Greasable idler pulley and related kit and method

Greasable idler pulleys and related kits and methods are disclosed. The greasable idler pulley has a rotating body, a bearing, to enable the rotating body to rotate with respect to a shaft, and grease fitting defined through the rotating body. The rotating body may have a bearing seal cap having an orifice and a rotator. The grease fitting may be in fluid communication with the bearing through the orifice in the bearing seal cap. Kits are also contemplated, such as a kit for retrofitting a non-regreasable idler pulley including a rotator to a regreasable idler pulley. Methods may include methods of producing a regreasable idler pulley from a non-regreasable idler pulley.

FIELD

The disclosure generally relates to an idler pulley, and in particular to a greasable idler pulley and related kit and method.

BACKGROUND

An idler pulley, also sometimes referred to as a guide pulley, is an apparatus that rotates with respect to a shaft and presses against a belt or chain to guide or tighten it.

Virtually all machines using idler pulleys employ idler pulleys with a bearing that is not regreasable (hereinafter a “non-regreasable idler pulley”). That is to say, once the non-regreasable idler pulley is assembled no additional grease can be added to its bearing.

Advantages of the non-regreasable idler pulley include the fact that they have seals which prevent dust from getting into the bearings and that they are relatively easy to maintain, that is to say, no greasing is required to be added with a non-regreasable idler pulley. But this is useful only up to the point where the bearing fails. Bearing failure in non-regreasable idler pulleys can result, for example, from the breakdown of the grease in the bearing, and requires that the entire non-regreasable idler pulley be replaced with a new one. This can be very costly in most instances in loss or downtime and mechanical repair expenses.

SUMMARY

According to one aspect of the disclosure there is provided an idler pulley, comprising: a rotating body comprising: a bearing seal cap having an orifice; and a rotator; a bearing to enable the rotating body to rotate with respect to a shaft; and a grease fitting defined through the rotating body and in fluid communication with the bearing through the orifice in the bearing seal cap. The rotator may be pulley and/or a sprocket.

The bearing may comprise an inner race, and the bearing seal cap may be adapted to seal against both the shaft and the inner race. In an aspect, the bearing seal cap is biased against the shaft by a spring retainer.

The rotating body may include a bearing cover. The bearing seal cap may be disposed between the bearing cover and the bearing, and the bearing may be disposed between the bearing seal cap and the rotator. In an aspect, the grease fitting is further defined through the bearing cover. In an aspect, the bearing cover is coupled to the rotator with a quick change fastener. The bearing cover may be integral with the rotator.

According to an aspect of the disclosure, the grease fitting may be radially displaced from an axis of rotation of the rotating body.

According to another aspect of the disclosure, there is provided a kit for retrofitting a non-regreasable idler pulley comprising a rotator to a regreasable idler pulley, the kit comprising: an unsealed bearing; a bearing cap having an orifice; a fastener to secure the bearing cap to the unsealed bearing; and a grease fitting adapted to be defined through a rotating body comprising the bearing cap and the rotator, the grease fitting adapted to be in fluid communication with the unsealed bearing.

According to an aspect, the unsealed bearing comprises an inner race, and the bearing seal cap is adapted to seal against both a shaft and the inner race. The kit may further comprise a bearing cover. According to an aspect where the kit comprises a bearing cover, the bearing seal cap may be adapted to be disposed between the bearing cover and the unsealed bearing, and the unsealed bearing may be adapted to be disposed between the bearing seal cap and the rotator.

According to another aspect of the disclosure there is provided a method of producing a regreasable idler pulley from a non-regreasable idler pulley, comprising the steps of: providing the non-regreasable idler pulley comprising a rotator and a sealed bearing; replacing the sealed bearing with an unsealed bearing; fixing a bearing seal cap having an orifice to the unsealed bearing; and aligning the orifice with a grease fitting defined through a rotating body comprising the bearing seal cap and the rotator.

The method may further include sealing the bearing seal cap against the bearing. In an aspect, the method includes sealing the bearing seal cap against the shaft. In another aspect, the method includes fixing a bearing cover against the bearing seal cap. The bearing cover may be sealed against the bearing seal cap, in an aspect.

