Abstract: High-offset belt tensioners have a support base with a pivot tube and an arm coupled thereto rotation about a pivot axis. A flat wire torsion spring has an inner spring hook attached to the pivot tube and an outer spring hook attached to a first end of the arm at a position that counterbalances a hub load force. The torsion spring applies a spring force to the arm in a direction that moves with the arm throughout its entire sweep in a belt engaging direction. A first plane of the hub load force is axially offset from a second plane of the spring force, a fulcrum is defined between first and second ends of the arm, and a first lineal axial distance from the fulcrum to the first plane is greater than or equal to a second lineal axial distance from the fulcrum to the second plane.

Abstract: A tensioning system including a base and an arm pivotally coupled to the base, the arm having an engagement surface and being configured to pivot relative to the base about a pivot axis. The system further includes a biasing mechanism operatively coupled to the arm to bias the arm relative to the base, and a seal assembly sealingly positioned between the arm and the base. The seal assembly is coaxial with the pivot axis and configured to accommodate relative axial movement between the base and the arm and relative radial movement between the base and the arm while still maintaining a seal therebetween.

Abstract: Zed-type belt tensioners are described that include an arm having a first end rotatable about a first axis to move a second end of the arm into engagement with a belt, a tensioner component coupled to the first end of the arm, and a supplemental force element positioned between the arm and the tensioner component. The second end of the arm while tensioning a belt experiences a hub load applied by the belt and the supplemental force element is positioned at a point to apply a force that counteracts the hub load thereby reducing cocking of the arm. Also described herein are methods of counteracting the hub load using such belt tensioners and methods of assembly of such belt tensioners.

Abstract: A tensioning system including a base and an arm pivotally coupled to the base, the arm having an engagement surface and being configured to pivot relative to the base about a pivot axis. The system further includes a biasing mechanism operatively coupled to the arm to bias the arm relative to the base, and a seal assembly sealingly positioned between the arm and the base. The seal assembly is coaxial with the pivot axis and configured to accommodate relative axial movement between the base and the arm and relative radial movement between the base and the arm while still maintaining a seal therebetween.

Abstract: A tensioning system including a base and an arm pivotally coupled to the base, the arm having an engagement surface and being configured to pivot relative to the base about a pivot axis. The system further includes a biasing mechanism operatively coupled to the arm to bias the arm relative to the base, and a seal assembly sealingly positioned between the arm and the base. The seal assembly is coaxial with the pivot axis and configured to accommodate relative axial movement between the base and the arm and relative radial movement between the base and the arm while still maintaining a seal therebetween.

Abstract: Zed-type belt tensioners are described that include an arm having a first end rotatable about a first axis to move a second end of the arm into engagement with a belt, a tensioner component coupled to the first end of the arm, and a supplemental force element positioned between the arm and the tensioner component. The second end of the arm while tensioning a belt experiences a hub load applied by the belt and the supplemental force element is positioned at a point to apply a force that counteracts the hub load thereby reducing cocking of the arm. Also described herein are methods of counteracting the hub load using such belt tensioners and methods of assembly of such belt tensioners.

Abstract: Pulley assemblies are disclosed that include a pulley body, a hub disposed within the bore of the pulley body, and a one-way clutch concentric about the hub. The one-way clutch has a plurality of cantilevered members that each include a friction surface and a cantilevered end and a biasing member in contact with one cantilevered member to bias the cantilevered members into continuous frictional engagement with the bore of the pulley body. Each of the cantilevered members is pivotable about its cantilevered end and is partially nested within an adjacent cantilevered member to form an annular body. This construction places the friction surface of each cantilevered member facing the bore of the pulley body. In operation, the pulley body rotates in a predominant direction which activates the plurality of cantilevered members to link the pulley body to the hub for simultaneous rotation.

Abstract: Disclosed is a pulley assembly including a pulley having an axis of rotation a pulley shell, and a bearing; a shaft having a pulley-receiving end that receives the pulley; and a first bearing shield disposed at the pulley-receiving end of the shaft. The pulley shell includes an annular wall that defines an opening for housing the bearing. The bearing is housed therein and has an inner race, outer race, and a rolling element. The first bearing shield includes a deflected sealing member biases against at least one of the outer race of the bearing and the pulley shell as a first contact seal to protect the bearing from contaminants.

