POWER TRANSMISSION

6.1 Introduction
The rotational motion can be transmitted from one mechanical element to the other with
the help of certain systems known as transmission systems. The one that drives is called driving
system and the other which is driven is called driven system. The methods of power transmission
are:
i. Belt drive.
ii. Gear drive.
iii. Rope drive.
iv. Chain drive.
Objectives:
After studying this unit, you will able to:
Explain open difference between open and cross belt drive
Explain working of Different types of pulleys
Find out length of belt. Velocity ratio and power transmitted
Explain working of chain drive-belt drive, rope drive & gear drive
Explain different types of gears used for transmission.
Derive equations for Simple gear trains and compound gear train.
6.2 Belt Drives
It is one of the most common and effective devices of transmitting motion from one
shaft to another by means of a thin inextensible band running over two pulleys. Belt drive is
generally employed whenever rotary motion is to be transmitted between two parallel shafts.
They are generally used when the drive and driven end are far apart. The drive consists of 2
pulleys over which endless belt are passed encircling both of them. The power is transmitted
from driving pulley to driven pulley because of the frictional grip that exists between the belt
and pulley.
Belt materials of Power transmission belts are generally made from Leather. Rubber
Canvas, and are used in mills & factories. Advantage is low cost, low maintenance, and long
life. Limitations are Not a Positive Drive, less efficiency due to Slip and Creep and not suitable
for short distance.
 Fig. 6.1: Belt Drive
6.2.1 Types of Belt drives
Open Belt Drive: This type of belt drive shown in figure below is employed when the two
parallel shafts have to rotate in the same direction. When the shafts are placed fax apart, the
lower side of the belt should be the tight side and the upper side must be the slack side. This is
because, when the upper side becomes the slack side, it will sag due to its own weight and thus
increases the arc of contact which in turn increases the capacity of the drive.

Fig. 6.2: Open Belt Drive

Flat belt drives of the open system should always have their shaft axes either horizontal
or inclined. They should never be vertical, for if so arranged the centrifugal force developed in
the belt combined with the force of gravity causes the bell to stretch and tend to leave the rim of
the pulleys, thereby losing contact with their rim surfaces.
Crossed Belt Drive: This type of belt drive shown in fig. below is employed when two
parallel shafts have to rotate in the opposite direction. At the junction where the belt crosses, it
rubs against itself and wears off. To avoid excessive wear, the shafts must be placed at a
maximum distance from each other and operated at very low speeds.
 Fig. 6.3: Crossed Belt Drive
6.3 Velocity Ratio of Belt Drive
The velocity ratio of a belt drive is defined as the ratio of the speed of the driven pulley to
the speed of the driving pulley.
Velocity Ratio = N2 / N1 = d1 / d2

Velocity Ratio = [ ]=[ ]

6.4 Stepped cone pulley (Speed Cone)

Fig. 6.4: Stepped/Speed Cone Pulley

A stepped cone pulley is an Integral casting having three or more number of pulleys of
different sizes one adjacent to the other as shown in figure above. One set of stepped cone pulley
mounted in reverse on the driven shaft. An endless belt will be wrapped around one pair of
pulleys. By shifting the belt from one pair of pulleys to the other, the speed of the driven
shaft can be varied. The diameters of the driving and driven pulleys are such that the same
belt will operate when shifted on different pairs of pulleys.
 It is used when speed of the driven shaft is to be changed very frequently as in the case of
machine tools such as lathe, drilling machine etc.
6.5 Fast and loose pulley
When many machines obtain the drive from a main driving shaft, it may be required to
run some machines intermittently without having to Start and stop the main driving shaft. Fast
pulley securely keyed to the machine shaft. Loose pulley (with brass bush) Mounted freely on
the machine shaft, rotates freely. When the belt is on the fast pulley, Power transmitted to the
machine shaft, when machine shaft is to be brought to rest, Belt is shifted from fast pulley to
loose pulley.
The axial movement of the loose pulley towards the fast pulley is prevented, while axial
movement of the loose pulley away fast pulley is prevented by the collar fixed to the machine
shaft.

Fig. 6.5: Fast and Loose Pulley

6.6 Length of Belt
6.6.1 Length of Open Belt
L = length of the belt = (r1+r2) + (r1-r2)2 / X + 2X
where, r1 = Radius of the larger pulley P
r2 = Radius of the smaller pulley Q and
 X = Distance between the centers of the pulleys.

