Cast idler wheel
Manufacturing idler wheels as a single component with specific geometries and casting techniques addresses the reliability and cost issues of traditional assemblies, enhancing durability and reducing maintenance needs.
Patent Information
- Application Number
- JP2024564481
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-05-12
- Filing Date
- 2023-05-04
- Publication Date
- 2025-05-20
AI Technical Summary
Existing idler wheel manufacturing processes result in assemblies with multiple joints, increasing costs and reducing reliability due to weak points that require maintenance and downtime.
The idler wheel is manufactured as a single component using a casting process, with specific geometries that include a hub, outer rim, and side plates, featuring through openings and internal ribs to reduce material usage and enhance robustness.
This approach reduces material requirements while providing the necessary strength to withstand machine weight and shock loads, minimizing assembly costs and downtime.
Smart Images
Figure 2025515620000001_ABST
Abstract
Description
[Technical field]
[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to manufacturing processes for producing idler wheels. More specifically, the present disclosure relates to geometries that facilitate manufacturing of idler wheels using a casting process. [Background technology]
[0002] Idler wheels are routinely used by machines in the earthmoving, mining, agricultural, construction, and other industries to guide the track chains of their undercarriage and / or support the weight of the machine as well as shock loads during use. These components are typically manufactured as assemblies, which can increase costs and reduce reliability due to the multiple joints required to create such assemblies. More specifically, the side plates and hubs of such idler wheel assemblies may be welded together. However, this creates a weak point that can limit the useful life of the idler assembly and require maintenance and unwanted downtime of the machine using the idler assembly.
[0003] CN110735082B discloses a guide wheel for an endless track drive. The guide wheel includes a guide wheel body having a wheel body base body, an outer wheel ring, and a wheel hub. The guide wheel also includes an inner wheel ring and wheel spokes connecting the wheel hub and the inner. The outer wheel ring is made of a wear-resistant material and is fixedly connected to the inner wheel ring at a circumferential surface radially outward of the inner wheel ring. The guide wheel is manufactured using a process including the following steps: The wheel body base body has an outer rim first component or first component blank integrally formed with the wheel body base body second component or second component blank. This is done via a casting process.
[0004] However, the '082 patent does not address the manufacturing process in sufficient detail to permit, nor does the '082 patent teach how to manufacture the entire idler wheel in a manner that reduces its weight and reduces costs while also providing the necessary robustness. Summary of the Invention
[0005] An idler wheel according to one embodiment of the present disclosure may define an axis of rotation, a radial direction, and a circumferential direction. The idler wheel may include a hub, an outer rim, and a first side plate, and a second side plate extending radially from the hub to the outer rim. The hub, the outer rim, the first side plate, and the second side plate may be formed as a single component. Additionally, the first side plate may define a first through opening, and the second side plate may define a second through opening.
[0006] An idler wheel according to another embodiment of the present disclosure may be comprised of a hub defining a cylindrical bore in a rotation axis, radially, and circumferentially, and an outer rim. Additionally, a first side plate and a second side plate may extend radially from the hub to the outer rim. The hub, outer rim, first side plate, and second side plate may form an internal cavity radially between the outer rim and the hub, and axially between the first side plate and the second side plate. The first side plate may define a maximum first side plate axial thickness disposed radially adjacent the hub and a minimum first side plate thickness disposed radially adjacent the outer rim in a cross-sectional plane including the radial direction and the rotation axis. A ratio of the maximum first side plate axial thickness to the minimum first side plate thickness may be in the range of 1.325 to 1.900.
