, flange 116 for supporting adaptor flange 121 and holes 118 for fasteners 136 to accurately position adaptor 120 thereon.

[034] Figure 3b shows a second perspective view of the spun sheet metal pulley of crankshaft pulley assembly shown in Figs. 2a-2b. Here, in addition to features of Fig. 3a, spun sheet-metal pulley 110 also indicates the face 117 for supporting the adaptor flange 121.

[035] Figure 4a shows a first perspective view of the unitized CI adaptor 120 of crankshaft pulley assembly 100 shown in Figs. 2a-2b. CI adaptor 120 is casted in cast iron (CI) and includes a flange 121 with a profiled balancing weight 122 suspended therefrom. In three-cylinder engines, using this multi-function pulley assembly 100, rotating and reciprocating forces require balancing thereof. So, the balancing mass/weight on pulley 110 helps in optimizing the power trail layout. So, balancing weight 122 is added to spun sheet metal pulley 110 for balancing the rotating and reciprocating forces of three-cylinder engine (not shown). This balancing weight 122 helps in maintaining these forces in equilibrium. Mass of this balance weight 122 can also be removed by making one or more holes 130 therein. While removing static mass from balancing weight 122 by drilling balancing holes 130 of calculated static weight mounted in threaded hole 132. This threaded hole 132 is made at the calculated PCD and disposed at an angle opposite to balancing weight 122. The surface of flange 121 facing the crankshaft is machined with annular adaptor shaft 124 protruding out therefrom and having bore 125 with keyway 128 for mounting and locking the crankshaft (not shown) by means of a woodruff key fitted therebetween. Keyway 128 is machined as a blind keyway which ends on flange 121 by integrated spacer 134 (see Fig. 4b). Flange 121 has threaded holes 132 (e.g. 6 Nos.) for holding the pulley 110 thereon by tightening bolts 136 (not shown) therein and for required positioning of pulley 110 thereby. Adaptor shaft 124 also includes outer portion thereof hardened and fine-ground to obtain a smooth surface 126 for mounting front oil seal (not shown).

[036] Figure 4b shows a second perspective view of the centrally sectioned unitized CI adaptor 120 of the crankshaft pulley assembly of Figs. 2a-2b. Integrated spacer 134 serves as pulley locator as well as washer. This spacer 134 also helps in locating the center of pulley 110 aligned with the center of pulley hub 114 by controlled machining of the dimensions thereof. Integrated spacer 134 also has a center hole 135 for mounting pulley 110 on unitized CI adaptor 120 by means of a bolt 140 (Fig.7).

[037] Figure 5 shows a centrally sectioned perspective view of unitized CI adaptor 120 of multi-function pulley assembly 100 of Figs. 4a-4b. Here, a machined relief groove 138 is provided for facilitating machining of blind keyway 128 in unitized CI adaptor 120. This keyway 128 enables a positive locking of multi-function pulley assembly 100 on the crankshaft in order to transfer crankshaft motion to this crankshaft pulley assembly 100.

[038] Figure 6 shows a centrally sectioned perspective view of the crankshaft pulley assembly of Figs. 2a-2b. Here, crankshaft pulley assembly 100 is made by tightening (e.g. 6 Nos.) of bolts 140 through flange 116 of spun sheet-metal pulley 110 and flange 121 of unitized CI adaptor 120.

[039] Figure 7 shows a perspective view of the crankshaft pulley assembly of Figs. 2a-2b and sectioned along the keyway 128 in the unitized CI adaptor thereof. Blind keyway 128 closed by adaptor 134 is visible here. The crankshaft pulley assembly 100 is made by mounting bolts 140 through flange 116 of spun sheet-metal pulley 110 and flange 121 of unitized CI adaptor 120 mounted on the crank shaft (not shown). CI adaptor 120 provides a uniform and high-torque pressure of pulley mounting bolt 140 for mounting the pulley assembly 100 on the crankshaft.

[040] Accordingly, the completely unitized multi-function pulley assembly 100 having spun sheet-metal pulley 110 fitted with unitized CI adaptor 120 provides approximately 50-60% weight reduction in comparison to the conventional cast pulleys used in automotive applications.
[041] Unitized CI adaptor 120 serves multiple functions indicated below:

1. For positioning of pulley 110 in pulley assembly 100,

2. For locating pulley 110 in pulley assembly 100,

3. As a washer for resting bolt 140 thereon,

4. For oil seal mounting,

5. For machining a blind keyway 128, and
6. For providing a balancing mass for balancing the rotating and reciprocating forces acting on the drive system on connecting with the crankshaft.

TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE

[042] The unitized spun sheet-metal pulley assembly fitted with multi-function CI adaptor assembly and configured in accordance with the present invention has the following technical and economic advantages:

• A substantially low-weight construction.

• A substantially low-cost of manufacture per engine.

• Suitable for facilitating used for multiple function configuration, e.g. oil sealing, crankshaft locking etc.

• Offers excellent rigidity.

