Tensioner Pulley Collar Assembly for Precise Axial Retention
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Solution Overview
Problem
Existing pulley devices for tensioner and winding rollers require multiple fastening elements, leading to increased production costs, assembly complexity, and potential deformation issues that affect mounting accuracy and durability.
Innovation Solution
A pulley device design featuring C-shaped pulley elements with radially set-back recessed zones in their through-openings, which allows for axial retention without additional fasteners, reducing manufacturing complexity and minimizing deformation risks, while maintaining optimal mounting on the bearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple rivets are used to secure the two C-shaped pulley elements, then the pulley elements are firmly attached, but the production cost increases and assembly complexity increases
Solution Approach 1:
The patent combines the attachment function and retention function into a single integrated collar structure. The collar is formed by deforming the free axial end of the protruding portion, merging multiple fastening elements into one unified component that simultaneously provides attachment and retention without requiring separate rivets or fasteners.
Solution Approach 2:
The collar structure is self-forming through deformation of the protruding portion's free axial end. The deformation process creates the retention mechanism inherently within the same structural element, eliminating the need for additional fastening components and simplifying the assembly process.
2Stability of the object's composition
If protrusions are deformed to provide axial retention, then axial retention is achieved, but weakness is introduced in the pulley elements at the peripheries of openings and joint zones
Solution Approach 1:
The patent applies local quality by creating a collar structure with specific geometric characteristics at the deformation zone. The collar's radially directed free end and its interaction with the recessed zone create a localized retention mechanism that does not compromise the overall structural integrity of the pulley element, concentrating the retention function in a specific area while preserving strength elsewhere.
Solution Approach 2:
The collar acts as an intermediary element between the protruding portion and the opening. By deforming the free axial end into a collar that engages with the recessed zone, the patent creates an intermediate structure that provides axial retention while distributing stresses more favorably, avoiding direct deformation of the protrusion itself and thus preserving the strength of the pulley element.
3Stability of the object's composition
If forces are transmitted to the peripheral borders of the openings during protrusion deformation, then axial retention is achieved, but overall deformation of the pulley element occurs resulting in incorrect mounting
Solution Approach 1:
The recessed zone is strategically positioned and shaped to intercept and contain the deformation forces within a localized area. This local structural feature ensures that when the collar is formed by deforming the protruding portion, the forces are confined to the recessed zone rather than being transmitted to the peripheral borders of the openings, thus preserving the overall geometry and mounting precision of the pulley element.
4Reliability
If additional fastening elements are used, then secure attachment is achieved, but production cost increases and stock management complexity increases
Solution Approach 1:
The patent merges the attachment and retention functions into the single collar structure formed from the protruding portion. This integration eliminates the need for separate fastening elements, reducing the number of parts that need to be manufactured, managed in inventory, and assembled, thereby improving production economy while maintaining attachment reliability.
Solution Approach 2:
The collar structure is self-forming through the deformation of the protruding portion's free axial end. This self-service mechanism creates the retention feature inherently within the existing structural element, eliminating the need for additional fastening components and simplifying both production and stock 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
The solution results in a more economical, easy-to-assemble pulley device with reduced risk of breakage and precise size control, eliminating weak zones and ensuring accurate mounting on the bearing, thus enhancing operational reliability.
Implementation Method 1
a collar being formed by deformation of a free axial end of the protruding portion that is directed in a substantially radial direction in order to provide axial retention with the peripheral border of the opening
Data Source
AI summary
A pulley device for a tensioner roller or winding roller for a transmission element, providing a bearing and a pulley. The pulley including two pulley elements that are C-shaped in axial section. At least one of the pulley elements has an axial through-opening, the other pulley element providing an axially protruding portion housed in the opening, a collar being formed by deformation of the protruding portion in order to provide axial retention with the opening. The at least one through-opening is provided at its periphery with at least one recessed zone formed in a substantially radially set-back manner with respect to the protrusion, which passes through the opening.