Professional Documents
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SCHOOL OF ENGINEERING
PRESENTED BY
OF
Students
This report is our original work and has not been published or presented for award of
degree in any university there before.
Signed………………………………………
Date…………………………………………
Signed...…………………………………
Date……………………………………..
Supervisor
This report has been submitted by the above students for examination with my
approval as a university lecturer and supervisor of the project.
Signed…………………………………..
Date…………………………………….
i
DEDICATION
We would like to dedicate this project to our dear parents, siblings and friends for the moral
and material support they have accorded to us through our academic life and their effort to
seeing us pursue our dreams towards attaining a higher education.
Page | ii
ACKNOWLEDGEMENTS
Would like to express our sincere and utmost gratitude to the following individuals, without
whose assistance and constant supervision, this project would never have been completed.
First and foremost, we express our heartfelt gratitude to our supervisor Dr. MF Oduori, for all
the guidance and time he had made available towards the completion of this project. Not to
forget also the materials assistance he had made available to us in terms of books and other
forms of information he afforded to us.
Last but not the least; we would like to thank the university fraternity, our friends and family
for their endless support during this time.
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Table of Contents
DECLARATION.......................................................................................................................................... i
DEDICATION............................................................................................................................................. ii
ACKNOWLEDGEMENTS ...................................................................................................................... iii
ABSTRACT ................................................................................................................................................. 1
PART 1: INTRODUCTION ...................................................................................................................... 2
CHAPTER ONE ......................................................................................................................................... 2
1. INTRODUCTION ...................................................................................................................... 2
1.1. DESIGN .................................................................................................................................. 2
1.2. COMPUTER-AIDED ENGINEERING & DESIGN (C.A.E & C.A.D) ................................ 3
PART 2: LITERATURE REVIEW .......................................................................................................... 5
CHAPTER TWO ........................................................................................................................................ 5
2. REVIEW OF LITERATURE ON V-BELTS AND V-BELTS DESIGN................................... 5
2.1. HISTORY / ORIGIN AND DEVELOPMENTS OF V-BELTS ............................................ 5
2.2. STRUCTURE OF A V-BELT ................................................................................................ 7
2.3. PARTS OF A V-BELT ........................................................................................................... 8
2.4. V-BELT DRIVES ................................................................................................................... 8
2.4.1. STRUCTURE OF A V-BELT DRIVE ............................................................................... 9
2.4.2. TYPES OF BELT DRIVE SYSTEMS ............................................................................ 10
2.4.3. DEFINITION OF TERMS USED IN BELT DRIVES .................................................. 11
2.4.4 THEORY OF BELT DRIVES ......................................................................................... 12
CHAPTER THREE .......................................................................................................................... 14
3. REVIEW OF LITERATURE ON DEVELOPMENT OF A COMPUTER AIDED DESIGN
FOR V-BELTS / V-BELT DRIVES ................................................................................................. 14
3.1. INTRODUCTION ................................................................................................................ 14
3.2. DESIGN PROCESS.............................................................................................................. 14
3.3. COMPUTER AIDED DESIGN OF V-BELTS .................................................................... 20
3.3.1. How to create a C.A.D from Matlab program (method) ................................................... 21
3.3.1.1. Algorithms used in Matlab ............................................................................................ 23
3.3.2. Developing a GUI for v-belt design program ................................................................... 26
CHAPTER FOUR............................................................................................................................. 30
4. REVIEW OF LITERATURE ON CHAINS, CHAIN DRIVES AND COMPUTER AIDED
DESIGN OF CHAIN DRIVES ......................................................................................................... 30
4.1. INTRODUCTION TO CHAINS .......................................................................................... 30
4.2. MECHANICS OF CHAIN DRIVES ................................................................................... 32
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4.3. DESIGN OF A ROLLER CHAIN DRIVE ........................................................................... 34
4.3.1. Number of teeth in sprockets ............................................................................................ 34
4.3.2. Drive Ratio ........................................................................................................................ 36
4.3.3. Drive Arrangements .......................................................................................................... 36
4.3.4 Shafts Centre Distance ............................................................................................................... 37
4.3.3.1. Centre Distance Adjustment ......................................................................................... 38
4.3.3.2. Chain lubrication ........................................................................................................... 39
4.4. SELECTION PROCEDURE FOR CHAIN DRIVES WITH TWO SPROCKETS ............. 41
4.5. COMPUTER AIDED DESIGN OF CHAIN DRIVES ......................................................... 45
4.5.1. Developing a graphical user interface (GUI) .................................................................... 46
PART THREE: CASE STUDY ............................................................................................................... 49
CHAPTER FIVE ...................................................................................................................................... 49
5. CASE STUDY ON THE APPLICATION OF THE V-BELT AND CHAIN DRIVE DESIGN
PROGRAM FOR A SISAL DECORTICATOR MACHINE ........................................................... 49
5.1. INTRODUCTION ................................................................................................................ 49
5.2. DESIGN DATA .................................................................................................................... 49
5.3. APPLICATION / USING THE PROGRAM ........................................................................ 52
CHAPTER SIX ......................................................................................................................................... 57
6. CLOSURE ................................................................................................................................ 57
6.1. DISCUSSION OF RESULTS............................................................................................... 57
6.2. CONCLUSION ..................................................................................................................... 58
6.3. RECOMMENDATIONS ...................................................................................................... 58
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ABSTRACT
The aim of this project is to develop a computer aided design program for the selection of v-
belt and chain drives. It encompasses simplifying the bulky and time consuming process of
using tables and charts into a simplified user friendly program.
Before the creation of this program, proper review of the selection procedure of v-belts and
chain drives was carried out in order to understand the most important aspects of design.
Once determined it was important to code them in a machine language that the computer can
interpret .This involved the generation of equations from design charts in order to fully
computerize the process. This was done in the case of determination of power rating for v-
belt drives where equations were generated for belt sections A to E conforming to ANSI
standard classifications. In cases where equations could not be developed, tables were
provided whereby specific values needed were to be input by the user in the final program.
These included service factors and correction factor.
Matlab programming language was used to develop the source code and an executable
program. This was chosen because it is a scripting programming language applicable in most
engineering applications and is easy to understand. The complete code used for the design
program is provided in the appendix.
To ascertain the accuracy of the program created, a case study was done to determine the
appropriate belt drive and also chain drive for use on a sisal decorticator machine and the
results obtained were compared with values obtained earlier using theoretical calculations,
charts and tables. The motor rating for the sisal decorticator studied was 1.5 kW, 600mm
center distance, service factor of 1.1. Using design charts the appropriate belt drive
determined was an ANSI standard B section, driven diameter of 183.6mm, driving diameter
of 135mm, belt length of 1703.7mm, and number of belt 1. For the chains, the driving
sprocket, 22 teeth, driven sprocket, 30 teeth, chain pitch length of 152.02~152 pitches. Using
the program an appropriate belt drive would be of ANSI standard B section, 183.5mm driven
diameter, 135mm driving diameter and belt length of 1703.1mm whereas for chain drives the
pitch length was found to be 152.2~152 pitches for using an ANSI standard chain of ⅜
inch(9.525mm) pitch.