[0007] An idler wheel according to another embodiment of the present disclosure may be comprised of a hub defining a cylindrical bore in the axis of rotation, radially, and circumferentially, and an outer rim. A first side plate and a second side plate may extend radially from the hub to the outer rim. The hub, outer rim, first side plate, and second side plate may form an internal cavity radially between the outer rim and the hub, and axially between the first side plate and the second side plate. A rib may be disposed within the internal cavity extending from the first side plate to the second side plate in a cross-sectional plane including the radial direction and the axis of rotation. The rib may define a rib opening extending circumferentially through the rib. [Brief description of the drawings]
[0008] [Figure 1] FIG. 1 is a side view of a machine, such as a hydraulic excavator, that uses an idler wheel constructed in accordance with one embodiment of the present disclosure. [Diagram 2] FIG. 2 is a side view of the undercarriage of FIG. 1 shown separated from the remainder of the machine. [Diagram 3] FIG. 3 is a perspective view of an idler wheel that engages the track chain and rollers of the undercarriage of FIG. 2 with the remainder of the undercarriage removed for clarity. [Figure 4] FIG. 4 is a perspective cross-sectional view of the idler wheel of FIG. 3 shown mated with a yoke via a shaft. [Diagram 5] FIG. 5 is a non-sectional side view of the idler wheel of FIG. 4 shown in isolation. [Figure 6] Figure 6 is a cross-sectional view of the idler wheel of Figure 5 taken along line 6-6. Only a portion of the cross-section is shown (e.g., the right side of the idler wheel of Figure 5) that lacks the standoff openings. This cross-section is between the ribs of the idler wheel. [Figure 7] Figure 7 is a cross-sectional view of the idler wheel of Figure 5 taken along line 7-7 through the top and bottom ribs. Only the top portion of the cross-section is shown. [Figure 8]8 is a cross-sectional view of the idler wheel of FIG. 5 taken along the midplane shown in FIG. [Figure 9] FIG. 9 is a side view of the idler wheel of FIG. 5 showing possible gate locations. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0009] Reference will now be made in detail to the embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or similar parts. In some instances, a reference number is shown herein and the drawings will show the reference number followed by a letter, e.g., 100a, 100b, or a prime indicator, e.g., 100', 100''. It should be understood that the use of a letter or prime immediately following a reference number indicates that these features are similarly shaped and have similar functions, as is often the case when geometric shapes are mirrored about a plane of symmetry. For ease of description herein, letters and primes are often not included herein, but may be shown in the drawings to indicate overlap of features discussed within this specification.
[0010] Various embodiments of idler wheels are disclosed that can improve manufacturing processes, reduce the material required to manufacture the idler wheels, and provide the robustness required to support the weight and shock loads of the machine in use. More specifically, the geometry of the idler wheels may allow them to be manufactured as a single cast component in some embodiments of the present disclosure.
[0011] 1 illustrates one embodiment of a track machine 20 in the form of an excavator that includes an embodiment of an idler wheel constructed in accordance with the principles of the present disclosure. Among other uses, excavators can be used to remove material from a work site using a bucket.
[0012] More specifically, Figure 1 illustrates a machine 20 including an undercarriage system 22 including a track assembly 24, consistent with certain embodiments of the present disclosure. Although the machine 20 is illustrated as a hydraulic excavator, it should be understood that the machine 20 may be any other type of machine that includes a track undercarriage system 22. As used herein, the term "machine" refers to a mobile machine that performs operative operations involving physical movement associated with certain industries, such as civil engineering, construction, landscaping, forestry, mining, agriculture, and the like.
[0013] For example, the machine may be a hydraulic mining shovel, a wheel loader, a cable shovel, a track-type tractor, a dozer, or a dragline, etc. Additionally, one or more implements may be connected to the machine. Such implements may be utilized for a variety of tasks including, for example, lifting and loading.
[0014] Undercarriage system 22 may be configured to support machine 20 and move machine 20 along ground, roads, and other types of terrain. As shown in Figures 2 and 3, track chain assembly 24 of undercarriage system 22 may include a track roller frame 26 and various guide components connected to track roller frame 26. The guide components may guide the track and include drive sprockets 30, idler wheels 100, supplier rollers 34, track guides 36, and carrier rollers 38, although other components may be used.
[0015] The track chain assembly 24 may include a plurality of track links 40 having a plurality of shoes 42 secured thereto. The rotatable connections between adjacent track links 40 form a flexible backbone of the track chain assembly 24, with the shoes 42 providing traction on various types of terrain. The track links 40 may extend in an endless chain around the drive sprocket 30, the support rollers 34 that support the heavy load of the machine 20, and the idler wheels and carrier rollers 38.
