140 Analysis and Design of Machine Elements

Steps Computation Results Units

6. Confirm initial From Eq. (6.30)

P
( )
tension, F 0 2.5
F0 = 500 ca − 1 + qv2
zv Ka
8.25 2.5
( )
= 500 × − 1 + 0.105 × 7.592 = 139 N
7 × 7.59 0.92
F 0 = 139 N
7. Compute the force From Eq. (6.31)
acting on the sheave ∘
𝛼1 150.9
shaft, F Q FQ = 2zF 0 sin = 2 × 7 × 139 × sin = 1884 N
2 2
F Q = 1884 N
Select solid sheave
8. Structural design D1 = 100 mm for driving sheave,
of V-belt sheaves and spoke sheave
D2 = 355 mm for driven sheave

6.5 Installation and Maintenance

At installation, the two sheaves are first moved closer to facilitate belt assembly. The cen-
tre distance is then increased to a designed value to generate initial tension in the belt.
A proper amount of initial tension must be well maintained. An excessive initial tension
shortens belt life and overloads bearings and shafts, while insufficient initial tension may
cause slippage and generate heat and wear, which may also reduce belt life. Besides, belts
stretch permanently and loose initial tension after a period of service. Therefore, a belt
drive must have provisions to allow for belt adjustment and replacement.
When the centre distance of a belt drive is fixed, a grooved idler is preferably used
on the inside of slack strand close to the large sheave to take up slack (Figure 6.13).
If the centre distance is adjustable, belt tension can be maintained by regular manual
tensioning or by the weight of pivoted, overhung motor [9]. Manufacturers’ catalogues
and design handbooks give details for proper belt-tensioning procedures.

Figure 6.13 Belt tensioning by an idler pulley.

 Belt Drives 141

References
1 Mott, R.L. (2003). Machine Elements in Mechanical Design, 4e. Prentice Hall.
2 Collins, J.A. (2002). Mechanical Design of Machine Elements and Machines: A Failure
Prevention Perspective, 1e. New York: Wiley.
3 Hindhede, U., Zimmerman, J.R., Hopkins, R.B. et al. (1983). Machine Design Funda-
mentals: A Practical Approach. New York: Wiley.
4 GB/T13575.1-2008 (1995). Classical and Narrow V-Belt Drives-Part 1: System Based
on Datum Width. Beijing: Standardization Administration of the People’s Republic of
China.
5 Qiu, X.H. (1997). Mechanical Design, 4e. Beijing: Higher Education Press.
6 Pu, L.G. and Ji, M.G. (2006). Mechanical Design, 8e. Beijing: Higher Education
Press.
7 Gere, J.M. and Timoshenko, S.P. (1996). Mechanics of Materials, 4e. CL
Engineering.
8 Wen, B.C. (2010). Machine Design Handbook, 5e, vol. 2. Beijing: China Machine
Press.
9 Juvinall, R.C. and Marshek, K.M. (2011). Fundamentals of Machine Component
Design, 5e. New York: Wiley.

Problems
Review Questions
1 Why are belt drives are usually arranged at a high-speed stage instead of low speed
stage in a power transmission?

2 What causes a V-belt to have a greater load carrying capacity than a flat belt?

3 Which measure could be used to increase power transmission capacity of a belt

drive?

4 While designing a V-belt drive, how should one solve the following problems?
(1) the speed of the belt is either too fast or too slow;
(2) the contact angle on the driving sheave is too small;
(3) too many number of stress cycles;
(4) too many number of belts.

5 During belt drive design, why do we need to set a limitation on belt speeds?
142 Analysis and Design of Machine Elements

Objective Questions
1 The variable speed ratio in a belt drive is because ______.
(a) the contact angles of the driving sheave and driven sheave are different
(b) of belt slippage
(c) the coefficient of friction is unstable
(d) of the elastic creep of the belt

2 In V-belt drive design, the purpose of limiting the minimum diameter of small sheave
is ______.
(a) to limit bending stress
(b) to make structure compact
(c) to ensure enough friction on the contact surface between the belt and sheave
(d) to limit contact angle on the small sheave

3 The difference between tensions on the tight side and slack side of a belt drive is
3000 N. If the belt speed is 15 m s−1 , the transmitted power is ______ kW.
(a) 90
(b) 22.5
(c) 100
(d) 45

4 The selection of a belt type is according to ______.

(a) the diameter of driving sheave
(b) the rotational speed of a belt drive
(c) the calculated power and the rotational speed of the driving sheave
(d) the transmitted power

5 The reason of elastic creep in a belt drive is because ________.

(a) the belt is not absolutely flexible
(b) the coefficient of friction is small
(c) the centrifugal force appears
(d) of the difference between tight side tension and slack side tension

Calculation Questions
1 A flat belt transmits power between two 600 mm diameter pulleys. The coefficient
of friction between the belt and pulley is 0.3. The force acting on the sheave shaft
should not exceed 1200 N. Find the limiting values of the tight side tension F 1 and
slack side tension F 2 . Disregard service factors.

