U.S. patent application number 11/128562 was filed with the patent office on 2006-11-16 for belt drive kit and module.
Invention is credited to Andrzej Dec, David A. Hanes, K. Bruce Jackson.
Application Number | 20060254548 11/128562 |
Document ID | / |
Family ID | 36693612 |
Filed Date | 2006-11-16 |
United States Patent
Application |
20060254548 |
Kind Code |
A1 |
Dec; Andrzej ; et
al. |
November 16, 2006 |
Belt drive kit and module
Abstract
A belt drive kit comprising a driver sprocket, a driven
sprocket, an idler, a belt tensioning device and a toothed belt and
fasteners for attaching the components to an engine.
Inventors: |
Dec; Andrzej; (Rochester
Hills, MI) ; Hanes; David A.; (Troy, MI) ;
Jackson; K. Bruce; (Swartz Creek, MI) |
Correspondence
Address: |
Jeffrey Thurnau;The Gates Corporation
MS: IP Law Dept. 10-A3
1551 Wewatta Street
Denver
CO
80202
US
|
Family ID: |
36693612 |
Appl. No.: |
11/128562 |
Filed: |
May 13, 2005 |
Current U.S.
Class: |
123/90.31 |
Current CPC
Class: |
F16H 55/171 20130101;
F16H 7/023 20130101; F01L 1/02 20130101; F16H 7/1281 20130101; F01L
1/024 20130101; F01L 2001/028 20130101 |
Class at
Publication: |
123/090.31 |
International
Class: |
F01L 1/02 20060101
F01L001/02 |
Claims
1. A belt drive kit comprising: a driver member; a driven member; a
belt tensioning device; a fastener for attaching the driver member
to a first engine component; a fastener for attaching the driven
member to a second engine component; a fastener for attaching the
belt tensioning device to a mounting surface; and a toothed
belt.
2. The kit as in claim 1 further comprising a pulley and a fastener
for rotationally attaching the pulley to a mounting surface.
3. The kit as in claim 1 further comprising instructions for
assembling the kit on an engine.
4. The kit as in claim 1, wherein the first engine component
comprises a crankshaft.
5. The kit as in claim 1, wherein the second engine component
comprises a camshaft.
6. The kit as in claim 1 further comprising a timing member engaged
to the driver member, the timing member comprising a detent for
indicating a piston position.
7. The kit as in claim 1 further comprising a flange attached to
the driver member.
8. The kit as in claim 1 further comprising an instruction
manual.
9. The kit as in claim 1, wherein the driven member comprises
urethane.
10. The kit as in claim 1, wherein the driver member comprises
teeth.
11. The kit as in claim 1, wherein the driven member comprises
teeth.
12. The kit as in claim 1, wherein the belt tensioning device
comprises an eccentric arm tensioner.
13. The kit as in claim 1 further comprising a package for
containing the kit components.
14. The kit as in claim 13 further comprising insert means for
retaining the components in predetermined positions.
15. A belt drive module comprising: a driver member attachable to a
driver shaft; a driven member attachable to a driven shaft; an
idler pulley; a belt tensioning device; a toothed belt; a frame for
receiving the driver shaft and the driven shaft; the idler pulley
and the belt tensioning device attached to the frame; and the
toothed belt engaged with the driver member, the driven member, the
idler pulley and the belt tensioning device.
16. The belt drive module as in claim 15, wherein the driver member
and the driven member have a toothed profile.
17. The belt drive module as in claim 15, wherein the belt
tensioning device is an eccentric tensioner.
18. The belt drive module as in claim 15, wherein the frame is
connectable to an engine crankcase.
19. The belt drive module as in claim 15, wherein the driver shaft
comprises a crankshaft.
20. The belt drive module as in claim 15, wherein the driven shaft
comprises a camshaft.
Description
FIELD OF THE INVENTION
[0001] The invention relates to a belt drive kit and module,
namely, a kit comprising components for use in a belt driven
camshaft system and preassembled module for fitment to an
engine.
BACKGROUND OF THE INVENTION
[0002] Engine assembly generally comprises combining the component
parts in a predetermined sequence. To accomplish the assembly the
parts must be made available to the engine builder. This comprises
sourcing and taking delivery of various system parts from a variety
of manufacturers. The system parts are inventoried and stored. When
the sequence requires a certain part to be assembled to the engine
the part is retrieved from inventory, made available to the engine
builder who then affixes it to the engine build.
[0003] Components may be obtained from a single source or from a
variety of sources. Tracking and sequencing the various components
involves labor time and facilities for handling the components.
Further, the absence of a single component can stop the assembly
process even though all other components are readily available.