[0016] As can be seen by viewing Figure 3, track shoes 42 (not shown in Figure 3) may be secured to the outer periphery of the track chain assembly 24. For example, one shoe 42 may be attached to each pair of laterally spaced links 40 via fasteners (not shown) that connect the track shoes to the links via threaded openings 44. Other attachment methods may be used in other embodiments.
[0017] 4 shows an idler wheel 100 held in place in a rotational manner by a yoke 46 and a shaft 48. Also shown is a metal-to-metal face seal 50 (which may be, for example, a DUOCONE face seal) that allows the idler wheel 100 to rotate relative to the yoke 46. Also shown are a thrust washer, and a lubrication groove 200. As can be seen, the idler wheel 100 is hollow, but may be unitary.
[0018] To achieve this result, various embodiments of an idler wheel that are configured to facilitate its manufacture as a single component via a lost core or hollow core casting process will now be described.
[0019] Such an idler wheel 100 is shown in Figures 5 and 6 and may define an axis of rotation 102, a radial direction 104, and a circumferential direction 106. The idler wheel 100 may also include a hub 108, an outer rim 110, a first side plate 112, and a second side plate 112a extending radially from the hub 108 to the outer rim 110. As shown in Figures 5 and 6, the hub 108, the outer rim 110, the first side plate 112, and the second side plate 112a may (but need not be) formed as a single component. To facilitate the casting process, the first side plate 112 may define a first through opening 114 (e.g., extending axially completely through the first side plate), while the second side plate 112a may define a second through opening 116 (Figure 8).
[0020] 5 and 8, the first side plate 112 can define a third through opening 118 circumferentially spaced from the first through opening 114 and the second through opening 116. At the same time, the first through opening 114 can be circumferentially spaced from the second through opening 116 and the third through opening 118.
[0021] In some embodiments, the first through opening 114, the second through opening 116, and the third through opening 118 may extend completely through the first side plate 112 and the second side plate 112a. This allows support pillars to extend through these openings in the mold to hold the hollow core in place axially so that when the casting is poured, the hollow core forms the internal shape of the idler wheel. Although not shown, the support pillars may have pilot portions that hold the hollow core in the proper radial position. After the casting process is complete, the idler wheel may be removed from the mold so that these openings are empty. The hollow core is then shaken (when a sand core is used), dissolved, melted, or otherwise loosened or liquefied to allow it to flow from these openings.
[0022] As shown in Figure 4, in addition to or instead of these openings, the outer rim 110 may further define at least one radially extending opening 120 that extends completely through the outer rim 110. A series of similar openings may be spaced circumferentially along the outer rim. These openings may be used to support or properly position the hollow core and / or to allow the hollow core to flow therefrom after its loosening or liquefaction.
[0023] As seen in Figures 5 and 8, the first through aperture 114, the second through aperture 116, and the third through aperture 118 form a circular array circumferentially around the axis of rotation 102 separated by 120.0 degrees. In such a case, the aperture diameter 122 of all apertures may range from 58.0 mm (millimeters) to 72.0 mm, but in no case less than 38.0 mm. In other embodiments, the apertures may be circumferentially spaced 60.0 degrees apart (i.e., there may be six apertures), and the aperture diameters of these apertures may range from 38.0 mm to 52.0 mm. Other arrangements, configurations, and sizes of these apertures are possible in other embodiments of the present disclosure.
[0024] As best understood with reference to Figures 4, 7, and 8, one or more ribs 124 may extend from the outer rim 110 to the hub 108 within an interior cavity 126 spaced circumferentially between the first through opening 114 and the second through opening 116. More specifically, the ribs 124 may be identical and may form a circular array about the axis of rotation 102, spaced at 60.0 degree intervals. The openings 114, 116, and 118 may be traversed by these ribs 124, which are centered therebetween. Other configurations, arrangements, and sizes of the ribs are possible in other embodiments of the present disclosure.
[0025] The idler wheel 100 may be gated in a variety of manners. For example, as shown in Figures 5 and 6, the first side plate 112 may define a first radially extending outer surface 128 and the second side plate 112a may define a second radially extending outer surface 128a. A plurality of gate defects 130 may be disposed on the first radially extending outer surface 128 and / or the second radially extending outer surface 128a (e.g., in the absence of through openings 114, 116, 118) circumferentially between the ribs 124.