1
PART 1: INTRODUCTION
CHAPTER ONE
1. INTRODUCTION
1.1. DESIGN
To design is either to formulate a plan for the satisfaction of a specified need or to solve a
problem. If the plan results in the creation of something having a physical reality, then the
product must be functional, safe, reliable, competitive, usable, manufactureable and
marketable.
Design is a communication-intensive activity in which both words and pictures are used, and
written and oral forms employed. Engineers have to communicate effectively and work with
people of many disciplines. These are important skills, and an engineer`s success depends on
them.
1. Recognition of need.
2. Formulation of specifications, that is, conformance of product to need of designer.
3. Creative synthesis (creativity, invention, imaginative combination of parts to form a
new design/product).
4. Drafting.
1 th
Refer; Shigley`s Mechanical Engineering Design 8 edition Chapter 1 Design pg 4-5
Page | 2
5. Analyzing (determining stresses and deflections, and comparing them with strength
and acceptable deflection.)
6. Redesigning as required.
7. Manufacturing and testing.
Computer aided engineering is the practice of engineering with help of using computers.
Engineering is a wide discipline of science and involves various branches/fields of practices
such as nuclear, mechanical, civil & structural and many more.
A designer describes the proposed design and then displays it on the computer monitor as an
output image, user interface or even a plot. Design changes can be made quickly and
inexpensively at this point. Furthermore, CAD can be used to create an accurate three
dimensional (3-D) geometry /shape, database, produce a bill of materials, and to eliminate the
need for a prototype, or create a prototype via stereo-lithography2.Thus CAD can reduce
concept-to-production time, improving competitiveness3.
The importance of (CAE) is that it allows flexibility in decision making. During design, there
may be need to try altering the design to check outcomes limited by certain considerations.
For example, how to reduce costs incurred in designing? What can be adjusted to increase
efficiency? What is the end result if a given dimension is changed?
An Institute for Defense Analysis report (1986) defines concurrent engineering (CE) as “a
systematic approach to integrated, concurrent design of products and their related processes.
2
A rapid prototyping method particularly suited to parts with complex geometry.
3
Refer; Computer Integrated Machine Design By Charles E .Wilson Creative design chapter 1 pg 2-3
Page | 3
CE requires teamwork and coordination involving research and development engineers,
designers, manufacturing engineers and technicians, and personnel from other functions.
The focus is on product-based teams rather than on departments. With CE aspects of product
design and development can be carried out simultaneously. Thus, CE is a parallel process,
while the traditional process is a series approach. Problems sometimes result from lack of co-
ordination in the traditional approach. CE attempts to eliminate such problems in the concept
and design phase.’’
Page | 4
PART 2: LITERATURE REVIEW
CHAPTER TWO
The V-belt was developed in 1917 by John Gates of the Gates rubber Company. They are
generally endless, and their general cross-section shape is trapezoidal. The V-shape of the
belt tracks in a mating groove in the pulley (sheave), with the result that the belt cannot slip
off. The belt tends to wedge into the groove as the load increases-the greater the load, the
greater the wedging action-improving torque transmission and making the v-belt an effective
solution, needing less width and tension than flat belts.4
Belt Definition; a flexible non-metallic member (Friction Belt drives by, Prof. M.F. Oduori)
A V-belt is a type of belt drive classification in which the belt drives cross sections are
trapezoidal.
Belt drives are a type of flexible machine element used in various industrial applications for
power transmission. The belt is looped over pulleys and is used to link motion between the
two pulleys from the driving pulley (motor shaft) to the driven pulley.
Cogged belts
Fig 2.1a
4
Courtesy of www.wikipedia.org-belt(mechanical)
Page | 5
Synchronous belts
Fig 2.1b
Flat belts
Fig 2.1c
V-belts are known as classical V-belts and also exist in different sizes and sections among
their classification. This is because belts, pulleys and sheaves for high volume produced
products such as home appliance and passenger car engines are usually custom designed and
manufactured by the thousands for specific functions and operating conditions. Furthermore
to minimize the heavy expense of custom belt design, extensive testing, and special tooling
are absorbed easily in the volume production of identical belts.
The standard V-belt sections are A, B, C, D and E. The table 2.1 contains design parameters
for all the sections of V-belt. The kW rating given for a particular section indicates that, belt
section selection depends solely on the power transmission required, irrespective of number
of belts. If the required power transmission falls in the overlapping zone, then one has to
justify the selection from the economic view point also.
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Table 2.1 Power ranges for belt sections.
As for example, a single belt of B-section may be sufficient to transmit the power, instead of
two belts of A- section. This may increase the cost as well as weight of the pulley, as two-
grooved pulley is required. In general, it is better to choose that section for which the required
power transmission falls in the lower side of the given range.
1. Slippage can occur, especially if belt tension is not properly set and checked
frequently.
2. Belts usually cannot be repaired when they wear, they must be replaced.
V-belts are ordinarily made of reinforced rubber and may be fabric wrapped to reduce
abrasion. Materials used consist of;
Fabric.
Nylon.
Cords of cotton, polyester, aramid, Kevlar etc.
All the above impregnated in a rubber matrix.
Page | 7
Fig 2.2: V-belt cross section
Pitch line is the neutral axis of the belt section. Design calculations for V-belt drives are
based on the pitch line or the neutral axis.
Most belt drives (with an exception of synchronous belt drives) are classified under friction
belt drives because belts transmit power by virtue of relative difference in magnitude of belt
tension between the points which the belt mounts onto the pulley and the point at which the
Page | 8
belt leaves the pulley. Belt drive mechanisms are designed such that slip is limited to less
than 2%.Power transmission efficiencies of friction belt drives range from 97% to 99%
(neglecting shaft bearing losses).
Used in conveyor systems, such as; transportation of coal/mineral ores over a long distance.
Used for power transmission; such as power transmission from motors to driven appliances,
in industrial combustion engines, also link the engine crankshaft rotation to radiator cooling
fan.
Quiet applications; Belt drives are favorably used in industrial machine elements that are
required for use in quiet environments.
Used in applications where centre distances involved are too large for a chain or gear drive.
Where exact speed ratio is not of necessity, thus most common in speed reducing applications
or torque amplifiers.
It consists of;
a) Belt.
b) Sheaves (pulleys).
c) Bushings.
d) Transmission shafts.
e) Power source (Motor).
Page | 9
Fig 2.4c : Sheaves & Bushings used for V-belt drives.
Courtesy of; VBD selection for fans, achieving optimum performance, comparison of drive bushings and
sheaves. © Twin City Fan Companies,ltd.
The belt operates in conjunction with a pulley or sheave that is mounted on each of the rotating shafts.