Other aspects and features of embodiments of the present disclosure will become apparent to those ordinarily skilled in the art upon review of the following description.

DETAILED DESCRIPTION

During manufacture of the non-regreasable idler pulley, grease is added to its bearing and the bearing is sealed by a neoprene or steel cover installed by the bearing manufacturer.

Grease is used in idler pulleys to lubricate the bearing, keeping its wear to a minimum when in use. During an idler pulley's use the grease slowly breaks down, resulting in less lubrication of the bearing and increased wear.

Many non-regreasable idler pulleys have the potential for a very limited lifespan depending on the application and operating conditions. The lifespan of these pulleys is due, in part, to the temperature and load conditions the idler pulley is exposed to in addition to the amount and quality of the grease added by the manufacturer.

With non-regreasable idler pulleys, the customer is reliant upon the manufacturer to ensure a sufficient amount of high quality grease is used. The inventors have found that some non-regreasable idler pulleys, even when newly sold, have insufficient and/or improper grease. Furthermore, when the grease in the non-regreasable idler pulley breaks down or effectively wears out the owner/operator of the equipment must replace the entire idler pulley with a new idler pulley, resulting in a cost of loss of machine operation time and the added expense to the owner/operator. In some cases replacing the entire non-regreasable idler pulley is also a waste of good materials as parts of the idler pulley are still useable. In addition, some operators would rather have the option to be able to grease idler pulleys rather than to have to wait until a non-regreasable idler pulley fails.

The greasable idler pulleys described herein allow the owner/operator to maintain the idler pulley by greasing the bearing on a regular basis, for example, by following a regular maintenance schedule. The amount of re-greasing may be determined by the owner/operator, taking into account such things as operating parameters, hours of use and environmental factors. In this way, the owner/operator does not need to trust that the manufacturer has added sufficient, high quality grease. The new greasable idler pulleys described herein have been tested and found to exceed the service lives of non-greasable idlers by adding a few shots of high quality grease for every 300 hours of idler pulley operation.

In embodiments, the greasable idler pulley described herein is provided with a bearing cover. Removing the bearing cover facilitates quick and easy replacement of the bearing if, for example, the bearing fails due to insufficient greasing and/or using an improper type of grease.

In some embodiments, the greasable idler pulleys described herein are designed in a compact manner to fit into tight applications.

Now, turning to the drawings, it should be appreciated that the drawings are intended solely for illustrative purposes, and that the present invention is in no way limited to the particular example embodiments explicitly shown in the drawings and described herein.

An embodiment will now be described with reference toFIGS. 1-3. Other embodiments will be described with reference toFIGS. 4-14.

FIG. 1is a perspective view of an idler pulley100according to an embodiment,FIG. 2is a perspective, cross section view of the idler pulley shown inFIG. 1, along a line2-2shown inFIG. 1andFIG. 3is an exploded view of the idler pulley100.

InFIGS. 1-3, the idler pulley100generally has a bearing102, a bearing seal cap104, a bearing cover106and a rotator108. The bearing102is disposed inside the rotator108and has an inner race102b, cylindrical rollers102aand an outer race102c. As shown inFIG. 2, the bearing102contacts the rotator108.

The bearing seal cap104, the bearing cover106, and the rotator108together form a rotating body106a. Other components, such as the outer race102c, may rotate with the rotating body106a, as described in further detail below. In this way, the rotating body may be thought of as one or more principle components of the idler pulley, apart from the bearing, that may rotate together about a shaft (not shown).

As shown inFIG. 2, the bearing cover106has a receiving portion, tab, orifice or angled channel107, which will hereinafter be referred to as the receiving portion107for clarity, passing from a top of the bearing cover106to a bottom of the bearing cover106. An axis parallel to the receiving portion107is slanted, angled or off-axis relative to an axis of rotation118of the rotating body106a. The receiving portion107receives a grease fitting110.

