Method of making a pulley construction

Claim 2

In a method of making a pulley, the steps which include, longitudinally advancing a strip of material adjacent a forming element and thereby forming a longitudinal groove in the strip, coiling the strip into a plurality of generally helical convolutions, severing successive convolution sections from the strip, aligning the ends of each severed convolution section and securing the aligned ends of each severed convolution together so as to form a pulley rim, concentrically arranging the rim relative to an annular pulley hub having an outer peripheral surface provided with a generally radially outwardly extending portion, moving the rim and hub axially relative to one another to a position wherein one axial side of the rim is abuttingly engaged with the axially outwardly extending portion of the hub and thereby predeterminately axially orienting the rim relative to the hub, and fixedly securing the rim to the hub in said position.

Claim 3

The method of claim 1 which includes the step of dimensioning the rim so as to provide for a press fit when the rim is assembled onto the hub.

Claim 4

The method of claim 2 including the step of brazing the hub to the rim.

Claim 5

The method of claim 1 which includes the step of forming a V-shaped longitudinal groove in the strip as the strip advances relative to the forming element.

Claim 6

The method of claim 4 wherein the V-shaped longitudinal groove is formed midway between the side edges of the strip.

Claim 7

The method of claim 1 wherein a pair of longitudinal grooves are formed in the advancing strip by the forming element.

Claim 8

The method of claim 1 wherein the longitudinal groove is formed by passing the strip between a pair of opposed complementary shaping rolls disposed on opposite sides of the strip.

Claim 9

The method of claim 1 wherein each convolution is severed by a straight transverse cut across the strip.

Claim 10

The method of claim 1 wherein the aligned ends of each severed donvolution are secured together by welding.

Claim 11

The method of claim 1 wherein each successive convolution section severed from the strip comprises a sufficient length of the strip so as to constitute a complete circular pulley rim.

Claim 12

In a method of making a pulley, the steps of: providing a hub having receiving means extending around the periphery thereof for receiving sections of rim, providing a strip of metal, longitudinally advancing the strip, forming a longitudinal groove in the strip as the strip advances, coiling the strip into a plurality of convolutions, severing a fraction of each convolution from the strip, inserting the severed section into said receiving means and inserting a complementary rim section into the remainder of said receiving means to form a continuous rim extending around the hub.

Claim 13

In a method of making a pulley, the steps of: providing a hub having receiving means extending around the periphery thereof for receiving sections of rim, providing a strip of metal, longitudinally advancing the strip, forming a longitudinal groove in the strip as the strip advances, coiling the strip into a plurality of convolutions, severing a fraction of each convolution from the strip, inserting the severed section into said receiving means and inserting a complementary rim section into the remainder of said receiving means to form a continuous rim extending around the hub.

Claim 14

The method of claim 11 wherein two half convolutions are severed from the strip and inserted into said receiving means to form the pulley rim.

Claim 17

The method of claim 13 including the step of brazing the hub to the rim.

Claim 18

The method of claim 13 which includes the step of dimensioning the rim so as to provide for a press fit between the inner diameter of the rim and the non-radially extending portion of the hub surface.

Claim 19

In the method of fabricating and assembling a pulley, the steps which include, forming the pulley rim by first passing an elongated flat strip of material through a forming machine whereby the strip is formed into a series of helical convolutions and is also formed with a longitudinal V-shaped groove comprising an intermediate portion and a pair of outwardly extending side portions inclined at a predetermined angle from a plane extending perpendicular to the central axis of the pulley, thereafter severing at least part of a convolution and fixedly securing the opposite ends thereof to one another, coaxially orienting the rim with a pulley hub comprising an outer peripheral rim receiving section which includes a first portion of having substantially the same diameter as the inner diameter of the rim intermediate portion, and a second radially and axially outwardly extending portion inclined at substantially the same angle from said plane extending perpendicular to the central axis of the pulley as said first mentioned angle, moving the pulley hub and rim axially of one another and thereby inserting the first portion of the pulley hub interiorly of the intermediate portion of the pulley rim until one of the side portions of the pulley rim abuttingly engages the second portion of the pulley hub, whereby the rim and hub are predeterminately axially positioned relative to each other, and fixedly securing the rim to the hub while the same are in said predetermined position.

Claim 20

In the method of fabricating and assembling a pulley, the steps which include, forming the pulley rim by first passing an elongated flat strip of material through a forming machine whereby the strip is formed into a series of helical convolutions and is also formed with a longitudinal V-shaped groove comprising an intermediate portion and a pair of outwardly extending side portions inclined at a predetermined angle from a plane extending perpendicular to the central axis of the pulley, thereafter severing at least part of a convolution and fixedly securing the opposite ends thereof to one another, coaxially orienting the rim with a pulley hub comprising an outer peripheral rim receiving section which includes a first portion of having substantially the same diameter as the inner diameter of the rim intermediate portion, and a second radially and axially outwardly extending portion inclined at substantially the same angle from said plane extending perpendicular to the central axis of the pulley as said first mentioned angle, moving the pulley hub and rim axially of one another and thereby inserting the first portion of the pulley hub interiorly of the intermediate portion of the pulley rim until one of the side portions of the pulley rim abuttingly engages the second portion of the pulley hub, whereby the rim and hub are predeterminately axially positioned relative to each other, and fixedly securing the rim to the hub while the same are in said predetermined position.

Claim 21

The method of claim 16 including the step of brazing the hub to the rim.

Claim 22

The method of claim 16 which includes the step of dimensioning the rim so as to provide for a press fit between the first portion of the pulley hub and the intermediate portion of the pulley rim.

Claim 23

The method of claim 16 wherein the longitudinal groove is formed by passing the strip between a pair of opposed complementary shaping rolls disposed on opposite sides of the strip.

Claim 24

The method of claim 16 wherein the longitudinal groove is formed by passing the strip between a pair of opposed complementary shaping rolls disposed on opposite sides of the strip.