V-Belt drive sheaves are available with a single groove or with multiple grooves. If separate belts are
used on a multi-groove sheave, they should be purchased in matched sets. When necessary, all should
be replaced at the same time because belts undergo permanent stretching during use .Band belts
consisting of two or more V-belts joined with a single back are also available.
Light duty fractional horse power drives often employ sheaves made of Aluminum, stamped steel,
plastic, or die-cast zinc. Cast iron sheaves are used in industrial service for belt speeds up to about
1200 in/s or 30m/s for classical belts(types A,B,C and D) and up to 1300 in/s or 33m/s for narrow
belts (types 3V,5V and 8V).Ductile iron sheaves can be used at higher speeds.
Also V-belt sheaves can be used as idlers on the inside of a belt. Idlers are used to reduce belt whip
for long-center-distance drives, to tension drives with a fixed centre distance, and to clear obstructions
that would otherwise be in belt path. Idler diameter should equal the smaller driving sheave diameter
in this case. Although the inside location reduces angle of contact on the loaded sheaves, it is
preferred because reverse bending is avoided.
There are two main types of v-belt drive systems that are used to date. These are;
1. Open belt drive system: The rotation of both pulleys is in the same direction.
2. Cross belt drive system: Opposite direction of rotation is observed.
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∝𝑙 𝐷𝑙
∝𝑠
𝐷𝑠
∝𝑙 𝐷𝑙
∝𝑠
𝐷𝑠
Below is a listing of various universal symbols and their respective meanings as used in belt
drives.
Page | 11
C- Center distance between the two pulleys.
This refers to an in depth look at the various dimensional properties that can be used to describe a
belt/belt drive system. They include quantities such as; Belt length, diameters of large and small
pulley, angle of wrap, friction coefficients, centrifugal force, belt tension, torque and power
transmitted.
The figure 2.7 shown below will be used to illustrate the geometry and formulae for belt drives.
Fig 2.7
O2e = C sin β
Page | 12
𝐷1
And eb = aO1 =
2
𝐷2
O2b = 2
Therefore:
𝐷2 𝐷1
= C sin β + =
2 2
𝐷2 −𝐷1
Sin β = …..(1)
2𝐶
∝1 = π - 2 β radians
L = 2ab + ac + bd
𝐷2 𝐷1
= 2C Cos β + (π + 2 β) + (π - 2 β) …. (3)
2 2
𝜋
= 2C Cos β + 2 (𝐷1 + 𝐷2 ) + β (𝐷2 − 𝐷1 )
Page | 13
CHAPTER THREE
3.1. INTRODUCTION
Manufacturers have standardized and classified V-belts according to standard belt section
designated by alphabetical letters that are A, B, C, D, and E for various sizes in inch
dimensions while metric sizes are designated in numbers.
Each belt section has a standard measure of width, thickness, minimum sheave diameter for
use and kilo-watt range for use of the belts. These data are then tabulated for all V-belt
sections as shown in table 3.7.
Belt drives are used to transmit power from a primary mover such as a motor to an output
point such as a rotating shaft that carries a load. When designing a v-belt to use, it is
necessary to know how much power is given at the input since different belt sections have
limits to how much power they can transmit per belt .e.g. V-belt section-A belts can transmit
power in the range of 0.2kW – 7.5 kW while section-B belts transmit power from 0.7kw –
18.5 kW range.
Service factor is a modifier quantity used to multiply the power transmitted/input to give a
design power that will be used as the running power for the design. Service factor are
tabulated in terms of conditions of driven machinery, whether uniform, light shock, medium
shock, or heavy shock. Table 3.5 shows the various available service factors to use.
For example if the tabulated power for belt section A is 0.2 - 7.5kw range and the design
power from step above lies within this range, then a belt from section A is acceptable for use
otherwise if the design power exceeds the range ,then compare values in the next belt section
.i.e. B,C,D or E .
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STEP 5: Matching Minimum Sheave Diameter
Belt sections are classified with corresponding minimum sheave diameter sizes for use. Sizes
could be in metric / imperial units. For example; from table 3.6 in the appendix section A
page 60, A belt of section-A is used with minimum sheave diameters from 75mm to 135mm.
𝐷 𝜔
Also G=𝐷1 = 𝜔 2
2 1
𝐷2 = G x 𝐷1
The calculated diameter of driven sheave obtained as shown above is then approximated to
the nearest standard size of sheave diameter available.
Suitable v-belt speeds lie between 20m/s to 25m/s. However speeds higher than 25m/s or
lower than 5m/s could result in failures.
This refers to the distance between the centre of the small sheave 𝐷1 to the center of the large
sheave 𝐷2 .Center distance is limited by available space for use but is also advisable to lie
between 𝐷2 < C < 3(𝐷2 + 𝐷1 ).
𝜋 (𝐷2 −𝐷1 )2
𝐿𝑝 =2C + 2 (𝐷2 +𝐷1 ) + 4𝐶
Where;
C=Center distance.
Page | 15
The calculated length is then compared to nearest available standard belt length. Table 3.2 in
appendix section-A page 60, shows belt sections with corresponding inside circumferences,
while table 3.3 in page 60 also shows the length conversion dimensions5.
∝1 = π - 2 β radians
∝2 = π + 2 β radians
Use the belt speed and sheave diameter to determine the belt power rating for use.
5 th
Shigley`s Mechanical Engineering design,8 edition, by Richard G.Budynas,J.Keith Nisbett,page 879 table 17-
11
Page | 16
The Flow chart below shows a summary of the above design steps;
START
Step1: Identify
motor power
used.
Step2: Selection
of a service
factor
Step4: Compare
Tabulated Power
for Belt section to
design power.
Page | 17
A
Step5: Matching
Minimum
Sheave Diameter
𝜋𝐷1 𝑁1
Step8: Belt speed= 60
𝐷1 = Diameter of driving
wheel sheaves (m)
𝑁1 = Speed of motor/driving
wheel (rev/min)
Page | 18
B
Step13: Allowable
power per belt
END
Page | 19
3.3. COMPUTER AIDED DESIGN OF V-BELTS
C.A.D involves the use of computer programs/software’s which are programmed with inbuilt
commands similar to the theoretical calculations and steps involved in the design of v-belts
.The C.A.D program is made from a programming language in which algorithms are used to
create a systematic flow of steps/commands to be used in the final C.A.D software
developed.
In this case Programming language MATLAB was used. Matlab and other mathematical
computation tools are computer programs that combine computation and visualization power
that make them particularly useful tools for engineers. Furthermore it is both a computer
programming language and a software environment for using that language effectively.
The name Matlab stands for Matrix Laboratory, because the system was designed to make
matrix computations particularly easy. The Matlab environment allows the user to manage
variables, import and export data, perform calculations, generate plots, and develop and
manage files for use with Matlab.
1. Single-line commands can be entered and executed, the results displayed and
observed, and then a second command can be executed that interacts with results
from the first command that remain in memory. This means that you can type
commands at the Matlab prompt and get answers immediately, which is very useful
for simple problems.
2. Matlab is an executable program, developed in a high-level language, which
interprets user commands.