Abstract: Pulley assemblies are disclosed that include a pulley body, a hub disposed within the bore of the pulley body, and a one-way clutch concentric about the hub. The one-way clutch has a plurality of cantilevered members that each include a friction surface and a cantilevered end and a biasing member in contact with one cantilevered member to bias the cantilevered members into continuous frictional engagement with the bore of the pulley body. Each of the cantilevered members is pivotable about its cantilevered end and is partially nested within an adjacent cantilevered member to form an annular body. This construction places the friction surface of each cantilevered member facing the bore of the pulley body. In operation, the pulley body rotates in a predominant direction which activates the plurality of cantilevered members to link the pulley body to the hub for simultaneous rotation.

Abstract: A pulley assembly for an automobile accessory drive system includes a shaft engaging hub, a nut threaded onto the shaft engaging hub, an annular bushing, and one or more brake shoes positioned around the outside of the annular bushing all housed with a pulley member. The nut is capable of axial translation relative to the annular bushing and the annular bushing is capable of expanding radially outward in response to the axial translation of the nut in a first direction to provide frictional engagement between the inner coupling surface of the pulley member and the outer coupling surface of the brake shoes, which transfers torque from the pulley member to the input shaft. The nut includes a generally frustoconical outer surface, opposite its inner threaded surface, for seating the nut in the annular bushing.

Abstract: A tensioner is disclosed that may be part of a power system where the tensioner provides tension to an endless power transmitting element such as a belt, chain, or other continuous loop. The tensioner has an arm that is rotatable about a first axis and includes an arm arbor having a slot therethrough, a bushing having a protrusion and being positioned adjacent the arm arbor with the protrusion received in the arm arbor's slot, and a spring coupled to the arm urging the arm to rotate about the first axis into tensioning engagement with a power transmitting element. The spring is positioned where it can radially expand into contact with the protrusion of the bushing as the arm is rotated in a direction opposite the direction of tensioning engagement such that the bushing is urged radially outward relative to the arm arbor to provide frictional damping.

Abstract: A tensioning system including a base and an arm pivotally coupled to the base, the arm having an engagement surface and being configured to pivot relative to the base about a pivot axis. The system further includes a biasing mechanism operatively coupled to the arm to bias the arm relative to the base, and a seal assembly sealingly positioned between the arm and the base. The seal assembly is coaxial with the pivot axis and configured to accommodate relative axial movement between the base and the arm and relative radial movement between the base and the arm while still maintaining a seal therebetween.

Abstract: A tensioner may be part of a power system to tension an endless power transmitting element. The tensioner includes an arm having an arm arbor with a slot therethrough that is rotatable about a first axis, a bushing having a sleeve that includes a cut-out and a removable sleeve-segment that has a protrusion thereon, the sleeve-segment being receivable in the cut-out with the protrusion in the slot, and a spring coupled to the arm for rotation of the arm about the first axis into tensioning engagement with a power transmitting element. The spring is positioned where it can radially expand into contact with the protrusion of the bushing, at least the protrusion on the sleeve-segment, as the arm is rotated in a direction opposite the direction of tensioning engagement such that the bushing is urged radially outward relative to the arm arbor to provide frictional damping.

Abstract: A pulley assembly for use in an automobile accessory drive system includes a shaft engaging hub, a pulley member, a nut treaded onto the shaft engaging hub, and a brake member interposed between the pulley member and the nut. The shaft engaging hub is engaged with an accessory input shaft for rotation therewith. Frictional engagement between the pulley member, the brake member, and the nut transfers torque from the pulley member to the input shaft. The pulley member includes an inner coupling surface and a peripheral belt-engaging surface. The nut includes an outer coupling surface. The brake member includes a first coupling surface in frictional engagement the outer coupling surface of the nut and a second coupling surface in frictional engagement with the inner coupling surface of the pulley member. When torque is applied to the nut in a first direction the out coupling surface of the nut couples to the inner coupling surface of the brake member such that the hub and the nut rotate with the pulley member.