Fig. 6.6: Open Belt Drive

6.6.2 Length of Crossed Belt
L = length of the belt = (r1+r2) + (r1+r2)2 / X + 2X
where, r1 = Radius of the larger pulley P
r2 = Radius of the smaller pulley Q and
X = Distance between the centers of the pulleys.

Fig. 6.7: Crossed Belt Drive

6.7 Ratio of Tensions in belt drive

Fig. 6.8: Open Belt Drive

Ratio of Tension = =

where, T1 = tight side tension

T2 = slack side tension
= coefficient of friction
= angle of contact
6.8 Slip
The sliding motion of the belt which causes a relative motion between the pulley and the
belt.
Velocity Ratio = N2 / N1 = d1 / d2 [100-S/100]
where, S = % Slip
6.9 Creep
The phenomena of alternate stretching and contraction of the belt results in a relative
motion between the belt and the pulley surface. This relative motion is called creep.
6.10 Initial Tension in Belt
It is a uniform tension that exists initially when the drive
is not in motion. It is designated as To.
Initial Tension in Belt = To = (T1+T2) / 2
6.11 Power Transmitted in belt Drives
P = (T1 - T2) v / 1000 kW,
v = dN / 60 m/sec, T1 & T2 in Newtons.
P = (T1 - T2) v / 4500 HP,
v = dN / 60 m/min, T1 & T2 in kgf.
6.12 Chain Drives
Chain drives are positive drives there is no slip, hence the velocity ratio remains
constant. Chain drives are suitable for small centre distances and can be used generally up to
3metre but in special cases even up to 8 meter. It transmits power up to 100 kW and operating
peripheral velocities up to 15 m/sec. The velocity ratio can be as high as 8:1.
Chain drives are employed in bicycles, motor cycles, rolling mills, agricultural
machineries, machine tools, conveyors etc.
A chain drive consists of a chain and two sprockets. The sprockets are teethed wheels over
which an endless chain fitted.

Roller Chain

Driven Sprocket
Driving Sprocket
Fig. 6.9: Roller Chain
Advantages
Positive non-slip drives
Efficiency is high
Employed for small as well as large centre distances up to 8m.
Permit high velocity ratio up to 8:1
Transmit more power than belt drives
They produce less load on shafts compared to belt drives
Maintenance is low
Disadvantages
Driving and driven shafts should be in perfect alignment.
Requires good lubrication
High initial cost
6.13 Rope Drives
Used when centre distances are greater than 10m and power to be transmitted is more than
200 HP. Used in lifts, hoists etc.
6.14 Gear Drives
Gear drives find a very prominent place in mechanical power transmission. Gear drives
are preferred when considerable power has to be transmitted over a short distance positively with
a constant velocity ratio.
6.14.1 Types Gears
There are various types of gears to suit various applications. They differ in the shape of
the gear wheel like, cylindrical or conical or elliptical, the orientation of their axes and the angle
at which the teeth mesh. Gear drives transmit power between the shafts when their axes are:
i) Parallel ii) Intersecting iii) Neither parallel nor intersecting.
The different types of gears used are:
1. Spur Gears - For Parallel Axes shafts.
2. Helical Gears - For both Parallel and Non-parallel and Non-intersecting Axes shafts.
3. Spiral Gears - For Non-parallel and Non-intersecting Axes shafts.
4. Bevel Gears - For Intersecting Axes shafts.
5. Worm Gears - For Non-Parallel and Non-co-planar Axes shafts.
6. Rack and Pinion - For converting Rotary motion into linear motion.

Fig. 6.10: Different types of Gears

1. Spur Gears
When the axes of the driving and driven shafts are parallel and co-planar and the teeth of
the gear wheels are parallel to the axes, the gears are called spur gears. The contact between the
mating gears will be along a line; hence spur gears can transmit higher power. Because of the
instantaneous line contact when the teeth mesh, noise will be very high. They are widely used in
machine tools, automobile gear boxes and in all general cases of power transmission where gear
drives are preferred.

Fig. 6.11: Spur Gears

2. Helical Gears
Helical gears are similar to the spur gears except that the teeth are cut in the form of the
helix around the gear. Helical gears are used for transmitting power between two parallel shafts
and also between non parallel, non-intersecting shafts. The contact between the mating gears will
be along a curvilinear path. Helical gears are preferred to spur gears when smooth and quiet
running at higher speeds are necessary. The main disadvantage of the helical gears is that it
produces end thrusts on the driving and driven shafts. Generally they are used in automobile
power transmission.