3. Portions of the Matlab program execute in response to the user input, results are
displayed, and the program waits for additional user input.
4. When a command is entered that doesn’t meet the command rules, an error message
is displayed. The corrected command can then be entered.
5. While this interactive, line-by-line execution of Matlab commands is convenient for
simple computational tasks, a process of preparation and execution of programs
called scripts is employed for more complicated computational tasks.
A script is list of Matlab commands, prepared within a text editor. Matlab then executes a
script by reading a command from the script file, executing it, and then repeating the process
on the next command in the script file.
Errors in the syntax of a command are detected when Matlab attempts to execute the
command. A syntax error message is displayed and execution of the script is halted.
When syntax errors are encountered, the user must edit the script file to correct the error and
then direct Matlab to execute the script again.
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The script may execute without syntax errors, but produce incorrect results when a logic error
has been made in writing the script, which also requires that the script be edited and
execution re-initiated.
The boundaries between these steps can be blurred and for specific problems one or two of
the steps may be more important than others.
A) Problem Definition:
The first steps in problem solving include:
• Recognize and define the problem precisely by exploring and understanding it
thoroughly.
• Determine what question is to be answered and what output or results are to be
produced?
• Determine what theoretical and experimental knowledge can be applied?
• Determine what input information or data is available?
B) Mathematical Model:
To create a mathematical model of the problem to be solved:
• Determine what fundamental principles are applicable.
• Draw sketches or block diagrams to better understand the problem.
• Define necessary variables and assign notation.
Page | 21
• Reduce the problem as originally stated into one expressed in purely mathematical
terms.
• Apply mathematical expertise to extract the essentials from the underlying physical
description of the problem.
• Simplify the problem only enough to allow the required information and results to be
obtained.
• Identify and justify the assumptions and constraints inherent in this model.
C) Computational Method:
A computational method for solving the problem is to be developed, based on the
mathematical model.
• Derive a set of equations that allow the calculation of the desired parameters and
variables.
• Develop an algorithm, or step-by-step method of evaluating the equations involved in
the solution.
• Describe the algorithm in mathematical terms and then implement as a computer
program.
The mathematical algorithm developed in the previous step must be translated into a
computational algorithm and then implemented as a computer program.
The steps in the algorithm should first be outlined and then decomposed into smaller steps
that can be translated into programming commands.
One of the strengths of Matlab is that its commands match very closely to the steps that are
used to solve engineering problems; thus the process of determining the steps to solve the
problem also determines the Matlab commands. Furthermore, Matlab includes an extensive
toolbox of numerical analysis algorithms, so the programming effort often involves
implementing the mathematical model, characterizing the input data, and applying the
available numerical algorithms.
Page | 22
E) Test and Assess the Solution:
The final step is to test and assess the solution. In many aspects, assessment is the most open-
ended and difficult of the five steps involved in solving computational problems.
The numerical solution must be checked carefully:
• A simple version of the problem should be hand checked.
• Solution is either known or which can be obtained by independent means, such as
hand or calculator computation.
• Intermediate values should be compared with expected results and estimated
variations.
• When values deviate from expected results more than was estimated, the source of the
deviation should be determined and the program modified as needed.
• A “reality check” should be performed on the solution to determine if it makes sense.
In order to understand how to use Matlab /even other programming languages it is necessary
to have an understanding on fundamental programming terms.
In Matlab, variable names can be assigned to represent numerical values but first the rules to
be used for these variable names are:
Page | 23
When a command of this form is executed, the expression is evaluated, producing a number
that is assigned to the variable. The variable name and its value are displayed.
>> Length= 32
Length=
32
>> Height = 18
Height =
18
>> Width = 40;
>> Volume=Length * Height * Width
>> Volume = 23040
From the design steps in previous section 3.1, design codes were programmed into the Matlab
command prompt and are hereby illustrated in Appendix section C.
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The figure 3.3 below shows the V-belt design codes used in Appendix C written on the
Matlab M-file prompt.
Page | 25
Continued…
To start with it is necessary to understand that GUI stands for a graphical user interface of a
program in a computer. It is also where the user interacts/inputs his commands and a result is
output by the program in use.
In Matlab, for the GUI Files: By default, GUIDE stores a GUI in two files which are
generated the first time you save or run the GUI:
A FIG-file, with extension .fig, that contains a complete description of the GUI
layout and the GUI components, such as push buttons, axes, panels, menus, and so
on. The FIG-file is a binary file and you cannot modify it except by changing the
layout in GUIDE. Note that a FIG-file is a kind of MAT-file.
Page | 26
An M-file, with extension .m, that contains the code that controls the GUI,
including the callbacks for its components.
To develop a GUI, Start GUIDE by typing guide at the MATLAB command window. This
displays the GUIDE Quick Start dialog shown below in fig 3.4:
Fig 3.4
Page | 27
For opening a New GUI in the Layout Editor, Go to File New GUI. The dialogue box
below appears.
Fig 3.5
Page | 28
The figure 3.6 below shows the developed GUI layout for the V-belt design program.
Fig 3.6
The figure below shows the RUN V-belt .fig file, that contains a complete description of the
GUI layout and the GUI components, such as push buttons (calculate, reset, exit), text boxes
and so on.
Fig 3.7
Page | 29
CHAPTER FOUR
4. REVIEW OF LITERATURE ON CHAINS, CHAIN DRIVES AND
COMPUTER AIDED DESIGN OF CHAIN DRIVES
Chains may be regarded as a belt that is built up of short rigid links, which are hinged
together in order to provide the flexibility that is necessary for the chain to be wrapped
around the driving and driven wheels. These wheels have projected teeth, which fit into
suitable recesses in the chain links and thus enable a positive drive that operates without slip.
The wheels are known as chain sprockets and they bear a superficial resemblance to spur
wheels. However the tooth profiles on the chain sprockets are quite different from those of
spur gears.
Some principal advantages of chain drives as compared to belt drives are the following:
Chain drives may be used in applications with relatively long as well as short center
distances. The center distanced can be as large as eight meters.
Chain drives are compact as compared to flat belt drives.
Chain drives impose less severe loads on shafts as compared to belt drives.
Under ideal conditions, the mechanical efficiency may be as high as 98%to 99%.
There is no slippage between chain and sprocket teeth.
Chain stretch is negligible, allowing it to carry heavy loads.
Long shelf life because metal chain ordinarily doesn’t deteriorate with age and is
unaffected by sun, reasonable ranges of heat, moisture, and oil.
On the other hand, some disadvantages of chain drives as compared to belt drives are:
Chain drives find wide applications in industry. They are used with velocity ratios of less
than 8, linear chain speeds of up to 25m/s, power ratings of up to 110kw and sometimes
more. Chains can be classified into the following categories:
Page | 30
Traction or pulling chains.