[0026] In addition to or instead of these gate locations, the hub 108 may define a ring gate defect 132 on its exterior or interior. For example, the hub 108 may define the axis of rotation 102 and define a central bore 134 including a cylindrical surface 136 that receives the shaft 48, as shown in FIG. 4. Such a ring gate defect 132 is shown in FIG. 6. This region of the hub may be formed by another hollow core and / or may be machined to the desired shape.
[0027] Focusing on Figure 6, it can be clearly seen that the hub 108, the outer rim 110, the first side plate 112, and the second side plate 112a form an internal cavity 126 radially between the outer rim 110 and the hub 108, and axially between the first side plate 112 and the second side plate 112a. The first side plate 112 may define a maximum first side plate axial thickness 138 disposed radially adjacent the hub 108 in a cross-sectional plane 140 (e.g., the cross-sectional plane of Figure 6) that includes the radial direction 104 and the axis of rotation 102. The first side plate may also define a minimum first side plate thickness 142 disposed radially adjacent the outer rim 110.
[0028] The ratio of maximum first side plate axial thickness 138 to minimum first side plate thickness 142 may range from 1.325 to 1.900 (or may otherwise be greater than 1.1). This ratio may help provide the desired strength to withstand the weight and shock loads of the machine while at the same time minimizing the amount of material used to make the idler wheel without adversely affecting material flow during the casting process.
[0029] In some embodiments, the minimum first side plate thickness 142 may be 12.0 mm or less. More specifically, the minimum first side plate thickness 142 may range from 10.0 mm to 12.0 mm in small embodiments, but depending on the size of the idler wheel, may range from 8.0 mm to 28.0 mm, while the maximum first side plate shaft thickness 138 may range from 14.9 mm to 16.9 mm. Other dimensional ranges are possible in other embodiments of the present disclosure.
[0030] Similarly, the outer rim 110 may further include a bearing surface 144 (so-called because it supports the track chain assembly, hence the surface may or may not be axially interrupted by a guide ridge 146) that defines a bearing surface radial dimension 148 measured from the bearing surface 144 to the axis of rotation 102. The first side plate 112 may define a transition point 150 where the axial thickness of the first side plate (see, e.g., radially halfway between 138 and 142) stops changing. The transition point 150 may be spaced apart from the axis of rotation 102 by a transition point radial distance 152. In some embodiments of the present disclosure, the ratio of the bearing surface radial dimension 148 to the transition point radial distance 152 may range from 1.72 to 2.08. In some embodiments, the transition point radial distance ranges from 36.5 mm to 38.5 mm. Other ratios and dimension ranges are possible in other embodiments of the present disclosure.
[0031] Again, this ratio can help provide the desired strength to withstand the weight and shock loads of the machine while minimizing the amount of material used to create the idler wheel without simultaneously adversely affecting material flow during the casting process. In some embodiments, the outer rim defines a tread diameter or overall diameter defined by the bearing surface in the range of 456.0 millimeters (mm) to 770.0 millimeters (mm).
[0032] 6, the first side plate outer surface (see, e.g., 128) or the second side plate outer surface (see, e.g., 128a) may include a purely radially extending portion 154 disposed radially adjacent the hub 108, and an angled portion 156 extending radially and axially outwardly from the purely radially extending portion 154 at a flare angle 158 relative to the radial direction 104 in the range of 8.0 degrees to 10.0 degrees. This may not be the case in other embodiments of the present disclosure.
[0033] The outer rim 110 may also define a first axial tip 160 of the idler wheel 100, with the purely radially extending portion 154 spaced a first axial distance 162 away from the first axial tip 160, which in some embodiments of the present disclosure ranges from 30.0 mm to 33.0 mm. The idler wheel 100 may also define a mid-plane 163 (which may or may not be a plane of symmetry as shown) disposed along the axis of rotation 102, with the purely radially extending portion 154 spaced a second axial distance 164 away from the mid-plane 163, which in some embodiments of the present disclosure ranges from 46.5 mm to 49.5 mm.