2 For a flat belt drive with diameters of D1 = 125 mm and D2 = 400 mm, if the input
shaft rotates at 1440 rpm, calculate
(1) the rotational speed of the driven shaft if no elastic creep is considered.
(2) the rotational speed of the driven shaft if a slip ratio is 2%.
(3) how to compensate for the elastic creep.
 Belt Drives 143

3 A belt drive can transmit a maximum power of P = 3 kW. The driving sheave has a
diameter of d1 = 150 mm, rotating at n1 = 1420 r min−1 . The contact angle on the
driving sheave is 𝛼 1 = 160∘ . The coefficient of friction between the belt and belt
sheave is 0.3. Decide the maximum effective force F ec and tight side tension F 1 .

4 A single belt drive with an initial tension of F 0 = 300 N has a contact angle of
𝛼 1 = 150∘ on the small drive. The belt speed is v = 8 m s−1 . If the equivalent coef-
ficient of friction between the belt and belt drive is f = 0.5, neglecting centrifugal
force, decide the maximum power P the belt drive can transmit.

5 A belt drive has contact angles of 180∘ on the driving and driven sheaves with an
initial tension of F 0 = 150 N. The equivalent coefficient of friction is 0.5. Neglecting
centrifugal force, if the transmitted effective force is F e = 180 N, decide whether the
belt will slip and explain why.

Design Problems
1 Design a V-belt drive for a 5.5 kW motor running at 1440 rpm driving an air com-
pressor at 520 rpm. Ensure it has the shortest possible centre distance.

2 A single V-belt is selected to deliver 3 kW engine power to a tractor. Approximately

70% of this power is transmitted to the belt. The maximum engine speed is 3000 rpm.
The driving sheave has a diameter of 150 mm, the driven, 300 mm. The belt selected
should be as close to a 2300 mm datum length as possible. Select a satisfactory belt.

3 A 1.5 kW electric motor running at 1460 rpm is to drive a blower at a speed of

240 rpm. Select a V-belt drive for this application and specify standard V-belts,
sheave sizes and centre distance.

4 The compressor of a small air-conditioning unit requires a 1.5 kW, 1200 rpm motor.
The speed of compressor is 300 rpm. The centre distance should be minimized to
provide a compact design. Design a suitable V-belt drive.

Structure Design Problems

1 On a V-belt drive in Figure P6.1, the angle between the two working surfaces of
the V-belt is 𝜙 = 40∘ , then the corresponding angle on the sheave groove 𝜙1 is
________40∘ .
(a) >
(b) <
(c) =

2 In Figure P6.2, which one best depicts the position of a V-belt in a sheave groove?
______.

3 Figure P6.3 is a layout of power transmission. Find the errors and correct them.

4 For the tensioning scheme shown in Figure P6.4, part (a) is for a flat belt, while
(b) is for a V-belt. Make corrections where you see the errors occur.
144 Analysis and Design of Machine Elements

b Figure P6.1 Illustration for Structure

Design Problem 1.
bp

N N
h

φ1

(a) (b)

(a) (b) (c) (d)

Figure P6.2 Illustration for Structure Design Problem 2.

3 Figure P6.3 Illustration for Structure

Design Problem 3.

2 1 n1
n3

n2

n1 n1
o1 o2 o1 o2

1 2 3 4 1 2 3 4
(a) Flat belt (b) V-belt

Figure P6.4 Illustration for Structure Design Problem 4.

5 The power from an electric motor is used to drive a conveyor running at a low
speed. Propose the layout and connect components to realize the power transmis-
sion. Components are shown in Figure P6.5. At least two drives need to be used in
your design.
 Belt Drives 145

electric motor conveyor coupling (several)

belt drive chain drive gear drive

Figure P6.5 Illustration for Structure Design Problem 5.

CAD Problems
1 Write a flow chart for belt drive design process to complete the Example Problem 6.1.

2 Develop a program to implement a user interface similar to Figure P6.6 and complete
the Example Problem 6.1. Select different trial centre distance of a0 and compare the
results.

Figure P6.6 Illustration for CAD Problem 2.