MODULE 1: BELT machine

design
DRIVES two
A mechanical drive, sometimes called a power transmission, is usually used to A belt drive represents one of the
transmit power and motion from one rotational element to another. Mechanical major types of flexible drive. They
drives include belt drives, chain drives, gear drives, wormgear drives and so on. are extensively used in automotive or
They can be broadly classified as flexible and non-flexible or rigid power industrial drives to reduce a higher
transmission drives. rotational speed of one part to a lower
value over a considerable distance.
BELT DRIVES
The image shows a power transmission
system composed of a belt drive, gear drive,
and a chain drive.
The power required by the driven machine is
provided by an electric motor. Since the electric
motor usually operates at a high speed and
delivers a low torque, which is not appropriate
for the driven machine, a power transmission
system is employed. In a power transmission
system, belt drives are usually used at the first
stage from the power source. Gear reducers,
together with other drives with properly
designed speed ratios, are used between the belt
drive and the driven machine to satisfy the
speed requirement of the driven machine.
Be c a u s e o f co s t an d eff ic ie n c y, s ev e r a l t y pe s a n d s iz e s o f (a) Flat belt
b e lts a r e a v a ila bl e f o r di ff e r e n t lo a d l e v e ls . Th e r e a r e (b) V-belt
p r im a r il y f o u r ty p e s o f b e lt c o n f i g u r a ti o ns , th a t is , f la t , V- , (c) Ribbed belt
r o u n d a n d t im in g ( o r s yn c h r o no u s ) b e lt s , e a c h w ith i ts (d) Round belt
in d i vi d u al c h a r a c t e r is t ic s . (e) Timing or synchronous belt
(a) Flat belts are the simplest and least expensive type, with narrow
rectangular cross sections.They are designed to run on cylindrical
pulleys. The contact surface between the belt and pulley is the working
surface. The driving force is limited by frictional force on the working
surface. Flat belts are satisfactory at high speeds and relatively low
a) Flat belt
powers. When high powers are to be transmitted, flat belts become
overly large and cannot compete with v-belts.
( b ) V- b e l ts a r e g e n e r al ly e n d le s s , h a v in g tr a pe zo i d al cr o s s
s e c ti o ns w i th s ta n d ar d le n g th s . G r o ov ed pu l le y s , o r
s h e a v e s , a r e u se d f or V- b e lt s . Th e s h a p e o f c r o s s s e ct io n b) V-belt
c a u s e s th e V- b e lt t o w e d g e t ig h tly in to th e V- s h a p ed g r o o v e
a n d t h e tw o c o n ta c t sid e s a r e w o r k i ng s u r f ac e s .
( c ) Ri b b ed b e lt c o m b in e s a f la t b e lt w it h V- b e lts . T h e f l a t
b e lt s e c ti o n c a r r i e s lo a d s , w h il e th e V- b e lt s e c ti on p r o v id e s
g r ip o n th e sh e a v e . Rib b e d b e lt s im p r ov e l oa d c a r r y in g c) Ribbed belt
c a p a c ity a nd a v o id h ig h b e n d in g s tr es s es .
Ro u n d b e lts h a v e a c ir c u l ar c r o s s s ec tio n an d a r e lim ite d to
li g h t d u ti e s, m a in l y u s e d in m a c h in e r y f o r th e c l o th in g
in d u s tr y a n d in h o u s e h o ld a p p li a n ce s . T h e y m ay b e d) Round belt
p u r c h a s e d in v ar io u s l e n gt h s o r c u t t o le n g th a n d a r e jo in e d
e it he r b y a sta pl e , a m e ta lli c c o n n ec t o r, g lu in g o r w el d in g .
Ti m i n g or s y n ch r o n o u s b e l t s a r e e n d l e s s f l a t b e l t s w i t h a s e r i es of e v en l y
spaced teeth on the inner side of circumference, designed to engage with
mating toothed wheels or sprockets to minimize slippage.They are used for
synchronized power transmission to ensure that the driven sheave always e) Timing or
rotates at a constant speed ratio to the driving sheave. The power
transmission capacity of a timing belt is limited by the tensile strength of synchronous belt
b el t a n d t h e s h e ar s t re n g t h o f c o g s . Ti m i n g b e l t s p o s s e s s h i g h - s p e ed
characteristics of flat belts with power capacity approaching that of chains.
FLAT BELTS Formulas and exercises
BELT DRIVES
A typical belt drive consists of a driving pulley, a driven pulley and a continuous
belt. A belt is a flexible band passing around two wheels that transmits motion and
power from one to another. Wheels with a flat profile are called pulleys, while
wheels with grooves are termed sheaves. When a belt drive is used for speed
reduction, which is the usual case in industry, the small driving pulley is mounted on
the high-speed shaft while the large driven pulley is connected to the driven machine
shaft. The speed reduction will cause proportional increase of torque. Since belts are
virtually endless loops, machines must have provision to allow belt adjustment and
replacement.
An open-belt drive is used when the driven pulley is to be (1) Driving pulley
r o t a t e d i n t h e s a m e d i r e c t i o n a s t h e d r i v i n g p u l l e y. A c r o s s - b e l t
drive is adopted when the driven pulley is to be rotated in the (2) Belt
o p p o s i t e d i r e c t i o n t o t h e d r i v i n g p u l l e y. (3) Driven pulley
MATERIALS FOR
TRANSMISSION BELTS
Oak-tanned leather is the standard material for flat belts.
Chrome leather is used where very pliable material is desired.
Rubber belt is used when exposed to moisture, acids, and alkalis.
Fabric and canvas belts are used for light power transmission.
MATERIALS FOR PULLEYS
Cast iron pulleys formed from one solid casting may or may not have a split or
divided hub.
Wood pulleys are not only much lighter than cast iron pulleys but they are superior
as transmitters of power; in fact it is claimed that they will transmit from 35 to 50%
more power for the same belt tension.
Steel pulleys formed of sheet metal combine lightness with strength and they are
free from the initial stresses. The weight is ordinarily from 45 to 55% less than the
weight of the cast iron pulley of equal power transmitting capacity. A series of tests
showed data that the percentage of slip was from 2.35 to 2.70% less for steel pulleys
than for cast iron pulleys.
SAFE SPEED FOR PULLEYS
The maximum safe rim speeds for solid cast iron pulleys as a general rule is about
5000 fpm.
Steel pulleys may run at about 6000 fpm.
Wood pulleys have a recommended maximum speed at 5000 fpm and 10,000 fpm
for others of different construction.
For a pulley having a cast iron hub and arms, with a wood rim, it has been operated
under test at a rim speed of 29,000 fpm.
LENGTH AND ARC OF
CONTACT
 For open belt drive
Length of belt:

