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Special design V-belt pulleys

Customised manufacturing for direct assembly

As a specialised iron foundry focusing on industrial drive technology, we are your expert partner for ready-to-install V-belt pulleys in special designs. We manufacture customised V-belt pulleys in accordance with DIN 2211 / DIN 2217 – in all common profiles such as SPZ, SPA, SPB or SPC – with diameters up to 2,500 mm and unit weights up to 6,000 kg.

Thanks to our flexible moulding process, we can respond to your requirements quickly, economically and without model costs. In our own foundry, we manufacture all pulleys to fit perfectly – from one-off production to small series.

As a complete manufacturer, we take care of the entire production chain – from design and casting to mechanical processing on state-of-the-art CNC machines.

On our Schenk balancing machines, we ensure that your components are perfectly balanced – on request, also on a contract basis. We also offer various surface treatments, refinements and galvanising to optimally prepare your components for use in industrial environments.

Downloads

V-Belt pulleys(1530 KB)

Accessories

Industrial belts / V-belts

Measurement

Tensioning elements

TaperLock clamping bushes

Friction-locked connections | Clamping sets

At a glance

Features

Special production according to customers individual specifications or drawings
Standard for peripheral speeds up to 42 m/s
Maximum pulley diameter 2,500 mm
Maximum pulley weight approx. 6,000 kg
Maximum drive power 1,000 kW

Flexible moulding process | Fast delivery

Individual model setups are not required – there are no model costs!
Manufactured according to DIN 2211 / DIN 2217
Change requests or adaptations can be accommodated without costs
Short term production and delivery possible

Materials

Standard: Cast iron with lamellar graphite EN-GJL-200 to EN-GJL-300 (GG-20 to GG-30), DIN EN 1561
Alternatively: Ductile iron (EN-GJS-400 to EN-GJS-800) or cast steel (GS), welded steel design or aluminium

Standard-Profiles

SPZ, SPA, SPB, SPC
XPZ, XPA, XPB, XPC
3V, 5V, 8V
20, 25, 32, 40
10 (Z), 13 (A), 17 (B), 22 (C), 32 (D), 40 (E)

Possible shaft-hub connections

Cylindrical or conical bore, with or without keyway
TaperLock bushing
Clamping set bore (for one or more clamping sets)
Ball bearing bore with ring grooves / retaining grooves

Possible designs

Arm, solid or plate pulleys
Double arm / double base pulleys
Additional stiffening ribs

Balancing standards

Standard according to DIN 21940-11 in quality grade G16
Available in quality grades G6.3 or G2.5 on request

Surface treatment

Primed / black oxide finish as standard
Individual surface treatment and special painting is also possible

V-belt pulleys for industrial applications

Further variants

V-ribbed pulleys / Poly-V pulleys

In addition to classic V-belt pulleys, we also manufacture ribbed pulleys/Poly-V pulleys (profiles H, J, K, L, M) in special designs according to individual customer specifications. They are ideal solutions for multi-track or particularly compact drive systems.

V-belt pulleys as steel/welded construction

Since drive elements made of grey cast iron, spheroidal graphite cast iron or cast steel cannot be used in some applications, we also produce drive and flywheels as steel/welded constructions. This design offers increased stability despite its lower mass and is used primarily for large drive wheels with high workloads.

Manufacturing process of a V-belt pulley

Thanks to our unique, flexible moulding technology, we are able to produce drive pulleys and other rotationally symmetrical drive elements, such as coupling bodies, flanges or bearing shells, without model costs. For this project, we manufactured a customised V-belt pulley with TaperLock mounting and accompanied the process from the technical drawing to the preparation for dispatch. The pulley, made of grey cast iron (material EN GJL 250), has a diameter of 510 mm and a rim width of 314 mm. The raw weight before mechanical production was 220 kg and the production weight is 150 kg.