Our main concern is with power transmission chains. The most common types of are bush
chains, roller chains, and inverted tooth chains. However the most commonly used power
transmission chain is the roller chain. In a roller chain the outer rows of link plates are known
as pin links or coupling links whereas the inner link plates are known as roller links. The pins
are press-fitted into the pin links and the bushes, through which the pins pass, are press-fitted
into the roller links. The chain rollers are mounted on the bushes so as to be able to rotate
freely within and relative to the bushes. The sprocket teeth are specially designed to engage
smoothly with the rollers.
Roller chains are normally made of case-hardened and ground alloy steel. Materials such as
brass and bronze are used in special applications such as in food processing machines or
where corrosion may be a problem.
The pitch of the chain, which is the distance along a straight line joining the axes of
two adjacent chain joints.
The nominal width of the chain, which is the transverse distance between the inner
link plate.
The roller diameter, which is the outer diameter of the roller.
Roller chain is standardized in a range of pitches from 0.25 in. to 3 in. (6.35 mm to 76.2
mm); silent chain from 0.375 in. to 2 in. (9.525 mm to 50.8 mm). The strength and
horsepower capacity of a chain increase with pitch, but for high-speed drives, smaller pitch
must be used to limit sprocket size and variation in linear chain speed. Ideally, the smaller
sprocket should have an odd number of teeth, not less than 17 and preferably more. Usually
the speed ratio should not exceed 6:1, and the larger sprocket should not have more than 120
teeth. Sprockets can be very close together, but the chain should wrap around the smaller
sprocket at least 120 degrees. A centre distance of 30 to 50 pitches is good but 80 pitches is a
recommended maximum. The dimensions of various chain components are normally
determined in terms of chain pitch.
Page | 31
Fig 4.1 Shows parts of a chain link.
The following is a brief summary of the main equations used in the analysis of chains for any
particular operation.
Page | 32
Chain pitch length L;
2𝐶 𝑍2 + 𝑍1 𝑃(𝑍2 − 𝑍1 )2
𝐿= + +
𝑃 2 4𝜋 2 𝐶
Where;
L = length in pitches.
P= pitch in mm.
Speed ratio G,
𝑁1 𝑍2
G= =
𝑁2 𝑍1
Where;
Sprocket diameter’s,
𝑃 𝑃
D= 𝜋 ≅ ; for Z≥12
sin ( ) 𝑍
𝑍
Where;
P = pitch of chain.
Page | 33
Where;
A roller Chain by nature of its design is capable of transmitting high torque loads, and
provides the ideal drive media for the connection of slow to medium speed shafts located on
extended centers. The selection and application is reasonably simple by following normal
engineering practices, but there are points of good design practice specific to Roller Chain
Drives, and consideration of these will ensure successful drive design.
a) Chordal Action: As a chain engages and disengages with a sprocket there is a rise and
fall of each link, and a velocity variation. These are due to chordal action caused by the chain
forming a polygon on the sprocket. In the diagrams below as Roller B approaches the
sprocket it follows the chordal line of Roller A. Once engaged it is caused to rise following
the arc of the pitch circle. As the chain unwraps from the sprocket the reverse occurs. As well
as inducing a vibration into the chain, the linear velocity of the chain is varied from a
minimum on effective radius d to a maximum on the pitch circle radius r.
The level of this cyclic speed variation can be determined:-
180
Chordal velocity variation = 100{1 – Cos[ ]} %
𝑍
Page | 34
Fig 4.3 Chordal action in a chain drive
Chordal action is unavoidable, but its magnitude and effect can be minimized by using
sprockets with high numbers of teeth, the value becoming insignificant on drives with 25
tooth sprockets or larger.
Fig 4.3 and 4.4 adopted from Cross + Morse chain drive catalogue www.cross-morse.co.uk.
b) Odd Numbers of Teeth: As most drives have a chain with an even number of pitches,
using odd number teeth in the sprockets will assist uniform wear distribution for both chain
and sprocket. An exception to this is for 1:1 ratio drives where even tooth sprockets are
preferred to minimize the effects of chordal action on the drive.
c) Number of Teeth in Large Sprocket: It is recommended that chain wheels should have a
maximum of 120 teeth. This limitation is due to mis-matching of worn chain with large
Page | 35
sprockets which increases with the number of teeth in the sprocket. A simple formula to
200%
indicate percentage of chain wear a sprocket can accommodate is It is normally
𝑍
considered good practice to replace chain if wear elongation exceeds 2%. It is considered
good practice that the sum of teeth on drives and driven sprocket should not be less than 50.
Where both the driver and driven sprockets are operated by the same chain, e.g. on a 1:1 ratio
drive, both sprockets should have 25 teeth each.
For vertically displaced shaft drives, including drives with an inclination of over 60° to the
horizontal, additional maintenance is required to ensure chain is always correctly adjusted,
and for this reason automatic means of chain adjustment is recommended for these
Page | 36
arrangements. It is always preferred to have the driver sprocket above the driven sprocket, as
chain wear creates reduced contact on the lower sprocket.
Roller Chain is not recommended for drives with vertical shafts, but providing the drive is
well engineered, and certain basic rules followed, a satisfactory drive can be achieved. As the
chain is supported by its side-plates on the sprockets, it is essential to use sprockets with high
numbers of teeth (minimum 25 teeth) to spread the load. To minimize side loads on the chain
shaft, centers should be kept to a minimum (30 pitches max), and multistrand chains used
where possible. For slow speed drives (up to 1 M/S) special chain guides are available to
support simplex chain for longer centre drives. It is imperative that chains are maintained in
correct tension at all times, if acceptable life is to be achieved, and to minimize the effects of
wear, chain selection should be made with an additional design factor of 2.
Page | 37
Fig 4.6 A long centre drive using supporting guides
The minimum centre distance is sometimes governed by the amount of chain lap on the
driver sprocket, being not less than 6 teeth in engagement with the chain. The centre distance
is also governed by the desirability of using a chain with an even number of pitches to avoid
the use of a cranked link. For a drive in the horizontal plane the shortest centre distance
possible should be used consonant with recommended chain lap on the driver sprocket.
Page | 38
Fig 4.8 an idler or tensioner sprocket in use.
Fig 4.5, 4.6, 4.7 and 4.8 courtesy of Cross + Morse chain drive catalogue www.cross-
morse.co.uk
An adequate supply of lubrication is necessary to ensure a satisfactory wear life for any chain
drive. Roller chain when supplied is coated in a heavy petroleum grease to provide protection
until installation. For some slow, light load applications this lubrication is adequate providing
a short wear life can be accepted, but for the majority of applications an oil lubrication
system to provide further lubrication will be required, the type being dependant on chain size,
loads and operating speed. When oil is applied to a roller chain a separating wedge of fluid is
formed in the operating joints, similar to journal bearings, thereby minimizing metal to metal
contact. When applied in sufficient volume the oil also provides effective cooling and impact
dampening at higher speeds. Chain life will vary appreciably depending on the lubrication
system used, and therefore it is important that lubrication recommendations are complied
with. The chain rating tables used for selection only apply for drives lubricated in line with
the following recommendations. Chain drives should be encased for protection from dirt and
moisture, and oil supplies should be kept free of contamination. A good quality, petroleum-
based, non detergent thin oil should be used, and changed periodically (Max. 3000 hours
operating life). Heavy oils and greases are not recommended for most applications, because
they are too stiff to enter the small spaces between precision chain components.