Fig. 6.12: Helical Gears

3. Spiral Gears
Spiral gears are used to connect only two non-parallel, non-intersecting shafts. They
differ from the helical gears in that there is a point contact in spiral gears whereas a curvilinear
contact exists in helical gear drives. Because of the point contact the spiral gears are more
suitable for transmitting less power.

Fig. 13: Spiral Gears

4. Bevel gears
When the axes of the two shafts are inclined to one another, and intersect when produced
bevel gears are used. Teeth of the bevel gears are cut on the conical surfaces. The most common
examples of power transmission by bevel gears are those in which the axes of the two shafts are
at right angles to each other. When two bevel gears have their axes at right angles and are of
equal sizes, they are called miter gears.

Fig. 6.14: Bevel Gears

5. Worm and Worm Wheel
Worm gears are used to transmit power between the driving and driven shafts having
their axes at right angles and non-coplanar. A worm drive consists of a worm (essentially a
screw) which may have one or more number of helical threads of trapezoidal shape cut on it and
a worm wheel - a gear wheel with the tooth profile consisting of a small segment of a helix
which engages with the worm. Worm gears are suitable for transmission of power when a high
velocity ratio as high as 60:1 is required. They are generally employed in machine tools, like
lathe, milling, drilling machines etc. to get large speed reduction. Another important
characteristic of the worm and worm wheel drive is that it offers self-locking facility
between the driven and the driving units when the direction of the drive is reversed.

Fig. 6.15: Worm and Worm Wheel

6. Rack and Pinion
When a rotary motion is to be converted into a linear motion, rack and pinion
arrangement is used. Rack is a rectangular bar with a series of straight teeth cut on it.
Theoretically rack is considered to be a spur gear of infinite diameter. Rack and pinion
arrangement, find their application in machine tools, such as, lathe, drilling, planing machines,
and on some steep rail tracks, where the teeth of the locomotive wheel mesh with a rack
embedded in the ground, offering the locomotive improved traction.
 Fig. 6.16: Rack and Pinion
6.14.2 Advantages and Disadvantages of Gear Drives
Advantages:
1. They are positive non-slip drives.
2. Most convenient for very small centre distances.
3. By using different types of gears, it will be possible to transmit the power when the axes
of the shafts are not only parallel, but even when nonparallel, intersecting, non-
intersecting and co- planar or non-coplanar.
4. The velocity ratio will remain constant throughout.
5. They can be employed conveniently for low, medium and high power transmission.
6. Any velocity ratio as high as, even up to 60:1 can be obtained.
7. They have very high transmission efficiency.
8. Gears can be cast in a wide range of both metallic and non-metallic materials.
9. If required gears may be cast integral with the shafts.
10. Gears are employed for wide range of applications like in watches, precision measuring
instruments, machine tools, gear boxes fitted in automobiles, aero engines, etc.
Disadvantages:
1. They are not suitable for shafts of very large centre distances.
2. They always require some kind of lubrication.
3. At very high speeds noise and vibrations will be more.
4. They are not economical because of the increased cost of production of precision gears.
5. Use of large number of gear wheels in gear trains increases the weight of the machine.
6.15 Velocity Ratio of Gear drive
The velocity ratio of a gear drive is defined as the ratio of the speed of the driven gear to
the speed of the driving gear.

Velocity Ratio of a gear drive = =

where, d1 & d2 = diameter of the driver and driven respectively.

t1 & t2 = no. of teeth on the driver and driven respectively
Velocity ratio of worm and worm wheel is expressed as:

Velocity Ratio = =
6.16 Gear train
A gear train is an arrangement of number of successively meshing gear wheels through
which the power can be transmitted between the driving and driven shafts. The gear wheels used
in gear train may be spur, bevel or helical etc.
The different types of gear trains are:
1. Simple gear train.
2. Compound gear train.
3. Reverted gear train.
4. Epicyclic Gear train.
1. Simple gear train:

In a simple gear train a

series of gear wheels arc mounted
on different shafts between the
driving and driven shafts each gear
carrying only one gear. A is the
driving gear. B and C are
intermediate gears and D is the
driven gear.