Design, moulding and foundry

Design according to customer specifications, technical drawing, creation of the work plan including deadlines

Moulds without exclusive model equipment! Assembling the model with a modular system on a moulding table

Manufacturing two mould halves

Adding the moulding sand, mixing with resin and hardener

Applying mould release agent to half of the mould to optimise the casting surface of the blank

Composite and clamped mould

Filling the mould with liquid iron at a temperature of approx. 1,300 °C

Removing the casting moulds

Cast blank, already without sprues and risers, on its way to the blasting house

Blank after blasting, without any sand residue or scale adhering to it

Mechanical manufacturing

Deburring the edges in the finishing department

Pre-turning of the pulley, pre-drilling and grooving of the V-grooves

Drilling holes and cutting threads to accommodate the TaperLock bushing

V-belt pulley realigned with dial gauge and tapered bore introduced

Balancing in two planes, in accordance with quality grade G 6.3

Attaching counterweights, alternatively drilling opposite holes

Quality control, painting and preparing for shipping

Dimensional inspection of the V-belt pulley, tolerances in accordance with DIN 2211

Applying the primer with an electrostatic painting system

Application of wax, corrosion protection for machined surfaces

V-belt pulley sealed in shrink wrap – ready for transport

Why Lütgert?

Flexible moulding process without individual models and without model cost

Special designs according to individual customer specifications or drawings

Pulley geometry optimally adapted to the respective drive situation

Individual design, control, recalculation and optimization of your drive

Customised processing (drilling, grooving, surface) acc. to customer specifications

Ideal for prototypes, as well as individual or series parts

Full transparency through creation of released drawings

Documentation of residual imbalances and surface treatments

Documentation to prove material properties, balancing grades and surface treatments

Extensive stock and short-term availability of urgent spare parts

Frequently Asked Questions (FAQ)

Can a V-belt pulley be manufactured to a drawing or sample?

Yes. Every V-belt pulley can be manufactured exactly to the customer’s drawings, CAD data or a sample part. Design engineers benefit from technical support in designing the component geometry to suit the manufacturing process and optimising it.

What materials are used to manufacture a custom-made V-belt pulley?

The focus is on high-quality grey cast iron materials with lamellar graphite, ranging from EN-GJL-200 to EN-GJL-300 (GG-20 to GG-30). A V-belt pulley made of grey cast iron offers excellent damping properties, high dimensional stability and a long service life. Depending on the application, however, other material variants such as ductile iron (EN-GJS-400 to EN-GJS-800) or cast steel (GS), welded steel or aluminium are also available.

What standards and groove profiles can be used with a V-belt pulley?

We manufacture V-belt pulleys in accordance with common standards such as DIN 2211 and ISO profiles. A V-belt pulley can be manufactured to accommodate the common narrow V-belt profiles SPZ, SPA, SPB or SPC, the classic profiles 20, 25, 32 (D), 40 (E), the American standard 3V, 5V and 8V, as well as with V-ribbed profiles PH, PJ, PK, PL or PM, and other special profiles.

What special designs are available for V-belt pulleys?

Our custom V-belt pulleys are manufactured to individual customer drawings or technical specifications. This allows for custom diameters, special groove profiles and increased rim widths, amongst other features. Reinforced versions are available for applications involving shock loads, such as in the crushing or recycling sectors.

In addition, we offer alternative hub shapes, customised shaft-hub connections, and bespoke bore and fit designs. Optionally, the pulleys can be designed with cast-on flyweights or as V-belt flywheels. Dynamically balanced variants up to balance class G2.5 are also available.

In addition, special machining or coatings can be provided according to customer requirements.

Is there a design fee for a custom-made V-belt pulley?

As a rule, there are no moulding costs. An optimised production concept, combined with a modular system, enables the flexible moulding of almost all rotationally symmetrical contours without the need to produce moulds. This approach has proven particularly effective for spare parts required urgently: we do not have to wait for a mould maker, nor do we have to pay them. This means we can produce parts quickly and cost-effectively. The use of round moulding boxes reduces the amount of moulding sand required, which also has economic benefits. To achieve the best possible result, each mould assembly is individually created by qualified staff using hand moulding techniques. Of course, moulding can also be carried out using traditional hand moulding models.

Is a V-belt pulley also available fully machined and ready for installation?

Yes, as a foundry specialist in belt drives, we supply all V-belt pulleys fully machined and ready for installation, in accordance with your specifications or requirements. Balancing and surface coating are carried out in-house. On request, we can also pre-assemble tensioning kits or Taper-Lock bushings.