The bearing cover106is fixed to the rotator108with a quick change fastener. InFIGS. 1-3the quick change fastener is shown as bolts112. The bolts112extend into the rotator108and are anchored into threads (not shown) in the rotator108. While multiple bolts112are shown, more or fewer bolts are contemplated in embodiments. In some embodiments, no bolts are used and/or no quick change fastener is provided.

If, for example, the bearing102of the idler pulley100fails due to insufficient greasing and/or use of an improper type of grease, the bolts112may be removed from the idler pulley100to allow a user access to, amongst other components, the bearing seal cap104. Subsequently removing the bearing seal cap104allows access to a bearing space104cof the idler pulley100such that the bearing102may be repaired and/or replaced. The bolts112therefore facilitate replacement of the bearing102if, for example, the bearing102fails.

InFIGS. 1-3, the bearing seal cap104is disposed between the bearing cover106and the bearing102. The bearing cover106thereby retains the bearing seal cap104. The bearing102, in turn, is disposed between the bearing seal cap104and the rotator108. The bearing seal cap104thereby retains the bearing102. In this way the bearing cover106holds the bearing seal cap104in place adjacent to the bearing102.

As shown inFIG. 2, a seal114is disposed between the bearing cover106and the rotator108, and a seal116is disposed between the bearing102and the rotator108. The seal116may additionally be disposed between the shaft or a spacer, for example, and the rotator108, when the shaft or the spacer extends at least partially through the idler pulley100. A seal may also be formed at an interface104dsuch that the bearing seal cap104seals against the inner race102b. The seal at the interface104dmay be formed by an interference fit, for example, between the bearing seal cap104and the inner race102b(seeFIG. 3).

Additional or other seals may be provided in addition to or in lieu of those shown inFIGS. 2 and 3. For example, a second seal may be disposed between the bearing102and the rotator108, such as for example in a recess108a, or the bearing102may seal against the rotator108directly by an interference fit. A seal may also be disposed between the bearing seal cap104and the bearing cover106, or this seal may be effected by an interference fit between the bearing seal cap104and the bearing cover106.

To aid in sealing, a retaining means, such as a spring retainer104eas shown inFIG. 2, may be placed in a recess104bof the bearing seal cap104to bias the bearing seal cap104against the shaft. While the recess104band the spring retainer104eare only labelled on one, respective side of the bearing seal cap104for clarity, it is to be understood that in the embodiment shown inFIGS. 1-3both of the recess104band the spring retainer104eextend annularly around the bearing seal cap104.

Turning now to the bearing102, the outer race102cof the bearing102is coupled to the rotator108and the inner race102bof the bearing102is coupled to the shaft. The cylindrical rollers102aare disposed between the inner race102band the outer race102csuch that the inner race102band the outer race102cmay rotate with respect to each other. The bearing102thereby enables the rotator108, and other components of the idler pulley100such as the bearing seal cap104and the bearing cover106, to rotate with respect to the shaft. In an embodiment, the bearing102may be coupled to the shaft and to the rotator108by a friction fit. Other means of coupling the bearing102to the shaft and to the rotator108are also contemplated, such as by using a spline.

The rotator108ofFIGS. 1-3is adapted to be coupled to a belt, chain or other torque-transferring means. When the rotator108rotates with respect to or about the shaft, the bearing cover106and the bearing seal cap104, amongst other elements, rotate with the rotator108. The shaft is rotationally decoupled from the rotator108, and therefore need not rotate with the rotator108.

The grease fitting110allows grease to be provided to the bearing102. The grease fitting110is defined through or received by the rotating body106a. As shown inFIG. 2, the grease fitting110is defined through the bearing cover106. The grease fitting110has two portions,110aand110b, as shown inFIG. 2. Portion110aextends at substantially a 45° angle relative to the axis of rotation118of the rotating body106a, and portion110bextends substantially parallel to the axis of rotation118of the rotating body106a.

The grease fitting110is in fluid communication with the bearing102through an orifice104ain the bearing seal cap104. The orifice104ais perhaps best seen inFIG. 3. In preferred embodiments, the grease fitting110reversibly seals the bearing102by means of a one-way valve (not shown). InFIGS. 1-3the grease fitting110is radially displaced from the axis of rotation118of the rotating body106a.

