A new plastic pulley (inset), among the first of its kind in the world
and a cost-effective alternative to its cast aluminium counterpart, is
now being used across the full range of Hotpoint washing machines, which
are designed and manufactured by Merloni Elettrodomestici. The injection
moulded pulley, made of glass-reinforced Zytel nylon resin from DuPont,
offers lower part costs compared with cast aluminium without any
compromise to mechanical performance. The part was designed, analysed and
is currently being manufactured by Manchester-based Rolinx Plastics.
Some of the design constraints included the need to maintain the same
dimensions as the metal counterpart, and to produce a centre boss section
capable of withstanding a compressive force of 105N and a belt tension in
excess of 300N - all at an operating temperature of 70°C and above.
Finite element and injection mould flow analyses were used in the early
stages of the design, these data being later confirmed by vigorous
prototype testing carried out by Merloni UK.
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DuPont - Online Enquiry number 340
Online Enquiry number 340