Fig. 6.17: Simple Gear Train

Velocity Ratio = =

where, N & T = speed (in rpm) and no. of teeth on respective gears.
2. Compound gear train:
A compound gear train is one in which each shaft carries two or more gears and keyed to
it. Figure below represents a compound gear train in which gears Band C constitute a compound
gear.

Fig. 6.18: Compound Gear Train

Velocity Ratio = = .
where, N & T = speed (in rpm) and no. of teeth on respective gears.

Numerical
1. In an open belt drive, pulleys are 500mm and 1200mm in diameter on parallel shafts 4m
apart. The maximum tension in the belt is limited to 1800N and coefficient of friction =
0.3. The driving pulley 1200 mm diameter is running at 210 rpm, calculate power
transmitted by the belt drive.

2. A flat belt is required to transmit 35 KW from a pulley of 1.5m diameter running at 300
rpm. The angle of contact is 1600 and the coefficient of friction between the belt and the
pulley is 0.3. Determine the tight and slack side tension in the belt drive.
3. A shaft is to be driven at 480 rpm, from a driving shaft that rotates at 200 rpm, through an
open flat belt drive. The center distance of the drive is 1000 mm and the diameter of the
driving pulley is 240 mm. The coefficient of friction between the belt and the pulleys is
= 0.3. If the drive can transmit a maximum power of 3 kW without slipping of the belt
relative to the pulleys, determine the necessary belt width if the safe permissible belt
tension is 15 N per mm of belt width. Neglect any centrifugal effects.

4. A pump is driven by an electric motor through an open type flat belt drive. Determine the
belt specifications for the following data. Motor pulley diameter = 300 mm, Pump pulley
diameter = 600 mm, Coefficient of friction = 0.25. Center distance between the pulleys =
1000 mm, Rotational speed of the motor =1440 rpm, Power transmission = 20kW;
permissible tension = 10kN.

5. An open belt running over two pulleys 1.5m and 1.0m diameter connects two parallel
shafts 4.80m apart. The initial tension in the belt when stationary is 3000N, if the smaller
pulley is rotating at 600 rpm and coefficient of friction between the belt and pulley is 0.3.
Determine the power transmitted neglecting centrifugal tension into account.

6. Power transmitted between two shafts 3.5m apart by a crossed belt drive around two
pulleys 0.6m and 0.3m in diameters is 6KW. The speed of the larger pulley is 220 rpm.
The permissible load on the belt is 25M per mm width of the belt which is thick. The
coefficient of friction between the smaller pulley surface and the belt is 0.35 Determine:
i. The necessary length of the belt
ii. The width of the belt
iii. The necessary initial tension in the belt
7. Simple gear train consists of three gears. The number of teeth on the driving gear is 60
and on the idler is 40 and on the driven gear is 80. Find the velocity ratio. If the driving
gear rotates at 1200 rpm, calculate the speed of driven gear.

8. In a compound gear train of wheels, A, B, C and D have 15,30,20,40 teeth respectively.

The wheel B and C are keyed to the same shaft. If the wheel A runs at 400 rpm, find the
speed of wheel D. Sketch the arrangement if B meshes with A and C meshes with D.

9. The shaft from the motor is connected to gear A and rotates at 950 rpm. Gear B and C is
compound gear as well as D and E. Gear A meshes with gear B and gear C drives gear D.
The gear E meshes with gear F which is fixed on output shaft. Determine speed of gear F.
Number of teeth on gear A,B,C,D,E,F are 20,50,25,75,25,65 respectively. Sketch
arrangement and find the velocity ratio of the gear train.
10. A compound gear train consists of 4 gears, P, Q, R, S having 20, 40, 60 and 80 teeth
respectively. The gear P is keyed to the driving shaft, gear S to driven shaft. Q and R are
compound gears. Q meeting with P and R meshes with S. If P rotates with 150 rpm, what
is the speed of gear S.? Show the gear arrangements.

11. Five gears of 15, 20,25,30,35 are available. Show an arrangement of gears to obtain
maximum velocity ratio.

12. Two gears having teeth 20, 30 of spur gear is available along with three gears of helical
gear having 15, 20, 25 teeth. Show the gear arrangement to obtain maximum velocity
ratio.

13. There are 5 wheels having 20, 30, 40, 50 and 70 teeth with a diametral pitch of 3 and
another set of 4 wheels of diametral pitch of 2 having 20, 40, 60 and 80 teeth. Sketch an
arrangement to get maximum velocity ratio using maximum number of wheels from the
above lot. Also mention the conditions used.