632 Chapter 11 of a timing belt sprocket is the diameter at which the belt's tensile elements (usually fibrous cords) ride on the sheave. FLAT BE| DRIVE DESIGN & SELECTION PROCEDURE Transmissible power of a flat belt drive is a function of friction coeffi- cient and is calculated according to the Eytelwein’s equation and the formulas in Table 11-41. Because the belt is affected by centrifugal force at the pulleys, greater speeds will require greater preloads to counteract this force and pre- vent slip. If objects with weight are being carried by the belt, sufficient periph- eral force must be provided. Reflected torque of a conveyor belt drive on the driving shaft is detailed in Section 11.4, and can be used to calculate required drive power. When specifying a belt drive, care must be taken to account for any elevated starting and stopping torques. Table 11-41: Flat Belt Drive Load Formulas 1: Small Pulley 2: Large Pulley d., = Pitch diameter of pulley (in or mm) 7 = Tension in tight side 14 = Coefficient of friction between belt and pulley FF, =Tension in slack side @ =Wrap angle of belt around smaller pulley (radians) T= Torque at drive shaft 5), = Service factor (See Table 11-42) P=(R-Fy Inch: ‘TRANSMISSIBLE POWER ‘P=Power at shaft hp= Belt linear velocity (ft/min or m/min) Check units for consistency (Fv 33000 Metric: -F 6120 P, =S,P(SF SF = Safety Factor 5, POP) DRIVE TORQUE dn 71 =RPM or RPS of shaft EO ‘BELT PERIPHERAL VELOCITIES (WINEAR BELT SPEED) y2% Linear belt speed (in/time or mm/time) - . = RPM or RPS of shaft WaaAndy, v= Ady, Check units for consistency ‘TENSION FORCES aD ePower Transmission Devices 633 Table 11-41: Flat Belt Drive Load Formulas (Continued) SLIP EQUATION CENTRIFUGAL HOOP TENSION v= Linear belt speed (per second) w= Belt weight per unit length g = Accel. of gravity (386 in/sec’ or 9800 mm/sec’) b=Belt width {in or mm) t=Belt thickness {in or mm) = Belt specific weight (Ibf/in’ or MPa) INITIAL TENSION PEAK TENSION F, = Bending Tension (function of belt construction) BENDING FREQUENCY Z=Number of pulleys L=Belt length Check units for consistency FORCE EXERTED ON SHAFT Bending force on shaft along the line of centers T = Torque transmitted by belt pulley Table 11-42: Flat Belt Service Factors Prime Mover: Electric Motors Large Accelerated Masses ElectricMotors | With Starting Electric Motors ‘With starting | Torquebetween | With Starting Application Operating Torque <1.5x 15x and 2.5x Torque > 25x Conditions Nominal Torque | Nominal Torque | Nominal Torque Continuous Service, Small 1 1a 16 Accelerated Masses Interrupted Service Without Bumps, Medium-Sized 13 1s 17 Accelerated Masses Ineterrupted Service With Bumps, Medium-Sized 15 ww 18 Accelerated Masses Service With Severe Bumps, te 1s 9634 Chapter 11 Linear belt speed is a function of both shaft speed and pulley diameter, Because power is a function of belt speed and belt tension, an increase in belt speed (by increasing diameter, for instance) will require less belt tension for the same power output. Increasing the pulley diameter will reduce the tension requirement, which in turn reduces loads on the shafts and bearings. Modern flat belts are typically made up of multiple layers with differ- ent characteristics. As a result, any flat belt calculations should be based on current manufacturer's data. The best way to design and size a belt drive and its components is to talk to an applications engineer at the vendor of your choice. Have the information from step 1 of the following procedure ready for discussion. This procedure can be used when designing a flat belt drive and select- ing belts: 1. Determine the drive parameters. These include: * Drive horsepower (or kW) or flat belt linear speed * Shaft diameters * Preferred speeds of both shafts * Preferred distance between shaft centers Flat belts run best at speeds ranging from 2500 f/min (12.7 mvs) to 7500 ft/min (38.1 m/s). When selecting drive parameters from scratch, it is helpful to target a linear belt speed of 4000 ft/min (20.3 m/s) and calculate drive geometry from the belt speed using the equations in Table 11-40 and Table 11-41. 2. Select a flat belt type and thickness. Belt type (construction and material) is often chosen based on characteristics like coefficient of friction. Belt thickness for a particular type will typically be selected based on design power. Design power is equal to the drive horsepower (or kW) multi- plied by the service factor and some safety factor. Some guideline values for flat belt service factor can be selected from Table 11-42. Consult with the manufacturer on service factors. Sometimes flat belts are rated for power or allowable tension (or stress) per unit width. In this case, calcu late the tight side tension using the equations in Table 11-41 and apply the service factor as shown. The belt width b is not yet known, so leave that term in the solution for now and solve for it in subsequent steps. 