[043] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

[044] It is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. The exemplary embodiments described in this specification are intended merely to provide an understanding of various manners in which this embodiment may be used and to further enable the skilled person in the relevant art to practice this invention.

[045] Although, the embodiments presented in this disclosure have been described in terms of its preferred embodiments, the skilled person in the art would readily recognize that these embodiments can be applied with modifications possible within the spirit and scope of the present invention as described in this specification by making innumerable changes, variations, modifications, alterations and/or integrations in terms of materials and method used to configure, manufacture and assemble various constituents, components, subassemblies and assemblies, in terms of their size, shapes, orientations and interrelationships without departing from the scope and spirit of the present invention.

[046] The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the disclosure unless there is a statement in the specification to the contrary.

[047] Throughout this specification, the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to imply including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.

[048] The use of the expression “a”, “at least” or “at least one” shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention.
[049] The description of the exemplary embodiments is intended to be read in conjunction with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “below”, “up”, “down”, “top”, and “bottom” as well as derivatives thereof (e.g. “horizontally”, “downwardly”, “upwardly” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion.

[050] These relative terms are for convenience of description and do not require that the corresponding apparatus or device be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected”, refer to a relationship, wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

LIST OF COMPONENTS

100 Pulley with unitized adaptor
200 Crankshaft
300 Flywheel
110 Spun sheet-metal pulley
111 Flange
112 Belt groove
114 Pulley hub
115 Pulley center hole
116 Pulley flange
117 Pulley face for supporting adaptor flange.
118 Holes
120 Unitized cast iron (CI) adaptor
121 Adaptor flange
122 Balance weight
124 Adaptor shaft
125 Adaptor shaft center
126 Oil seal mounting surface
128 Blind keyway
130 Balancing holes
132 Threaded holes
134 Integrated spacer
135 Through center of integrated spacer
136 Bolts for pulley-adaptor assembly
138 Relief groove
140 Bolt for mounting pulley assembly on crankshaft
,CLAIMS:We claim:

1. A main drive pulley assembly of an engine, having a pulley with a multi-function adaptor, said main drive pulley assembly comprises:

• a sheet metal pulley;

• a unitized cast iron (CI) adaptor; and

• a plurality of fasteners for assembling together said pulley and said unitized CI adaptor after machining thereof;

wherein said unitized CI adaptor is cast and machined with a flange and a profiled balance weight for balancing the forces of rotating and reciprocating components of said engine; said unitized CI adaptor includes a unitized configuration including a pulley locator and multiple pulley positioners, an oil seal mounting arrangement, a blind keyway arrangement for positive locking and thereby to serve multiple functions by the unique casting and machining thereof.

2. Main drive or crankshaft pulley assembly as claimed in claim 1, wherein said pulley is made as a spun metal sheet, light-weight pulley for containing the overall weight of said crankshaft pulley assembly within a range of 50 to 60% of the conventional fully cast pulley assembly.

3. Main drive or crankshaft pulley assembly as claimed in claim 1, wherein said unitized CI adaptor comprises a partially circular flange cast with a profiled balance weight suspended therefrom, said balance weight having one face thereof planar with one face of said flange and the other face thereof protruding out of the other face of said flange.

4. Main drive or crankshaft pulley assembly as claimed in claim 3, wherein said balanced weight comprises one or more holes on the face thereof facing the spun metal sheet pulley for balancing the mass thereof for static balancing of the rotating and reciprocating forces of the engine.
5. Main drive or crankshaft pulley assembly as claimed in claim 3, wherein said flange comprises six (6) holes as pulley positioners for assembling said unitized CI adaptor thereto.

6. Main drive or crankshaft pulley assembly as claimed in claim 3, wherein said unitized CI adaptor having a flange comprising an integrated hollow spacer protruding out of one side thereof for keeping said balance weight away from the pulley hub and a hollow adaptor shaft extending away from said integrated hollow spacer from other side of said flange, said integrated hollow spacer and said adaptor shaft disposed around an center axis of said unitized CI adaptor.

7. Main drive or crankshaft pulley assembly as claimed in claim 6, wherein said integrated hollow spacer comprises a length smaller than said adaptor shaft and includes a hole at the center thereof for mounting said crankshaft pulley assembly on the engine crankshaft.

8. Main drive or crankshaft pulley assembly as claimed in claim 6, wherein said integrated hollow spacer comprises a relief groove formed on the side thereof facing said adaptor shaft keyway machining therein.

9. Main drive or crankshaft pulley assembly as claimed in claim 6, wherein said hollow adapter shaft comprises an outer diameter hardened and machined and subsequently ground to a high surface finish to obtain an oil seal fitment area for mounting a front oil seal thereon.

10. Main drive or crankshaft pulley assembly as claimed in claim 9, wherein said hollow adapter shaft comprises a blind keyway machined only up to said relief groove on said integrated hollow spacer for positively locking of said crankshaft pulley assembly to said engine crankshaft by placing a woodruff key therein.

Dated: this 31st day of May 2018.

Digitally Signed.
SANJAY KESHARWANI
APPLICANT’S PATENT AGENT
REGN. No. IN/PA-2043.