There are four basic types of lubrication for chain drives, the correct one being determined by
chain size and speed;
a) Manual Lubrication
Oil is applied with a brush or oil-can at least once every 8 hours of operation. The volume
and frequency of application should be sufficient to keep the chain wet with oil and prevent
overheating or discoloration of lubricant in the chain joints. The use of aerosol-can lubricant
is often satisfactory on slow speed drives. It is important that the lubricant used is of a type
specified for roller chains.
Page | 39
b) Drip Feed Lubrication
Oil drops are directed between the link plate edges from a drip lubricator. Volume and
frequency should be sufficient to prevent discoloration of lubricant in the chain joints.
Precaution must be taken against misdirection of the drops by wind from the passing chain.
Fig 4.9 various types of chain lubrication techniques. Adopted from Cross + Morse chain drive
catalogue www.cross-morse.co.uk
Page | 40
reservoir capacities should be a minimum of 3 times oil flow rate, and lubrication system
should include a full flow oil filter.
In order to use a selection procedure, it is first necessary to assemble all data relevant to the
application, which should include:
a) Power to be transmitted.
b) Input shaft speed, and output speed required or drive ratio.
c) Type of driver and driven equipment (uniform load, moderate shock, heavy
shock).
d) Center distance between shafts.
e) Environmental conditions.
f) Limits on space and position of drive.
g) Proposed lubrication method.
Unless shaft speeds are very low it is advisable to use a minimum of 17 tooth sprockets. If the
drive operates at high speeds or is subject to impulse load sprockets should have at least 25
teeth and should be hardened. For low ratio drives, sprockets with high numbers of teeth
minimize joint articulation, and bearing loads, thus extending chain life. On drives where
ratios exceed 5:1 the designer should consider using compound drives for maximum service
life.
Page | 41
By relating the design Power 𝑃𝑑 with the rotational speed of the small sprocket 𝑁1 the correct
size of chain for the application can be selected from standard charts.
2𝐶 𝑍2 + 𝑍1 𝑃(𝑍2 − 𝑍1 )2
𝐿= + +
𝑃 2 4𝜋 2 𝐶
The calculated number of pitches should be rounded up to a whole number of even pitches.
Odd numbers of pitches should be avoided because this would involve the use of a cranked
link which is not recommended. If a jockey sprocket is used for adjustment purposes, two
pitches should be added to the chain length (L).
The actual centre distance for the chain length (L) calculated by the method above, will in
general be greater than that originally contemplated. The revised centre distance can be
calculated from the formula below;
𝑃 2 𝜋 2
C= 8 2𝐿 − 𝑍2 − 𝑍1 + 2𝐿 − 𝑍2 − 𝑍1 − 𝑍2 − 𝑍1
3.88
The preferred centre distance ranges between 30 and 50 times the chain pitch, and there
should always be a minimum arc of contact of the chain on the small sprocket of 120°.
Page | 42
The following flowchart summarizes the above design procedure for chain drive selection in
a sequential manner.
Start
Design power=power
*service factor
Determine speed
ratio, G
Page | 43
B
Determination of
appropriate pitch
size
Determine type of
lubrication.
END
Page | 44
4.5. COMPUTER AIDED DESIGN OF CHAIN DRIVES
This work presents a computer-aided analysis for the selection of roller chain drives, which
are commonly used in mechanical power transmission systems. Computer programs are
written and proposed to improve the traditional method of drive selection for the roller chain
drives. The algorithms are mainly based on the existing equations for the mechanics of the
drives, including the geometry and the power transmission capabilities. The purpose of
attempting to computerize the selection procedures is to reduce the number of tables and
charts that are required in traditional selection routines. In addition, it is also intended to cut
down the amount of iteration, time and calculation work performed.
In this case MATLAB software was used in the creation of this program. This is because
MATLAB is a high-performance language for technical computing and integrates
computation, visualization, and programming in an easy-to-use environment where problems
and solutions are expressed in familiar mathematical notation.
In analysis of chain drives, link plate fatigue equation governs failure of link at lower speeds
whereas roller and bushing fatigue tend to govern failure at higher speeds. In developing this
program the limiting horsepower used in the design is the link plate fatigue equation which is
summarized as follows;
Where;
𝐻𝑑 =Design horse power
N = motor speed in RPM
n=number of teeth of driving sprocket
P= chain pitch
Since the program is based on the user selecting the pitch required for any application the
above equation was rearranged such that the pitch was made the subject of the formula.
Therefore;
3−0.07𝑃 = 𝐻𝑑
𝑃
0.004𝑁 1.08 𝑛 0.09
The appropriate value of pitch is determined when the value entered on the left hand side of
the equation is greater than or equal to the value on the right hand side. Variables used
include motor rating, center distance, service factor, number of teeth of small sprocket, speed
of rotating component and pitch. The following is the algorithm used to develop the program
for chain design.
Page | 45
4.5.1. Developing a graphical user interface (GUI)
With the desired algorithm in place, the above program is presented in a user friendly manner
by developing a graphical user interface. MATLAB has presented a sequential procedure that
makes it easy to create the desired GUI. The following pictures show the procedure used in
the creation of the GUI for chain drives. From the file menu, select new, then go down to
GUI.
Fig 4.5.1
Page | 46
On clicking, the GUI quick start guide dialogue box appears.
Fig 4.5.2
By clicking the blank GUI (default) option the following figure appears. It is here that the
desired outlook of the program is created.
Fig 4.5.3
Page | 47
The following two diagrams show the creation process and the final outlook of the program.
Fig 4.5.4
Fig 4.5.5
Page | 48
PART THREE: CASE STUDY
CHAPTER FIVE
5.1. INTRODUCTION
A case study was carried out on v-belt design for use on a sisal decorticator machine.
Analysis
𝐷2
Speed ratio G= ...5.2(a)
𝐷1
1360
= =1.36
1000
D₁=75mm
D₂=1.36*75=102mm …5.2(b)
𝜋 0.075 1360
= =5.34m/s
60
~5𝑚/𝑠
𝜋 (𝐷2 −𝐷1 )2
Pitch length 𝐿𝑝 =2C + 2 (𝐷2 +𝐷1 ) + n …5.2 (d)
4𝐶
𝜋 (105−75)2
=2(600) + 2 (105 + 75) + 4(600)
=1483.1mm
Page | 49
Standard length available=1500mm
105−75
θ=sin−1 =1.432: …5.2(e)
2(600)
1.8
=
0.49
=3.67 ~ 4 belts
D₁=135mm
D₂=1.36*135=183.6mm ...5.2(l)
𝜋 0.135 1360
= =9.61m/s
60
~10𝑚/𝑠
𝜋 (𝐷2 −𝐷1 )2
Pitch length 𝐿𝑝 =2C + 2 (𝐷2 +𝐷1 ) + …5.2(n)
4𝐶
𝜋 (185−135)2
=2(600) + 2 (185 + 135) + 4(600)
=1703.17mm
Page | 50
∝𝑙 =180 + 2*2.38=184.77: …5.2(p)
1.8
=1.833
=0.98 ~ 1 belt
We conclude that it would be more economical to select a V belt with cross section B as
opposed to cross section A.