3. Select one pulley pitch diameter and calculate the other using a manu- facturer’s catalog and the formulas in Table 11-40. With flat belts,Power Transmission Devices 635 diameters. If your calculated speed ratio or pulley pitch diameter is not achievable using stock pulleys, you will need to adjust your pulley speeds or diameters. Do not use a pulley that is below the minimum stock size for that belt because that will place more than the recom- mended bending stress on the belt. 4, Select or calculate a center distance and belt length, Using the manu- facturer’s data tables, select the manufacturer's recommended center distance closest to your desired center distance. Belt length will be given by the manufacturer for your selected center distance and pul- ley pitch diameters. If no data tables are available, you may calculate center distance as a function of belt length using the belt length for- mula in Table 11-40. This calculated or selected center distance will replace your desired center distance. Maximum center distance should be less than 20 times the pitch diameter of the small pulley. The center distance of a flat belt drive intended for high speeds should be selected such that the minimum center distance is equal to the pitch diameter of the large pulley plus half the pitch diameter of the small pulley ac- cording to the following equation: $CS20d, For flat belts, it is often recommended that belts be specified 1% shorter than nominal to account for installation tension. Check with the manufacturer to verify this for a particular flat belt. 5. Verify that the angle of wrap on the smaller pulley is greater than 120°, Wrap angle can be calculated using the formulas in Table 11-40, 6. Check the belt linear speed. The calculated linear belt speed should not exceed the belt maximum speed listed in the manufacturer's data for that belt, Belt linear speed can be calculated using formulas from Table 11-41. 7. Check the belt bending frequency. The bending frequency must be within an acceptable range given by the manufacturer for the chosen belt. Bending frequency has a large impact on belt life. Bending frequency can be calculated using the formula in Table 11-41. 8. Choose a belt width. First determine the specific rated power per unit width for your chosen belt. This is normally done using manu-636 Chapter 11 Based on this information, select a belt width. Select a width that yields a belt horsepower (or kW) rating that exceeds your target design power. Alternatively, belt width can be calculated based on tension requirements for power transmission using the formulas in Table 11-41 First solve for centrifugal hoop tension and leave belt width variable b in the solution, Then solve for tight side tension force and leave b in the solution. Substitute these values into the slip equation and solve for b. Choose a belt width that exceeds this value. If the calculated width is not satisfactory, recalculate based on a different belt thickness. A thicker belt will handle more stress per unit width 9. Determine the installation and takeup allowance. The allowance, or a formula to calculate allowance, is usually provided by the manufacturer. 10. Determine the required initial belt tension. This is sometimes provided by the manufacturer and other times must be calculated using manu- facturer-supplied equations or software. A formula for initial tension can be found in Table 11-41. Static shaft load due to belt tension can then be calculated based on static belt tension and wrap angle using the formula in Table 11-41. This calculation ignores the shaft load due to pulley weight. 11. Verify that your shaft diameters are sized appropriately for your power and speed requirement. Every shaft should be designed according to professional standards to ensure safety, performance, and acceptable deflection. See Section 11.1 for information on shaft design and calcu- lation, including loads caused on shafts by belt drives. If attaching the drive pulley directly to an electric motor, itis good practice to use the NEMA standards for shaft diameter sizing. A chart of these values can be found in Figure 11-43. 12. Fit the pulleys to your shaft diameters. Some pulleys have integral hubs, but others may have additional bushings that are required to fit your shafts. Most commonly, the purchaser must machine the proper bore size and attachment features into the pulleys. BELT DRIVE DESIGN AND SELECTION PROCEDURE Transmissible power of a V-belt drive is a function of friction coefficient and is calculated according to the Eytelwein’s equation and the formulas in