Split Rim Pulley Assembly for Large Press-Formed Manufacturing
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Solution Overview
Problem
Existing pulley manufacturing methods, particularly casting and forging, face challenges in producing large pulleys and result in environmental pollution, making them inefficient and harmful to workers.
Innovation Solution
A split rim-type assembly pulley is manufactured through press processing, allowing for easy production in various specifications and forms, including large sizes, with a split rim structure that is eco-friendly and improves work efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If casting or forging methods are used to manufacture pulleys, then traditional manufacturing capability is maintained, but large pulleys cannot be easily manufactured and environmental pollution occurs
Solution Approach 1:
The pulley is divided into multiple segments including a hub, multiple arms, and a split rim composed of multiple arc-shaped members. This segmentation allows each component to be manufactured separately using press processing and then assembled together, enabling easy production of large pulleys without the environmental pollution associated with traditional casting methods
Solution Approach 2:
The manufacturing method transitions from casting/forging to press processing, changing the fundamental manufacturing parameter. This parameter change enables eco-friendly production while maintaining the capability to manufacture pulleys of various sizes including large pulleys that were difficult to produce using traditional methods
2Productivity
If casting methods are used, then manufacturing capability is maintained, but work environment and worker health are deteriorated
Solution Approach 1:
The patent replaces the thermal-mechanical casting process with a cold press processing method. This substitution eliminates the harmful effects of casting operations on worker health and work environment while maintaining full manufacturing capability through the assembly of press-processed components
3Ease of manufacture
If traditional manufacturing methods are used, then established processes are followed, but various specifications and forms cannot be easily produced
Solution Approach 1:
By segmenting the pulley into standardized components (hub, arms, split rim members) that can be independently manufactured and then assembled, the invention enables easy production of various specifications and forms. The modular approach allows flexible configuration while maintaining manufacturing simplicity
Solution Approach 2:
The split rim structure with multiple arc-shaped members that can be stacked and assembled provides dynamic adaptability. This allows the pulley to be easily reconfigured for different specifications and forms by changing the number and arrangement of rim members, while the standardized components keep the overall system manageable
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
The split rim-type assembly pulley is easily manufactured in diverse configurations and large sizes, reducing environmental pollution and enhancing worker safety and efficiency.
Implementation Method 1
manufactured through press processing
Implementation Method 2
a plurality of fastening members fastened to the plurality of split rims to maintain a state in which the split rims constitute the rim
Data Source
AI summary
The present invention relates to a split rim assembly pulley and a manufacturing method thereof, the split rim assembly pulley comprising: a hub coupled to a shaft; a plurality of arms arranged radially around the hub; a plurality of split rims arranged in a circle to form a plurality of unit rings that are stacked on each other and coupled to the other end of each of the arms to form a rim that is concentrically fixed to the hub; and a plurality of fastening members fastened to the plurality of split rims so as to maintain the state in which the split rims form the rim.