If we were to consider a chain drive as opposed to a belt drive the following would be the
calculated analysis.
=1.5*1.1=1.65kw
3
Chain pitch chosen type fenner 06B, 8 (9.525mm)
1360
Speed ratio =1000 ...5.2(u)
=1.36
Since driving sprocket is larger than 19 pitches choose sprocket factor of 1.2
Where;
C = center distance in mm
P = pitch of chain in mm
Therefore,
2(600) 30+22 2(9.525)
L= + + = 152.01 pitches ....5.2(w)
9.525 2 600
122∗9.525
= =4.75 feet
305
~1.45m
3
152 pitches or 4.75 feet of Fenner 06B in. chain
8
With the developed V-Belt and Chain Drive C.A.D, its simple and faster to use. Below is a
simple illustration of the above calculations obtained from the C.A.D program.
Page | 52
Speed of decorticator machine N₂ =1000RPM
Step 2: load / start the executable program and a MENU page appears.
Select V-belts button, since we intend to perform a V-belt analysis of the design problem.
A new window is then opened for V-belt design commands from the user.
Step 3: Input the design data given above in step 1 and click on the button written CALCULATE.
This then outputs the first set of design options ,e.g. Belt classification available,
belt speed, minimum pitch diameter D1,belt power rating and minimum pitch diameter D2.
A close comparison of the program results to those calculated in section 5.2 are observed to
be similar.
Step 4: Enter an adjacent / closely available standard size for sheave diameter 2.e.g.
Step 5: Two results are then output as pitch length (mm) and angle of wrap (in radians).
Step 6: Enter an available standard pitch length (from Appendix section A Table 3.2),
Angle of contact correction factor k1 (from Appendix section A Table 3.4) and
Belt length correction factor K2 (from Appendix section A Table 3.5) then click
CALCULATE button.
Step 7: The final result is a modified power rating and number of belts required from which its
advised to base the final selection on the nearest whole number of belts.
Step 8: Use the reset button to clear the form or exit button to close the program.
Page | 53
The figure 5.3.1below shows a screen shot of the results output from the program.
Fig 5.3.1
Step 2: load / start the executable program and a MENU page appears.Select the chain drive button.
A new window is then opened for chain drive design commands from the user.
Step 3: Input the design data given above in step 1i.e. motor power rating and determine service
A close comparison of the program results to those calculated in section 5.2 are observed
to be similar.
Page | 54
Step 4: Enter the speed of motor, speed of rotating component or machine, number of teeth of
driving sprocket greater than 17, value of center distance and select the required pitch from
the given drop down list box starting from the smallest value then click on CALCULATE. If
the number of teeth entered is less than 17, there will be a display indicating “inappropriate
teeth”. If the value of pitch selected is wrong there will be a display text indicating
“inappropriate pitch”. If the pitch selected is correct there is a display text indicating
“appropriate pitch”.
Step 5: The program then calculates the speed ratio, number of teeth of larger sprocket, chain pitch
length in pitches, and the pitch diameter of driven and driving sprockets.
Step 6: Use the reset button to clear the form or exit button to close the program.
Page | 55
The figure 5.3.2 below shows a screen shot of the results output from the program.
Fig 5.3.2
Page | 56
CHAPTER SIX
6. CLOSURE
From the above calculations of determining the length of chain in pitches for sisal
decorticator, it was observed that using the manual method of charts and tables, the length of
chain was calculated to be 152.02 pitches, with pitch of 9.525mm. Using our computer aided
program the length was calculated to be 151.969mm, which when rounded off to the nearest
even number comes to 152 pitches with the same pitch of 9.525mm, number of teeth of larger
sprocket determined as 30 and pitch diameters for both driven and driving sprockets as
90.71mm and 66.7mm respectively. Proper selection procedure was observed and the whole
process of selection from manual to use of program was correctly done thus yielding similar
results. We can further conclude that by use of computer aided program, it simplifies the
cumbersome work of using tables and charts and is observed to be a quicker and simpler
method of determining chain length once all the variables needed are known.
In the case of V belt design the important parameters to be determined were belt section,
diameters of both driving and driven pulleys, pitch length, number of belts, angle of wrap and
angle of contact correction factors, and the modified power. The following are the results
obtained from the use of the program;
Belt section B
Driven pitch diameter 183.5mm
Driving pitch diameter 135mm
Speed ratio 1.36
Pitch length 1703.7mm
Angle of contact correction factor 0.99
Belt length correction factor 0.95
Number of belt 0.7218~1
Results obtained by use of theoretical calculations, using design charts and tables are;
Belt section B
Driven pitch diameter 183.6mm
Driving pitch diameter 135mm
Speed ratio 1.36
Pitch length 1703.17mm
Angle of contact correction factor 0.99
Belt length correction factor 0.95
Number of belt 0.98~1
With the same design procedure, it can be shown that the results obtained using the design
program is similar to the results obtained using the charts and tables of design. This indicates
the use of the design program as a substitute to the use of charts and calculations.
Page | 57
6.2. CONCLUSION
The success in integration of theoretical design procedures used for V-belts and chain drive
mechanism into an executable computer program enhanced the realization of the projects
main objectives.
From chapter 5, in the case study, not only was the program developed for design process but
it was also used and tested to check its comparison to theoretical design outcomes. The same
was done for the chain drives and the results obtained considered acceptable.
6.3. RECOMMENDATIONS
Although the development of a computer aided design program for v-Belts and chain drives
was achieved it also can be used as a good baseline for future work. This section presents a
variety of recommendations for future work on improved versions of the program.
1) For the V-belt design section
The design of chain drive mechanisms requires visual reading and resultant
input of data from carpet diagrams. In computer programming it is difficult to
find a way of letting the computer pick the accurate co-ordinate from a carpet
diagram since most carpet diagrams are not drawn too even scales.i.e. They
include scale variations. Hence it’s recommended to find a way of using carpet
diagrams to determine the chain pitch to use.
The CAD program developed is based on simplex chains design but further
improvement is necessary in regards to multi-strand chains design. Such as
duplex, triplex chains…etc.