Arc of contact:

+ sign for larger pulley

Arc of contact:
LENGTH AND ARC OF
CONTACT
 L = length of belt
D1 = smaller pulley diameter
D2 = larger pulley diameter
C = center distance
R = larger pulley radius
r = smaller pulley radius
= arc of contact, rad
SPEED RATIO AND RELATION
OF SPEED AND DIAMETER
 

Where:
N1 = speed of smaller pulley
N2 = speed of larger pulley
TENSION IN BELTS
 Neglecting centrifugal tension (slow velocity)

Working stress:
TENSION IN BELTS
 Where:
F1 = tension in tight side
F2 = tension in slack side
f = coefficient of friction
= arc of contact, rad
Sw = working stress, psi
b = belt width
t = belt thickness
CENTRIFUGAL TENSION
 

Where:
Fc = centrifugal force = , lbs
= density of belt, lb/in3
V = belt velocity, ft/sec =
g = 32.2 ft/sec2
MAXIMUM STRESS IN BELT, S 1
 

Where:
S1 = max. stress in belt (usually equal to allowable stress of the belt), Mpa
S2 = min. stress in belt, MPa
Sc = centrifugal stress, Mpa
MAXIMUM STRESS IN BELT, S 1
 

Where:
= density of belt material, kg/m3
V = belt speed, m/s
f = coefficient of friction
NET BELT PULL (TANGENTIAL
FORCE ON PULLEY)
 

POWER TRANSMITTED
T = torque = F x r = (F1 – F2)r
P = power =