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A stepped pulley system consists of two to four pulleys that can change operating speeds by changing the belt to a different pulley size. They can be cast or forged from billet material and can use V-belts or flat belts. Adjusting the speed is easy by opening the belt cover and changing the pulley system.
A stepped pulley is a system of pulleys made up of many different sizes. The typical stepped pulley consists of a configuration of two to four pulleys. This type of stepped pulley is found on equipment such as a drill press where different operating speeds can be produced simply by changing the belt to a different pulley size. The stepped pulley is always operated in pairs, and when the belt is changed on one pulley, it is also changed on the corresponding pulley on the other side of the belt.
Most stepped pulley assemblies are cast from liquid materials; However some of the very high quality pulleys are forged from solid billet material such as aluminum or steel. The billet pulley is much truer to turn than a cast version; However, there is a big cost difference between the two, as the ticket costs much more. Some designs use separate, independent pulleys to make the arrangement, although this is not a true stepped pulley.
While most stepper assemblies are configured for the use of V-belts, there are also some stepper pulleys that use flat belts. This type of stepping system can be changed or changed on the fly and is found on lathe drives or some milling machines. Flat belt pulleys are generally always forged from billet material and run much smoother than the V-belt design. However, the V-belt type of pulley is favored in higher torque applications, due to the ability of a V-belt to grip the pulley more tightly.
When it has been determined that the speed must be regulated on a machine equipped with a particular step pulley, the speed adjustment process is usually easy. With the engine in the off position, open the belt cover. Take note of the actual location of the belt on the pulleys. Remember, a large pulley driving a smaller pulley will result in more power but less output velocity. Conversely, a small pulley driving a large pulley will have more output velocity but less power.
Once the proper pulley system for the desired result has been determined, the belt cover can be closed and the machine can be turned on again. Now the machine can run at the proper speed to get the desired effect. Sanding projects, for example, are generally done at a faster speed than a cutting or shaping project. On a typical wood lathe project, the pulleys may be changed several times.
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