To add grease to the bearing102, a grease injector (not shown) may be coupled to the grease fitting110. Grease is then communicated through the grease fitting110into the receiving portion107of the bearing cover106and subsequently through the orifice104ainto the space104cadjacent to the bearing102. By pressure or other means the grease in the space104cis communicated into the cylindrical rollers102aof the bearing102.

The bearing102and the space104care in fluid communication with each other, and may be sealed with a variety of seals to prevent loss of grease from the idler pulley100.

The seals114and116, the seal formed at the intersection104dand the grease fitting110, amongst other features, may cooperate to seal the bearing102and the space104c, such that when grease is provided through the grease fitting110it is retained in or near the bearing102.

A seal may also be formed at a band105on the bearing seal cap104between the bearing seal cap104and the shaft. The seal at the band105may be integral with the bearing seal cap104, and therefore rotate with respect to the shaft. In another embodiment, the seal at the band105may be rotationally fixed to the shaft and rotate with respect to the bearing seal cap104. The combination of the seal formed at the band105and the seal formed at the interface104dallow the bearing seal cap104to seal against both the shaft and the inner race102of the bearing.

The seals described herein may substantially and/or completely seal the bearing102from the outside environment. However, each of the seals described herein are optional, and only partial sealing may be effective depending on the desired application.

For example, in an embodiment where the idler pulley100is used in the orientation shown inFIG. 2, partial sealing may be sufficient to retain grease in or near the bearing102. In both embodiments where a substantial or a complete sealing of the bearing102is effected, the idler pulley100may be referred to a sealed and greasable idler pulley.

The bearing seal cap104, the bearing cover106and the rotator108may be made of any material that is sufficiently rigid, for example, stainless steel or plastic. The bearing102may be any mechanical bearing that is designed to contain grease. In one embodiment, the bearing102could be a spherical roller bearing. InFIG. 1the rotator108is a single pulley, although other rotators are contemplated in embodiments, such as a plurality of pulleys or one or more sprockets.

The bearing seal cap104, the bearing cover106and the rotator108are shown as distinct pieces inFIGS. 1-3, however, any two or more of the bearing seal cap104, the bearing cover106, and/or the rotator108may be formed as a single, integral piece. For example, as shown inFIGS. 4 and 5and discussed below, a bearing cover may be integral with a rotator. In an embodiment, the outer race102cmay be formed integral with the rotating body106a.

The seals114and116may be made of any material sufficiently pliable and durable to create a seal. For example, plastic O-rings may be used for the seals114and116.

The grease fitting110can be any grease fitting that allows grease to be conducted from the grease injector through to the orifice104a, for example, a grease zerk or grease nipple can be used. While the grease fitting110is shown having two portions,110aand110b, the grease fitting110may have only one portion. In an embodiment, the grease fitting110may have only one portion extending at substantially a 45° angle relative to the axis of rotation118of the rotating body106a. In another embodiment, the grease fitting100may have only one portion extending substantially parallel to the axis of rotation118of the rotating body106a.

Turning now toFIGS. 4 and 5,FIG. 4is a perspective view of an idler pulley400according to a second embodiment, andFIG. 5is an exploded view of the idler pulley400ofFIG. 4.

As is perhaps most clearly shown inFIG. 5, the idler pulley400generally has a first component402, a second component404, a bearing seal cap410and a bearing412. The first component402and the second component404together form a rotator416. A grease fitting406is defined through or received by the second component404. The first component402, the second component404and the bearing seal cap410are collectively a rotating body414.

Both the first component402and the second component404have multiple, corresponding through holes408. The through holes408allow the first component402to be secured against the second component404, for example, using a quick change fastener such as bolts or rivets (not shown) through one or more of the through holes408. Other means to fasten the first component402to the second component404are also contemplated, for example, by using a snap fitting. While not labelled as such, the rotating body414may comprise a bearing cover integral with the rotator416.

The idler pulley400may be formed by securing the second component404to the first component402with the bearing seal cap410and the bearing412placed therebetween. The rotating body414, and other components, may then rotate with respect to a shaft (not shown) by virtue of the bearing412.