[0034] Additionally, the angled portion 156 may be spaced from the first axial tip 160 by a minimum axial distance 166 in a range of 19.3 mm to 22.3 mm in some embodiments of the present disclosure. The axial spacing between the first axial tip 160 of the outer rim and the axial tip of the hub (see dimension 190) may be approximately 10.5 mm (± 0.5 mm) in some embodiments of the present disclosure.
[0035] With continued reference to FIG. 6, the hub 108 may define a concave arcuate surface 168 that forms a radially lower portion 170 of the internal cavity 126, and the concave arcuate portion (or surface) 168 may be spaced a minimum radial distance 172 from the axis of rotation 102 in the range of 65.0 mm to 68.0 mm in some embodiments of the present disclosure.
[0036] On the other hand, the first side plate 112, the second side plate 112a and the outer rim 110 form a radially upper portion 174 of the internal cavity 126 and may include a first curved arcuate surface 176 (so-called because it looks like an S-curve), a second curved arcuate surface 176a, and an at least partially purely axially extending surface 178 positioned radially adjacent to a radially outermost portion or surface 180 of the idler wheel 100 that connects the first curved arcuate surface 176 to the second curved arcuate surface 176a.
[0037] The first curved arcuate surface 176 defines a first radial tangent 182 and the second curved arcuate surface 176a defines a second radial tangent 182a. In some embodiments of the present disclosure, a maximum internal cavity axial dimension 184 measured from the first radial tangent 182 to the second radial tangent 182a may be in the range of 92.4 mm to 95.4 mm.
[0038] Additionally, at least a portion of the purely axially extending surface 178 includes a first concave axial end 186, a second concave axial end 186a, and in some embodiments of the present disclosure defines a top maximum axial dimension 188, measured from the first concave axial end 186 to the second concave axial end 186a, in the range of 46.9 mm to 49.4 mm.
[0039] 6, the first curved arcuate surface 176 can include a first concave arcuate surface 192 and a first convex arcuate surface 194. Similarly, the second curved arcuate surface 176a can include a second concave arcuate surface 192a and a second convex arcuate surface 194a. In some embodiments of the present disclosure, the minimum axial dimension 196 measured from the first concave arcuate surface 192 to the second concave arcuate surface 192a can range from 75.6 mm to 78.6 mm, while the maximum axial dimension 198 measured from the first convex arcuate surface 194 to the second convex arcuate surface 194a can range from 57.1 mm to 60.0 mm.
[0040] 7, the hub 108 may define a lubrication groove 200 in communication with the central bore 134 defining a groove axial width 202 in the range of 34.5 mm to 37.5 mm. The groove may define a groove outer radial apex 204 having an inclined segment 206 extending from the groove outer radial apex 204 defining an inclination angle 208 with a line 210 parallel to the axis of rotation 102 in the range of 5.0 degrees to 7.0 degrees. Also, in some embodiments of the present disclosure, the groove outer radial apex 204 may be spaced an apex radial distance 212 away from the axis of rotation 102 in the range of 53.5 mm to 56.5 mm.
[0041] We will now discuss idler wheels that may be cast with internal reinforcing ribs as previously described herein. In FIG. 7, such ribs 124 may be disposed within an internal cavity 126 and may extend from the first side plate 112 to the second side plate 112 in a cross-sectional plane 300 (i.e., the cross-sectional plane of FIG. 7) that includes the radial direction 104 and the axis of rotation 102. In some embodiments, the ribs 124 may define rib openings 302 that extend circumferentially through the ribs 124. The ribs may lack openings in other embodiments of the present disclosure.
[0042] The rib opening 302 may include a rib opening perimeter 304 having a radially inner concave curve 306, a radially outer concave curve 308, and a first angled segment 310 radially and axially connecting the radially inner concave curve 306 to the radially outer concave curve 308. In some embodiments of the present disclosure, the radially inner concave curve 306 may define a minor radius 312, while the radially outer concave curve may define a major radius 314 having a ratio of major radius to minor radius in the range of 1.40 to 1.75.