This also applies to maintenance activities were parts are replaced
in addition to the part of primary interest because it is simply
financially prudent to replace a series of low cost parts based on
the time and cost required to access the part to be maintained.
[0004] Kits are known for retrofitting existing engines with
systems differing from those originally installed on the
engine.
[0005] Representative of the art 5,460,145 (1995) to Perry, Jr.
which discloses a kit for a motorcycle supercharger drive
assembly.
[0006] What is needed is a belt drive kit comprising a driver
sprocket, a driven sprocket, an idler, a belt tensioning device, a
toothed belt and fasteners for attaching the components to an
engine. What is needed is a preassembled module comprising the kit
components for fitment to an engine. The present invention meets
these needs.
SUMMARY OF THE INVENTION
[0007] The primary aspect of the invention is to provide a belt
drive kit comprising a driver sprocket, a driven sprocket, an
idler, a belt tensioning device and a toothed belt and fasteners
for attaching the components to an engine.
[0008] Another aspect of the invention is to provide a preassembled
module comprising the kit components for fitment to an engine.
[0009] Other aspects of the invention will be pointed out or made
obvious by the following description of the invention and the
accompanying drawings.
[0010] The invention comprises a belt drive kit comprising a driver
sprocket, a driven sprocket, an idler, a belt tensioning device and
a toothed belt and fasteners for attaching the components to an
engine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated in and
form a part of the specification, illustrate preferred embodiments
of the present invention, and together with a description, serve to
explain the principles of the invention.
[0012] FIG. 1 is a plan view of the synchronous drive kit.
[0013] FIG. 2 is a perspective partially exploded view of the
kit.
[0014] FIG. 3 is a top view of a module.
[0015] FIG. 4 is a perspective view of the module.
[0016] FIG. 5 is a front view of the module.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The invention comprises a belt drive kit and module. The kit
comprises components of a camshaft synchronous belt drive system
for use on an internal combustion engine, for example, on a
motorcycle engine. The module comprises the kit components
assembled on a frame, which frame is then attached to an engine
during engine assembly.
[0018] FIG. 1 is a plan view of the kit. The kit comprises
valvetrain timing components that would be used by an engine
assembler or mechanic for initial engine assembly or for repair of
an engine. The components generally comprise a camshaft belt drive
system.
[0019] In operation the system is used to transfer torque from a
driver such as an engine crankshaft through a flexible endless
member, i.e. a toothed (synchronous) belt, to sprockets on one or
more engine camshafts. The engine camshafts comprise lobes which
actuate the engine exhaust and inlet valves in a manner known in
the art. The kit further comprises components used for properly
setting and maintaining belt routing (idler pulleys); for belt
preload and tension (belt tensioning device); as well as for
fastening the sprockets, idlers and belt tensioning components to
the engine or frame. The kit conveniently makes available to a user
all of the necessary belt drive camshaft timing components. As
noted the components may be connected to an engine during engine
assembly, or, they may be connected to a module frame and the frame
is then fitted to an engine during final engine assembly.
[0020] The kit comprises a number of components, including a
crankshaft sprocket 5. Crankshaft sprocket 5, or driver member, is
toothed for the purpose of engaging a belt. Sprocket 5 is mountable
to an engine crankshaft (i.e. a driver shaft), see FIG. 2.
Crankshaft sprocket 5 comprises either metallic material, including
steel or aluminum, or non-metallic material, including urethane or
resin. The sprocket may be spun formed using methods known in the
art.
[0021] Crankshaft sprocket 5 comprises a crank position wheel 7.
Crankshaft position wheel 7 provides a reference detent 7a. Detent
7a can be used for determining the position of the engine pistons
as well as providing a reference signal generator for use by an
electronic ignition pick up, see FIG. 5. Piston position is an
important element of properly timing an engine. The detent trips a
pick up sensor causing the electronic ignition to fire a spark
plug.
[0022] Crankshaft sprocket 5 also comprises a flange 6. Flange 6 is
used to keep belt 15 entrained on the crankshaft sprocket 5 by
limiting lateral movement of the belt.
[0023] The kit also comprises camshaft sprockets 2. Each camshaft
sprocket 2, or driven member, is toothed. Each camshaft sprocket 2
is connected by a fastener 4 to an end of an engine camshaft
(driven shaft). Fasteners 4 in the present embodiment comprise nuts
known in the mechanical arts. Fasteners 4 may also comprise bolts.
This embodiment comprises three camshaft sprockets 2, and therefore
accommodates a three camshaft engine. The camshafts are used to
actuate inlet and exhaust valves on the engine in a form and manner
known in the art, see FIG. 3. Camshaft sprockets 2 comprise either
metallic material, including steel or aluminum, or non-metallic
material, including urethane or resin. Each camshaft sprocket may
also be spun formed using methods known in the art.