Abstract: A belt tensioner includes an arm, a spring case, and a helical spring having inwardly projecting first and second end portions. Another belt tensioner includes a spring, an arm, a spring case, and a pivot bushing surrounding the spring. An additional belt tensioner includes an idler pulley having a bearing with a mounting hole and includes an arm having a post. The post is positioned in the mounting hole, and an annular rim of the post is deformed radially outward and over the bearing. A method for manufacturing an arm and a spring case of a belt-tensioner includes obtaining a belt-tensioner-arm casting mold including a first section and a second section and obtaining a belt-tensioner-spring-case casting mold including a first segment and a second segment.

Abstract: A tensioner for an endless power transmitting element in a drive system is disclosed that includes an arm rotatable about an axis and having a sleeve that includes a ramp face or contoured face, a damper cup having a protrusion and a plate, a spring case that houses the sleeve of the arm and the damper cup with the damper cup's plate mated with the ramp face or contoured face of the sleeve. During wind-up of the tensioner, a normal force is applied to the damper cup's protrusion that moves the plate along the ramp face or contoured face in a first direction, and in the first direction the ramp face or contoured face pushes the damper cup generally radially outward into the spring case to provide frictional damping.

Abstract: A tensioner is disclosed that achieves asymmetric damping in part by using a ramp-ramp assembly. The tensioner comprises a tensioner axle defining a pivot axis, an arm mounted on the tensioner axle so as to permit the arm to pivot about the pivot axis, a first tensioner component having first ramp features, a second tensioner component having second ramp features, and a ramp bushing having an upper ramp surface and a lower ramp surface. The first tensioner component is engaged to the arm for rotation therewith and the second tensioner component is coupled to the tensioner axle. The ramp bushing is disposed between the first tensioner component and the second tensioner component such that the upper ramp surface seats within the first ramp features and the lower ramp surface seats within the second ramp features.

Abstract: A tensioner including a support structure defining a pivot axis, an arm coupled to the support structure for rotation about the pivot axis, and a damping mechanism. The arm includes a cup having the damping mechanism seated therein. The damping mechanism includes a first tensioner component that is generally cup-shaped and has first ramp features on the rim thereof, a second tensioner component having second ramp features, and a damper spring coupling the first tensioner component to the second tensioner component. The first tensioner component is rotatable with the arm and the second tensioner component is non-rotatable. The damper mechanism has the first ramp features aligned with the second ramp features and rotation of the first tensioner component in a first direction moves the first ramp features relative to the second ramp features and translates the first tensioner component into damping engagement with the arm.

Abstract: A tensioner may be part of a power system to tension an endless power transmitting element. The tensioner includes an arm having an arm arbor with a slot therethrough that is rotatable about a first axis, a bushing having a sleeve that includes a cut-out and a removable sleeve-segment that has a protrusion thereon, the sleeve-segment being receivable in the cut-out with the protrusion in the slot, and a spring coupled to the arm for rotation of the arm about the first axis into tensioning engagement with a power transmitting element. The spring is positioned where it can radially expand into contact with the protrusion of the bushing, at least the protrusion on the sleeve-segment, as the arm is rotated in a direction opposite the direction of tensioning engagement such that the bushing is urged radially outward relative to the arm arbor to provide frictional damping.

Abstract: A tensioner including a support structure defining a pivot axis, an arm coupled to the support structure for rotation about the pivot axis, and a damping mechanism. The arm includes a cup having the damping mechanism seated therein. The damping mechanism includes a first tensioner component that is generally cup-shaped and has first ramp features on the rim thereof, a second tensioner component having second ramp features, and a damper spring coupling the first tensioner component to the second tensioner component. The first tensioner component is rotatable with the arm and the second tensioner component is non-rotatable. The damper mechanism has the first ramp features aligned with the second ramp features and rotation of the first tensioner component in a first direction moves the first ramp features relative to the second ramp features and translates the first tensioner component into damping engagement with the arm.