[0043] Additionally, in certain embodiments of the present disclosure, the first angled segment 310 at least partially defines a rib cross-sectional thickness 318 (i.e., the minimum thickness at the cross-sectional plane 300 measured from the first angled segment to the side plate outer surface) in the range of 14.0 mm (millimeters) to 16.0 mm.
[0044] More specifically, the larger radius 314 may range from 38.0 mm to 40.0 mm, while the smaller radius 312 may range from 24.0 mm to 26.0 mm. In some embodiments, the radially inner concave curve 306 may be spaced from the axis of rotation 102 by a lower rib opening radial spacing distance 320 (i.e., minimum distance) in the range of 74.7 mm to 76.7 mm, while the radially outer concave curve 308 may be spaced from the outer rim 110 (i.e., circumferential surface 322 of the guide ridge 146) by an upper rib opening radial spacing distance 324 in the range of 39.0 mm to 41.0 mm, in some embodiments of the present disclosure.
[0045] As best seen in FIG. 8, the rib 124 may define a thickness 326 measured in a direction tangential to the circumferential direction 106 of the axial midplane 163 (i.e., the cross-sectional plane of FIG. 8) radially adjacent the outer rim 110 that is in the range of 10.0 mm to 14.0 mm in certain embodiments of the present disclosure.
[0046] The configurations, ratios, and dimensional ranges of any of the features of the embodiments discussed herein may be varied from those explicitly discussed or shown depending on the application. Although the various dimensions, ratios, and configurations of the features discussed herein for the various embodiments are suitable for casting, they may be useful and beneficial for use in manufactured or assembled idler wheels. [Industrial Applicability]
[0047] Indeed, idler wheels according to any embodiment described herein may be offered, sold, manufactured, purchased, etc. in an aftermarket or OEM (original equipment manufacturer) context as needed or desired. For example, the idler wheels may be used to retrofit the undercarriage of a machine already in the field, or may be sold with a piece of equipment (e.g., machines such as excavators, wheel loaders, etc.) with the undercarriage at a first point of sale for the piece of equipment.
[0048] The idler wheel may be made from iron, cast iron, steel, or gray cast iron, or other suitable material that is durable and can be used in a casting process. The idler wheel geometry may be formed during casting, and then rough machined and / or finish machined as needed. Suitable machining processes may include milling, turning, electric discharge machining, and the like. The idler wheel may be separated from the gate, forming a gate defect, which may be a protrusion, a recess, or some combination of protrusions and recesses, relative to the surface of the idler wheel. The gate defect may be removed by machining, grinding, and the like.
[0049] Also, the hollow core as previously described herein may be loosened via a shaking process or liquefied and removed. The openings may then be blocked to help prevent the ingress of debris, dirt, etc. when the idler wheel is used in the field. It should be understood that the mold used to manufacture the idler wheel is actually a negative image of the cast idler wheel before machining is completed.
[0050] The inventors have tested and / or performed FEA (Finite Element Analysis) on the idler wheels disclosed herein for both strength, flow of material during casting, lack of porosity, etc., and have found an idler that simultaneously provides the appropriate strength required and the desired manufacturability.
[0051] As used herein, the term "single" means that the idler wheels are not fastened or welded together, but are cast in a step or in one step depending on the application. For example, the hub and / or side plates may be cast together first, and then the outer rim may be cast over them. In such a case, the outer rim may be gated in multiple spots (e.g., at 90 degree intervals circumferentially, risers are also shown), leaving gate defects 328, as shown in FIG. 9. However, idler wheels that are fabricated, assembled, etc. are also contemplated to be within the scope of the present disclosure.
[0052] Of course, the foregoing description provides examples of the disclosed assemblies and techniques. However, it is contemplated that other implementations of the present disclosure may differ in details from the foregoing embodiments. All references to the present disclosure or its embodiments are intended to refer to the specific embodiments discussed in that respect, and are not intended to be limitations on the general disclosure. All language of distinction and disparagement regarding specific features is intended to indicate a lack of preference for those features, but does not completely exclude such from the scope of the present disclosure unless otherwise indicated.