The bearing412, the bearing seal cap410and the grease fitting406are made of similar materials and function in a similar manner to the bearing102, the bearing seal cap104and the grease fitting110ofFIGS. 1-3, respectively. For example, the bearing412is greasable by the grease fitting406defined through or received by the second component404and in fluid communication with the bearing412through an orifice410ain the bearing seal cap410. The grease fitting406could, instead of the form depicted inFIGS. 4-5, have a similar geometry to the grease fitting110.

While no seals are shown inFIGS. 4 and 5, sealing to prevent grease from being communicated from the idler pulley400to the outside environment may be effected via one or more seals (not shown) provided between the various components, and may be similar to the sealing described with respect toFIGS. 1-3, above.

Any two or more of the bearing seal cap410, the bearing412and the second component404may be formed integrally. Any two or more of the bearing seal cap410, the bearing412and the first component402may be formed integrally as a single component.

Turning now toFIGS. 6 and 7,FIG. 6is a perspective view of an idler pulley600according to a third embodiment andFIG. 7is an exploded view of the idler pulley600ofFIG. 6.

As shown inFIG. 7, the idler pulley600generally has a rotator602, a bearing606, a bearing seal cap608and a bearing cover612. In this embodiment, the rotator602, the bearing seal cap608and the bearing cover612are collectively a rotating body618. InFIGS. 6 and 7the rotator602is a sprocket.

As shown inFIG. 7, the bearing cover612is secured to the rotator602with a snap ring616that engages a shoulder602dof the rotator602when the idler pulley600is assembled. The rotator602is also provided with one or more recesses602cto each receive a respective protrusion612aof the bearing cover612. In the embodiment shown inFIGS. 6 and 7there are two recesses602con the rotator602and two protrusions612aon the bearing seal cap612, although only one recess602cand one protrusion612acan be seen inFIG. 7. The mating between the recesses602cand the protrusions612aresists rotation between the bearing seal cap612and the rotator602.

The bearing606enables the rotating body618, amongst other elements, to rotate with respect to a shaft (not shown), and a grease fitting614provided in the bearing cover612allows grease to be communicated to the bearing606through an orifice608ain the bearing seal cap608, in a manner analogous to how grease is communicated to the bearing102through the grease fitting110, the orifice104aand into the bearing102.

In an assembled state of the idler pulley600, a seal604rests in a groove602aof the rotator602to seal the bearing606against the shaft, and a seal610rests in a groove602bof the rotator602to seal the bearing cover612against the rotator602.

The rotator602, the bearing606, the bearing seal cap608the grease fitting614and the bearing cover612, function similar to, may be made of similar materials and have similar variants as the rotator108, the bearing102, the bearing seal cap104, the grease fitting110and the bearing cover106, respectively, ofFIGS. 1-3. The seals604,610may be made of similar materials and functions similarly to the seals116,114ofFIGS. 1-3. The snap ring616may be made of metal.

Other seals may be provided in addition to or in lieu of those shown inFIG. 7. In certain embodiments, one or more of the seals604,610may be omitted.

Turning now toFIGS. 8-10,FIG. 8is a perspective view of an idler pulley800according to a fourth embodiment,FIG. 9is an exploded view of the idler pulley800ofFIG. 8, andFIG. 10is a cross section of the idler pulley800ofFIG. 8, along a line10-10shown inFIG. 8.

With reference toFIG. 9, the idler pulley800has, among other components, a rotator802, a bearing cover814, a first bearing seal cap808, a bearing810and a second bearing seal cap812. In the embodiment shown inFIGS. 8-10, a rotating body820includes the rotator802, the bearing cover814, the first bearing seal cap808and the second bearing seal cap812.

As described above with respect to the bearing102ofFIGS. 1-3, the bearing810enables the rotating body820to rotate with respect to a shaft (not shown).

However, the idler pulley800differs, in part, from the idler pulley100in that two bearing seal caps are provided, namely, the first bearing seal808and the second bearing seal812. Further, a grease fitting818, defined through or received by the rotator802, allows the bearing810to be greased by communicating grease from the grease fitting818to the bearing810through an orifice808ain the first bearing seal cap808.