[0024] The kit also comprises idlers. Idlers 8, also referred to as
pulleys or idler pulleys, are used to maintain the proper
predetermined routing of belt 15. Idlers 8 are shown as "back-side"
idlers since they engage the side of the belt opposite the toothed
side. Synchronous belt 15 is entrained between the crankshaft
sprocket 5 and camshaft sprockets 2. Synchronous belt 15 comprises
teeth 15a which engage cooperating grooves 15b on each of the
camshaft sprockets 2 in a manner known in the art. Crankshaft
sprocket 5 also comprises teeth and grooves for engaging belt
15.
[0025] The toothed engagement between belt 15 and sprocket 5 and
sprockets 2 maintains the proper timing relationship between
crankshaft (and thereby the pistons), and the camshafts (and
thereby the inlet and exhaust valves). Teeth 15a further comprise a
profile which allows belt 15 to efficiently transmit torque from
the crankshaft sprocket 5 to the camshaft sprockets 2.
[0026] The kit also comprises a belt tensioning device or
tensioner. Tensioner 1 is disposed between the crankshaft sprocket
5 and a camshaft sprocket 2. Tensioner 1 comprises an eccentric arm
type tensioner known in the art. For example, and not by way of
limitation, an eccentric type tensioner disclosed in U.S. Pat. No.
5,256,112, incorporated herein by reference, may be used.
[0027] Tensioner 1 is used to maintain proper belt preload and
operating tension thereby preventing the belt from ratcheting, that
is, skipping teeth with respect to the sprocket in the direction of
movement, or otherwise disengaging from the sprocket by lateral
movement.
[0028] The kit is contained in a box 16, or package, for containing
the kit components as well as for shipping to an assembly location.
The components may be restrained during shipping in box 16 by use
of a molded plastic insert 16a. Insert means 16a comprises
receiving portions dedicated to receiving and organizing each of
the described components in predetermined positions for ease of
shipping and use.
[0029] The kit may also comprise an instruction manual 16b, in
written or electronic form for example CD, used to explain
installation of the kit components on an engine. The instruction
manual may include torque values for attaching each sprocket to the
respective camshaft or crankshaft; torque values for attaching each
idler to a mounting surface such as an engine crankcase; torque
values for attaching the tensioner to a mounting surface such as a
crankcase; the proper method of installing and loading the
tensioner for setting a belt preload; the proper method of setting
the position of the timing wheel 7 with respect to an engine piston
position; the proper method of attaching each camshaft sprocket to
each camshaft for proper valve timing; and the proper method of
installing the belt on the sprockets and idlers, including proper
belt routing. The instruction manual may contain any further
information deemed relevant to the installation and operation of
the kit, its components and the engine on which it is
installed.
[0030] FIG. 2 is a perspective partially exploded view of the kit.
In this embodiment, the idlers each comprise a fastener bolt 14,
washer 13, shaft 12, snap ring 11, bearing 10, washer 9 and idler
pulley 8 in stacked relation to each other as shown. Each of the
foregoing components is known in the art. When the idler is
installed on a mounting surface, bolt 14 is simply torqued into a
receiving hole on a cam timing cover or other crankcase mounting
surface as may be required by the engine design and in accordance
with the torque rating for bolt 14.
[0031] With respect to each of the camshaft sprockets 2, fastener
nut 4 and washer 3 are used to attach the sprocket 2 to a
respective camshaft (not shown) . The noted parts are assembled on
an engine by nut 4 and washer 3 being torqued on each respective
camshaft, see FIG. 3. The camshaft end comprises a threaded portion
to engage the nut. The camshaft sprocket may be aligned with the
camshaft by use of keyways, pins, splines and the like.
[0032] With respect to the crankshaft sprocket 5, nut 4 and flange
6 are used to attach sprocket 5 to the engine crankshaft.
Crankshaft position wheel 7 is disposed between the crankshaft and
the crankshaft sprocket 5. The noted parts are assembled on an
engine by nut 4 and washer 3 being torqued on the crankshaft (not
shown). Crankshaft sprocket 5 and wheel 7 may be aligned with the
crankshaft by use of keyways, pins, splines, and the like. Teeth 5a
are shown on sprocket 5.
[0033] FIG. 3 is a top view of a module. This view depicts a
complete module ready for installation on an engine, as opposed to
FIGS. 1 and 2 which show the kit components in a box. Namely, the
kit components described in FIGS. 1 and 2 are assembled on a module
frame 100 which is then permanently installed on an engine.