[0053] Recitation of ranges of values herein is intended to serve as a shorthand method of referring individually to each individual value within that range, unless otherwise stated herein, and each individual value is incorporated herein as if it were individually set forth herein.
[0054] As used herein, the articles "a" and "an" are intended to include one or more items and may be used interchangeably with "one or more." Where only one item is intended, "one" or similar language is used. Also, as used herein, the terms "has," "have," "having," "with" or similar terms are intended to be open-ended. Furthermore, the phrase "based on" is intended to mean "based at least in part on," unless expressly stated otherwise.
[0055] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments of the apparatus and assembly methods as discussed herein without departing from the scope or spirit of the invention. Other embodiments of the present disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the various embodiments disclosed herein. For example, some devices may have different structures and functions than those described herein, and certain steps of any method may be omitted, performed in a different order than specifically mentioned, or sometimes performed simultaneously or in sub-steps. Furthermore, variations or modifications to specific aspects or features of the various embodiments may be made to create further embodiments, and features and aspects of the various embodiments may be added to or substituted for other features or aspects of other embodiments to provide still further embodiments.
[0056] Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by this disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.
Claims
1. An idler wheel (100), a hub (108) defining an axis of rotation (102), a radial (104), and a circumferential (106) cylindrical bore (134); An outer rim (110); a first side plate (112) and a second side plate (112a) extending radially from the hub (108) to the outer rim (110); the hub (108), the outer rim (110), the first side plate (112), and the second side plate (112a) form an internal cavity (126) radially between the outer rim (110) and the hub (108) and axially between the first side plate (112) and the second side plate (112a), the first side plate (112) defines a maximum first side plate axial thickness (138) disposed radially adjacent the hub (108) in a cross-sectional plane (140) containing the radial direction (104) and the axis of rotation (102), and a minimum first side plate axial thickness (142) disposed radially adjacent the outer rim (110), and a ratio of the maximum first side plate axial thickness (138) to the minimum first side plate axial thickness (142) is in the range of 1.325 to 1.
900.
2. 2. The idler wheel of claim 1, wherein the outer rim further comprises a support surface defining a support surface radial dimension measured from the support surface to the axis of rotation, the first side plate defining a transition point at which the first side plate axial thickness stops changing, the transition point being spaced a transition point radial distance from the axis of rotation, a ratio of the support surface radial dimension to the transition point radial distance being in the range of 1.72 to 2.08, and the maximum first side plate axial thickness being in the range of 8.0 mm to 28.0 mm.
3. the first side plate (112) defines a first side plate outer surface (128) including a radially extending portion (154) disposed radially adjacent the hub (108) and an angled portion (156) extending radially and axially outwardly from the radially extending portion (154) at a flare angle (158) relative to the radial direction (104) in a range of 8.0 degrees to 10.0 degrees, the transition point radial distance (152) is in a range of 36.5 mm to 38.5 mm, the outer rim (110) defines a first axial tip (160) of the idler wheel (100), and the first 3. The idler wheel (100) of claim 2, wherein the radially extending portion (154) of the side plate outer surface (128) is spaced a first axial distance (162) from the first axial tip (160) in a range of 30.0 mm to 33.0 mm, the idler wheel (100) defines a midplane (163) disposed along the axis of rotation (102), and the radially extending portion (154) of the first side plate outer surface (128) is spaced from the midplane (163) a second axial distance (164) in a range of 46.5 mm to 49.5 mm;
4. 4. The idler wheel (100) of claim 3, wherein the angled portion (156) of the first side plate outer surface (128) is spaced from the first axial tip (160) by a minimum axial distance (166) in the range of 19.3 mm to 22.3 mm, and wherein the midplane (163) is a plane of symmetry for the idler wheel (100).
5. The hub (108) defines a concave arcuate surface (168) that forms a radially lower portion (170) of the internal cavity (126), the concave arcuate surface (168) being spaced a minimum radial distance (172) from the axis of rotation (102) that ranges from 65.0 mm to 68.0 mm, and the first side plate (112), the second side plate (112a), and the outer rim (110) define a first curved arcuate surface (1 2. The idler wheel (100) of claim 1, further comprising: a first curved arcuate surface (176) formed at a radially upper portion (174) of said internal cavity (126) including a first curved arcuate surface (176a), a second curved arcuate surface (176a), and an at least partially axially extending face (178) disposed radially proximate a radially outermost surface (180) of the idler wheel (100) connecting said first curved arcuate surface (176) to said second curved arcuate surface (176a).