Other differences between the embodiment shown inFIGS. 8-10and the embodiment shown inFIGS. 1-3include that the grease fitting818inFIG. 9is shown with an orientation similar to the grease fitting406shown inFIGS. 4 and 5. One orifice808ais shown inFIG. 9, which is in alignment with the grease fitting818. However, in another embodiment, more than one orifice may be provided and one of these orifices may be in alignment with the grease fitting818.

A second bearing seal cap812is provided on the other end of the bearing810to seal the bearing810. In another embodiment, instead of a second bearing seal cap812the bearing810may be sealed on one side as in a conventional sealed bearing, with a bottom plate. In a further embodiment, the bearing810may seal against the bearing cover814by one or more seals or may alternatively or additionally seal directly against the bearing cover814.

As shown most clearly inFIG. 10, a seal804is provided to seal between the bearing810and the rotator802. A seal806is provided to aid in sealing the bearing810.

Similar to the embodiment described inFIGS. 6 and 7, the bearing cover814includes two protrusions814ato mate with corresponding recesses (not shown) on the rotator802. The mating between the protrusions814aand the corresponding recesses is similar to and provides similar function as the mating between the protrusions612aand the recesses602c. A snap ring816is provided to retain the bearing cover814against the rotator802, and functions similarly to and is made of similar materials as the snap ring616described herein. The seals804,806may be made of similar materials to the seals114,116as described above in relation toFIGS. 1-3.

Turning now toFIGS. 11-13,FIG. 11is a perspective, view of an idler pulley1100according to a fifth embodiment showing a spacer1124and a bolt1122adjacent thereto.FIG. 12is a perspective, cross section view of the idler pulley1100shown inFIG. 11, along a line12-12shown inFIG. 11.FIG. 13is a cross section view of the idler pulley1100ofFIG. 11, along the line12-12shown inFIG. 11, with the bolt1122and the spacer1124ofFIG. 11assembled thereto.

With reference toFIG. 12, the idler pulley1100is similar to the idler pulley100described herein and includes many shared features. For example, the idler pulley1100generally has a bearing1102, a bearing seal cap1104, a bearing cover1106and a rotator1108. In the embodiment shown inFIGS. 11-13, the bearing seal cap1104, the bearing cover1106, and the rotator1108together form a rotating body1106a.

The bearing1102is disposed inside the rotator1108and has an inner race1102b, cylindrical rollers1102aand an outer race1102c. For clarity, some of the features that are shared between the idler pulley100and the idler pulley1100are not labelled in the drawings or described herein.

The difference between the idler pulley100and the idler pulley1100is that the idler pulley1100has a face1102don the bearing1102that extends radially inward from the bearing seal cap1104. As shown inFIG. 12, the face1102dis orthogonal to an axis of rotation of the idler pulley1100and is exposed to the environment outside the idler pulley1100.

Now, referring toFIG. 13, in this embodiment in an assembled state the bolt1122passes through the idler pulley1100and engages with the spacer1124. The engagement between the bolt1122and the spacer1124may be a threaded connection, for example, but could also be an interference fit. In the embodiment ofFIG. 13, the bolt1122is rotationally decoupled from the spacer1124such that the bolt1122may rotate independently of the spacer1124.

As shown inFIG. 13, a shoulder1122aon the bolt1122abuts or rests against the face1102dof the bearing1102. This may prevent the bolt1122from moving axially relative to the idler pulley1100at least in a first direction. The spacer1124abuts or rests against the bearing1102. In the embodiment where the spacer1124is coupled to the bolt1122, the spacer1124resists the bolt1122moving axially relative to the idler pulley1100at least in a second direction.

A seal may be formed between the bolt1122and the bearing seal cap1104, such as at a band1115. A seal may also be formed, for example, by the seal1116between the spacer1124and the rotator1108to help seal the bearing1102from the outside environment.

Turning now toFIG. 14,FIG. 14is a flow chart of a method1400according to one embodiment. The method1400is a method of producing a regreasable idler pulley from a non-regreasable idler pulley.