[0034] Module frame 100 is an engine component which is a permanent
part of the engine into which it is installed. More particularly,
frame 100 is attachable to an engine crankcase 300, the engine
crankcase having a shape suitable for receiving frame 100.
[0035] Crankcase 300 is shown in partial schematic form since its
shape is ultimately determined by the particular engine. Hence, the
particular crankcase form is not specifically described since the
frame can be shaped to accommodate any engine crankcase style or
shape.
[0036] Portion 200 comprises a structural member of frame 100.
Bolts 201 fasten portion 200 to an engine crankcase. The shape or
need for portion 200 is determined by the shape of the particular
engine to which frame 100 is mounted.
[0037] The engine crankcase and related components may comprise a
crankshaft, connecting rods, pushrods, valves, cylinders, pistons
heads, and so on. Frame 100 is fastened to the crankcase in a
manner which properly disposes the camshafts in operational
relation to the valve pushrods and/or rocker arms. Frame 100 also
mounts in predetermined relation to the crankshaft for proper
fitment of the crankshaft sprocket 5 and timing wheel 7. Sprocket 5
and timing wheel 7 are connected to the crankshaft when frame 100
is fastened to the crankcase. Frame 100 also serves to seal the
internals of the crankcase to allow proper oil circulation, see
FIG. 4 which depicts gasket 35 used for this purpose. Frame 100 may
be cast, sintered or machined from known metal stocks, such as
aluminum, magnesium or steel or combinations of two or more
thereof.
[0038] Camshafts 70, 80, and 90 are installed in their respective
races on the side of frame 100 opposite sprockets 2. In this
embodiment bolts 14 are used in lieu of nuts 4 to secure sprockets
2 to each of the camshafts 70, 80, 90.
[0039] Camshafts 70, 80, 90 may be included in the kit, or, may be
included with the engine. Camshafts 70, 80, 90 also engage bearing
races (not shown) in the engine crankcase that are disposed
opposite frame 100 in accord with the engine design.
[0040] Each camshaft 70, 80, 90 engages a respective bearing 70a,
80a, 90a. Each bearing is engaged with a receiving socket in frame
100. As part of assembly of the module, each camshaft and thereby
cam lobe 70b, 80b, 90b is rotationally oriented with respect to the
other camshafts for the purpose of properly timing inlet and
exhaust valve operation when the module is assembled in an engine
crankcase. Pin 36 is used to properly align frame 100 with an
engine crankcase.
[0041] FIG. 4 is a perspective view of the module. Each of the
components described in FIG. 1 are assembled on the module frame
100. Before final assembly of the frame to the engine, the idler
pulley 8 and the belt tensioning device 1 are attached to frame
100. Toothed belt 15 is temporarily loosely engaged with the driver
sprocket 5, the driven sprockets 2, the idler pulley 8 and the belt
tensioning device 1 as described herein.
[0042] Camshafts 70, 80, 90 are each inserted into its respective
bearing, which is then inserted into the respective frame receiving
socket. Sprockets 2 are secured to each camshaft by bolts 14.
Idlers 8 are secured to the frame 100 by bolts 14. Tensioner 1 is
secured to frame 100 by bolt 1a. The tensioner is locked in a
preload position using a pin or other means known in the art. Belt
15 is routed on the sprockets, idlers and tensioner. Once the belt
is properly routed, the tensioner is released from the preloaded
position to properly engage and thereby preload the belt. The
tensioner may be released upon assembly of the module, or, upon
assembly of the module to the crankcase. Gasket 35 seals frame 100
with the engine crankcase.
[0043] Crankshaft sprocket 5 is secured to the crankshaft 400 using
bolt 14 engaged at threaded hole 401 when the module is attached to
the engine crankcase. For installation it is necessary that the
engine crankshaft be already installed in the engine crankcase in
order to receive sprocket 5 and bolt 14.
[0044] In this FIG. 4 a bolt 14 is described. Referring to FIG. 1 a
nut 4 is also described. Either a nut 4 or bolt 14 may be used to
fasten sprocket 5 to crankshaft 400 with equal success. This is
also the case with respect to sprockets 2, which may be fastened
with a nut 4 as described in FIG. 1, or with a bolt 14 as described
in FIG. 4.
[0045] FIG. 5 is a front view of the module. Ignition timing sensor
45 is aligned with the timing wheel 7. Connector 44 is included in
an engine wiring harness (not shown). Once frame 100 is fastened to
the engine, connector 44 is connected to the wiring harness. Frame
100 is fastened to the engine using bolts (not shown) that are
engaged through holes 101.
[0046] Although forms of the invention have been described herein,
it will be obvious to those skilled in the art that variations may
be made in the process and construction and relation of parts
without departing from the spirit and scope of the invention
described herein.
* * * * *