6. said first curved arcuate surface (176) defines a first radial tangent (182), said second curved arcuate surface (176a) defines a second radial tangent (182a), a maximum internal cavity axial dimension (184) measured from said first radial tangent (182) to said second radial tangent (182a) is in the range of 92.4 mm to 95.4 mm, said at least partially extending axial surface (178) includes a first concave axial end (186), a second concave axial end (186a), and a top maximum axial dimension (184) measured from said first concave axial end (186) to said second concave axial end (186a) is in the range of 46.9 mm to 49.4 mm. 88), said first curved arcuate surface (176) includes a first concave arcuate surface (192) and a first convex arcuate surface (194), said second curved arcuate surface (176a) includes a second concave arcuate surface (192a) and a second convex arcuate surface (194a), a minimum axial dimension (196) measured from said first concave arcuate surface (192) to said second concave arcuate surface (192a) ranges from 75.6 mm to 78.6 mm, and a maximum axial dimension (198) measured from said first convex arcuate surface (194) to said second convex arcuate surface (194a) ranges from 57.1 mm to 60.0 mm.
7. 2. The idler wheel of claim 1, wherein the hub defines a lubrication groove in communication with the central bore, the lubrication groove defining a groove axial width in the range of 34.5 mm to 37.5 mm, a groove outer radial apex having an inclined segment extending from the groove outer radial apex, the groove outer radial apex being spaced an apex radial distance away from the axis of rotation in the range of 53.5 mm to 56.5 mm, the inclined segment defining an inclination angle having a line parallel to the axis of rotation in the range of 5.0 degrees to 7.0 degrees.
8. An idler wheel (100), a hub (108) defining an axis of rotation (102), a radial (104), and a circumferential (106) cylindrical bore (134); An outer rim (110); a first side plate (112) and a second side plate (112a) extending radially from the hub (108) to the outer rim (110); the hub (108), the outer rim (110), the first side plate (112), and the second side plate (112a) form an internal cavity (126) radially between the outer rim (110) and the hub (108) and axially between the first side plate (112) and the second side plate (112a), the idler wheel (100) further including ribs (124) within the internal cavity (126) extending from the first side plate (112) to the second side plate (112a) in a cross-sectional plane (300) including the radial direction (104) and the axis of rotation (102), the ribs (124) defining rib openings (302) extending circumferentially therethrough.
9. The rib opening (302) includes a rib opening perimeter (304) including a radially inner concave curve (306), a radially outer concave curve (308), and a first angled segment (316) radially and axially connecting the radially inner concave curve (306) and the radially outer concave curve (308), the radially inner concave radial curve (306) defining a small radius (312) and the radially outer concave radial curve (308) defining a large radius (314), the first angled segment (316) at least partially defining a rib cross-sectional thickness (318) in the range of 14.0 mm to 16.0 mm, and the large radius (314) defining a rib cross-sectional thickness (318) in the range of 14.0 mm to 16.0 mm.
9. The idler wheel (100) of claim 8, wherein a ratio of said larger radius (314) to said smaller radius (312) is in the range of 1.40 to 1.75, said larger radius (314) is in the range of 38.0 mm to 40.0 mm, said smaller radius (312) is in the range of 24.0 mm to 26.0 mm, said radially inner concave curve (306) is spaced from said axis of rotation (102) by a lower rib opening radial spacing distance (320) in the range of 74.7 mm to 76.7 mm, and said radially outer concave curve (308) is spaced from said outer rim (110) by an upper rib opening radial spacing distance (324) in the range of 39.0 mm to 41.0 mm.
10. 9. The idler wheel (100) of claim 8, wherein said rib (124) defines a thickness (326) measured in a direction tangential to said circumferential direction (106) within an axial midplane (163) that is in the range of 10.0 mm to 14.0 mm.