Page | 58
REFERENCES
Page | 59
APPENDICES
Table 3.3: Length Conversion Dimensions (Add the listed Quantity to the Inside
Circumference to Obtain the Pitch Length in mm)
BELT A B C D E
SECTION
QUANTITY 32 45 72 82 112
TO BE
ADDED
Page | 60
Table 3.4: Angle of contact correction factor K1 for VV* and V-Flat Drives
Source of Power
Driven Machinery Normal Torque High or Non-uniform
characteristic Torque
Uniform 1.0 to 1.2 1.1 to 1.3
Light Shock 1.1 to 1.3 1.2 to 1.4
Medium Shock 1.2 to 1.4 1.4 to 1.6
Heavy shock 1.3 to 1.5 1.5 to 1.8
Page | 61
Table 3.7: Classification of Belt speeds to power rating of standard V-belts.
Page | 62
APPENDIX B : 3.1.2 Algorithms and codes used in the design of the V-belt program.
3- design_power=power_rating*service_factor
%command in line 3 here tells Matlab to get the multiplication product of value stored in variables:
power_rating and service_factor
4 - If ((design_power>=0.2)&&(design_power<=0.7))
5 - belt_section=('A')
%command in line 5, if the previous if logical expression is met then, variable Belt_section stores ‘A’.
6 - min_ApitchD1=75;
%command in line 6, if the previous if logical expression is met then, variable min_ApitchD1 stores
‘75’.
7 - elseif((design_power>0.7)&&(design_power<=7.5))
%command in line 7,elseif clause is used to clarify the program logic./That is, if condition in line 4
above is not met but a new condition exists similar to line 7,then the following commands follow.
8- belt_section=('A,B')
%command in line 8, variable Belt_section stores ‘A, B’.
9- min_ApitchD1=75;
10- min_BpitchD1=135;
11- min_ApitchD1
12- min_BpitchD1
14- if (design_power>=7.5)&&(design_power<=18.5)
15- belt_section=('B')
16- min_BpitchD1=135
17- end
18- belt_section
19- min_BpitchD1
20- elseif((design_power>=11)&&(design_power<=75))
Page | 63
21- if (design_power>11)&&(design_power<18.5)
22- belt_section=('B,C')
23- min_BpitchD1=135
24- min_CpitchD1=230
25- else
26- belt_section=('C')
27- min_CpitchD1=230
28- end
29-
30- else
31- belt_section=('D')
32- min_DpitchD1=325
33 - end
36 - speed_ratio=speed_rtmotor/speed_rtwheel
37 - G=speed_ratio;
39 - D1=selected_pitch_diaD1;
40- pitch_diaD2=selected_pitch_diaD1*G
42-D2=selected_pitch_diaD2;
44-C=center_distance;
45-B1=2*C
46-B2=pi*(D1+D2)/2
47-B3=(D2-D1)^2
Page | 64
48-B4=B3/C*0.25
49-pitch_length=B1+B2+B4
50-format short g
52-Lp=standard_pitchlength
53-A1=D2-D1
54-A2=A1/C*0.5
55-b=asin(A2)
56-a1=pi-(2*b)
59 - belt_speed=pi*min_pitchD1*speed_rtmotor*0.016666*0.001;
60 - x=square(belt_speed);
61 - if ((design_power>=0.2)&&(design_power<=0.7))
63 - p=p1
64 - elseif((design_power>0.7)&&(design_power<=7.5))
66 - p=p2
67 - elseif((design_power>0.7)&& (design_power<=11))
69 - p=p2
70 - elseif ((design_power>11)&&(design_power<18.5))
72 - p=p3
6
The power rating equation used here is determined from power rating line graphs shown in Appendix C.
Page | 65
73 - elseif((design_power>18.5)&&(design_power<=37))
75 - p=p3
76 - elseif((design_power>37)&&(design_power<=186))
78 - p=p4
79 – else
81 - p=p5
82 – end
84 – power_rating = p
83 - Ha=k1*k2*power_rating
84 - num_belts=design_power/Ha
Page | 66
APPENDIX C:
The graph below shows generated power rating equation for belt section A.
BELT SECTION A
1
POWER (kW) RATING OF
0.8
BELT SECTION A
STANDARD
PITCH DIA.
0.4
P= -0.004V2 + 0.125V -
0.2 0.036 Poly. (BELT
R² = 0.995 SECTION A -75mm
0 SHEAVE PITCH
0 10 20 30 DIA.)
The graph below shows generated power rating equation for belt section B.
BELT SECTION B
3
POWER (kW) RATING OF
2.5
STANDARD
2
V-BELT
Page | 67
The graph below shows generated power rating equation for belt section C.
BELT SECTION C
7
6
5
POWER (kW)
4
BELT SECTION
3 C
p = -0.013v2 + 0.567v - 0.032
2 Poly. (BELT
R² = 0.999
1 SECTION C)
0
0 10 20 30
BELT SPEED,m/s
The graph below shows generated power rating equation for belt section D.
BELT SECTION D
12
POWER (kW) RATING OF
10
8
STANDARD
V-BELT
6 BELT SECTION
p= -0.028v2 + 1.074v - D
4
0.002 Poly. (BELT
2 R² = 0.998 SECTION D)
0
0 10 20 30
BELT SPEED,m/s
Page | 68
The graph below shows generated power rating equation for belt section E.
BELT SECTION E
25
POWER (kW) RATING OF
20
STANDARD
V-BELT
15
BELT SECTION E
10
P = -0.041V2 + 1.942V - 0.026 Poly. (BELT
5 R² = 0.999 SECTION E)
0
0 10 20 30
BELT SPEED,m/s
The graph below shows STANDARD V-BELT SECTIONS POWER (kW) RATINGS Vs BELT
SPEED, m/s .
20
STANDARD V-BELT
SECTION B
15 SECTION C
SECTION D
10
SECTION E
5 Poly. (SECTION A)
0 Poly. (SECTION B)
0 10 20 30 Poly. (SECTION C)
Page | 69
Table 4.1 service factors for chain drive.
Page | 70
APPENDIX D : Algorithms and codes used in the design of the Chain drive program.
3-design_power=motor_power*service_factor
7-Z1=driving_teeth
8-if (Z1<17)
10-end
11-A=speed_rtmotor^0.9
12-B=driving_teeth^1.08
13-C=0.004*A*B
14-D=design_power/C
16-P=pitch
17-F=P/25.4
18-E=F^(3-0.07*F)
19-if (E<D)
21-elseif (E>=D)
23 –end
% the above loop determines the appropriate value of pitch if the above
conditions are satisfied. If not the error message is displayed.
24- speed_ratio=speed_rtmotor/speed_rtwheel
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25- G=speed_ratio
26- driven_teeth=G*driving_teeth
27- Z2=driven_teeth
29- C=center_distance
30- B1=(Z1+Z2)*0.5
31- P=pitch
32- D1=(P*Z1)/pi
33- D2=(P*Z2)/pi
34- H=(1/P)
35- B2=2*C*H
36- E=1/(2*pi)
37- B3=P*((Z2-Z1)*E)^2
38- B4=B3/C
39- chain_pitchlength=B1+B2+B4
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TABLE 4.2 PERFORMANCE DIAGRAM FOR CHAIN DRIVES
Page | 73
TABLE 4.3 RATIO OF NUMBER OF TEETH OF SPROCKETS
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