External Spring Tensioner for Engine Belt Systems
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Solution Overview
Problem
Current front end accessory drive automatic belt tensioners are not adaptable to variations in engine configurations, requiring unique designs for each engine setup, leading to increased manufacturing and service complexity and costs.
Innovation Solution
An externally-mounted spring tensioner system composed of spring steel, with adjustable length, material, and thickness, that can be easily attached to existing belt tensioners using conventional fasteners, providing additional tension without the need for re-tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a unique front end accessory drive automatic belt tensioner design is created for each engine configuration, then optimal belt tension is achieved for that specific engine, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies universality by designing a belt tensioner assembly that can be used across multiple engine configurations. The tensioner includes a mounting bracket with multiple mounting position openings that allow the same assembly to be mounted at different positions on the engine block, adapting to various accessory arrangements without requiring unique tensioner designs for each engine type.
Solution Approach 2:
The patent applies dynamics through the adjustable mounting system. The mounting bracket allows selection of different mounting positions depending on the specific engine configuration and accessory placement. This dynamic adaptability enables a single tensioner design to function optimally across multiple engine variants by adjusting the mounting location rather than redesigning the entire assembly.
2Adaptability or versatility
If accessories are added or changed from the initial engine design, then engine functionality is improved, but a new tensioner design is required increasing manufacturing cost
Solution Approach 1:
The mounting bracket is designed with multiple mounting position openings to accommodate different accessory configurations. This universal design allows the same tensioner assembly to be used whether the engine has standard accessories, additional accessories, or modified accessory placements, eliminating the need for new tensioner designs when accessory configurations change.
Solution Approach 2:
The mounting bracket is segmented into multiple mounting positions with separate openings. This segmentation allows selective use of different mounting locations based on the specific accessory arrangement, enabling flexibility in accessory configuration without requiring a complete redesign of the tensioner assembly.
3Ease of manufacture
If a standard front end accessory drive automatic belt tensioner design is used across different engines, then manufacturing cost decreases, but optimal belt tension cannot be achieved for all engine configurations
Solution Approach 1:
The mounting bracket provides dynamic adaptability through multiple mounting positions. While the tensioner assembly itself remains standardized for easy manufacturing, the ability to select different mounting positions allows optimization of belt tension for each specific engine configuration, reconciling manufacturing simplicity with tension optimization.
Solution Approach 2:
The mounting bracket incorporates local variations in the form of multiple mounting position openings at different locations. This allows the standardized tensioner assembly to be adapted to local requirements of different engine configurations by selecting the appropriate mounting position, maintaining both manufacturing simplicity and tension optimization.
4Reliability
If multiple unique tensioner designs are maintained for different engines, then each engine achieves optimal performance, but service complexity and inventory costs increase
Solution Approach 1:
The universal mounting bracket design with multiple mounting positions allows a single tensioner assembly to serve multiple engine configurations. This reduces service complexity by eliminating the need for technicians to identify and handle multiple unique tensioner designs, while still achieving optimal performance for each engine type through appropriate mounting position selection.
Solution Approach 2:
Instead of maintaining multiple unique tensioner designs, the industry can use a single standardized tensioner assembly design that copies the same basic structure across all engine applications. The adaptability is achieved through the mounting bracket's multiple positions rather than through design variations, simplifying service and inventory management.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible and cost-effective belt tensioning for modified engine configurations, maintaining optimal belt tension without requiring new tensioner designs, thus reducing manufacturing and service complexities.
Implementation Method 1
an external spring (40, 50) for use with a drive belt tensioner (24). The spring (40, 50) may be round or flat in cross section and is configured so as to conform to the outer dimension of a portion of the tensioner (24)
Data Source
AI summary
An easily attached and highly tunable spring arrangement for use with existing front end accessory drive automatic belt tensioners is provided. The spring arrangement of the disclosed inventive concept includes an external spring that can be attached to tensioners to provide a specifically desired amount of additional tension. The spring is flat or round and is externally mounted, conforming to the outer dimension of a portion of the tensioner. The spring can be used on existing tensioner-to-engine bosses using conventional fasteners. The spring includes an attachment end and a biasing end. The attachment end includes at least one bolt sleeve that is formed as part of or is fitted to the external spring by welding. The biasing end contacts the outside of the front end accessory drive automatic belt tensioner at an area adjacent the tensioner pulley. The spring length, material and thickness may be varied for proper tension.