According toFIG. 14, the method1400includes, at1402, providing a non-regreasable idler pulley comprising a rotator and a sealed bearing. The non-regreasable idler pulley may be an idler pulley described herein. The rotator may be one or more pulleys or sprockets, for example.

The method1400further includes, at1404, replacing the sealed bearing with an unsealed bearing. Replacing the sealed bearing may involve, for example, disengaging a fastening means, such as screw, to free the sealed bearing from the rotator of the non-regreasable idler pulley. In the embodiment where the non-regreasable idler pulley is a sealed, non-regreasable idler pulley, replacing the sealed bearing may involve breaking a seal between the rotator and the sealed bearing. The unsealed bearing may be a bearing such as the bearing102described herein. In an embodiment, the unsealed bearing may be a bearing that has had its bearing cover plate removed.

At the next step,1406, the method1400further includes fixing a bearing seal cap having an orifice to the unsealed bearing. In an embodiment, fixing the bearing seal cap to the unsealed bearing may involve engaging a fastening means that connects and/or secures the bearing seal cap to the unsealed bearing. In another embodiment, fixing the bearing seal cap could involve placing, connecting or otherwise securing the bearing seal cap to the rotator, thereby fixing the bearing seal cap to the unsealed bearing in the rotator. For example, a snap fitting, such as the snap ring616described herein, could be used to fix the bearing seal cap to the unsealed bearing.

At the final step shown inFIG. 14, 1408, the method1400additionally includes aligning the orifice with a grease fitting defined through a rotating body comprising the bearing seal cap and the rotator. Aligning the orifice of the bearing seal cap with the grease fitting defined through the rotating body allows grease to be communicated from the grease fitting to the bearing to allow the unsealed bearing to be greased.

While not shown inFIG. 14, the method1400may further include sealing the bearing seal cap against the bearing and/or sealing the bearing seal cap against the shaft. In an embodiment, the method1400may include fixing a bearing cover against the bearing seal cap. In embodiments where the bearing cover is provided, the method1400may include sealing the bearing cover against the bearing seal cap. The sealing may be accomplished using any of the seals described herein in addition to further/other seals. The seals may also be integrally formed on parts of the idler pulley, for example.

The provision of components as shown inFIG. 14need not necessarily involve manufacturing those components. For example, components could be sourced from a manufacturer and need not necessarily be manufactured by the same entity that actually builds idler pulley disclosed herein. Component manufacturing and assembly could thus be performed by separate entities, in which case a manufacturer “provides” system components by manufacturing them, and an assembler “provides” the components by purchasing them from a manufacturer or distributor.

Kits are also contemplated. For example, a kit for assembling the idler pulley may include a rotating body, a bearing and grease fitting defined through the rotating body. In an embodiment, the bearing is the bearing100and the rotating body is the rotating body106a, and the bearing and the rotating body of the kit have similar characteristics to and are made of similar materials as the bearing100and the rotating body106adescribed herein. In another embodiment, the bearing and the rotating body of the kit may be another bearing and another rotating body described herein.

In another embodiment, a kit may be for retrofitting a non-regreasable idler pulley including a rotator to a regreasable idler pulley, the kit including: an unsealed bearing; a bearing cap having an orifice; a fastener; and a grease fitting. The fastener may be to secure the bearing cap to the unsealed bearing. The grease fitting may be adapted to be defined through a rotating body comprising the bearing cap and the rotator. The grease fitting may also be adapted to be in fluid communication with the unsealed bearing.

In this embodiment, the non-regreasable idler pulley may be a non-regreasable idler pulley described herein. The rotator may be the rotator108and the unsealed bearing may be the bearing102. The bearing cap may be the bearing cap104, the fastener may be the bolts112, and the grease fitting may be the grease fitting110. The components of this kit may have similar features to the components described herein. In another embodiment, the components of this kit may be other components, such as those described in other embodiments herein.

Numbers and types of components shown in the drawings and described herein are also intended for illustrative purposes. Other types and/or numbers of components could be used in other embodiments.