2.0 "BELT DRIVE DESIGN 2.1 Introduction Belts are special classes of flexible connectors for trensmitting motion between two or more shafts at appreciable distances, especially where the shafts are perellel. Belts in use have different cross-sections, such as in flat-belt, V-belt, "toothed" or timing belt, wedge belt end round belt. Belts, except the "toothed" belt, have the outstanding advantage of absorbing vibration and shock, tending to transmit only a minimum to the connected shaft. They are quiet in operation. When properly main- tained, they can te designed to have a long trouble-free life. The maintenance of belt drives usually amounts to periodic centre-distance adjustment to compesate for stretch of the belt and, replacement of the belt when it is no longer serviceable. Belts are spoken of as wearing out, but the actual failure is much analogous to fatigue. In be}t drives, the belt-materiel tust be strong flexible, and durable and must heve 4 high coefficient of friction on the pulley, Common belt materials are leather, fabrics such as canvas, rubber, fabric and cords fhoulded in rubber and steel cables. Pulleys are generally nade of cast iron, cast steel, or pressed steel. The cast materials have good friction and wear characteristics. Pressed steels pulleys are lighter but they have lower friction and may produce excessive belt wear. Rubber belts meeting above stated conditions have high load capacity and they areoperated up to a maximum speed of 30m/s, Leather belts however can run up to 45m/s and they are durable even under shock loads. 2.1.1 Flat Belts and V-Belts Flat belts and V-belts may be employed to trqusmit power from one shaft to another, where it is not necessary to maintain an exact speed ratio between the two shafts power losses due to slip and creep amount to 3 to 5 percent for most drives. V-belts may also be used between non~ parallel shafts to meet special requirements. In such coses, in order for the belt to stay on the pulleys, it must approach each pulley in a central plane perpendicular to the axis of rotation of the pulley. A V-belt can be used to transmit power up to a ratio of 1031 with a belt speed of up to 35/s. A §lat belt is uséd ona flat belt pulley which is normally crowned so that the belt will not slip off in motion. 2.1.2 Timing Beats “Himing belts remove belt slippage, due to the positive grip of belt teeth with pulley. Less maintenance is required while the range of load capacity is very wide. Unlike flat and V-belts, timing belts need no high initial tensioning, belt speed can be up to 80m/s. Space require- ment is smaller and speed is uniformly transmitted without rise and fall of pitch line as with chains. Since it isnot a friction drive, heat generated is low and noise is also reduced tremendously. Timing belts are best suited for power transmission with synchronization or any special furction. Cross sections of different belt types and pulleys are shown in Fig. 2.1. 2.2 Belt Geometry and Stresses In this section a detailed analysis of the parameters governing the design of belts and pulleys is presented. The discussion is made to evaluate the geometry, stresses and forces in the belt, This will forma basis for selecting standard belts and pulleys. 2.2.1 Belt geometry. From Fig.2.2.1a, Open Belt. sin®= Ded oe. f= 180° + 20° =| 180% asin” (Dsa} 180° - 20° » 180° 2.2.e1n71 yy 23) 4 oN se eek Hence, Belt length, L = 2C Cos @+ 7 P + a} + we 2 Tih which can be approximated to, ats e 4 7 2 “Lae Lo = 2c + Tt (Ded) ¥ (Dea) + Pray ee vee (204)where, L.= effective outside length (mm) = distance between centres of pull~ys (mm) D = effective outside diameter of Inrre pulley (mm), for flat pulleys this is nominal belt diemeter plus twice the nominal belt thickness. d= effective outside diameter of smal? sheave (mm). The centre distance can be obteined as, cabs [v2 2 w-a27H... 4. 2.2 where beL- T (Dea). a For closed belts, Fig. 2.2.1b. Sin 0 = D+a B= BR = 180° + 206° = 180° + asin" (p + 3 % a Git The belt length in this condition is 2Cos 0° + (90° + 6°) (D + 2) acose + Z (+d) 180° 2c + Ti 2 + 120k * 3 Weer OA OP 4 has 1H kSometimes when one of the pulleys has been turned through an ungle it becomes difficult to estim:te the belt length, For pulleys in which the axis are »erpen- dicular to eech other Lae Fh 2 2% 3 253 Boras cts vie (?e eas The angle of contact for this case is pore a a ets Where the plus sign is used for evaluation of lrrger pulley are of contact and the minus sign for the smaller pulley. 2.2.2 Belt Stresses and forces when the belt is rotating, there is ciways a tigher side with a tension Tj. The other side is precsuned to have a tension T,. Taking into account the centri- fugel effects of the belt in motion, the relationship of the forces can be summed up aswhere, T, = tension on the slack side (N) Ty = tension on the tight side (N) 20) = "m of belt per unit length (Ad/m) * Vo= belt speed (m/s) (A = coefficient of, fricticn f = arc of contact (rad) The average tension in the belt is therefore, ROM ge ssn act 266 and the power thet con be transmitted with the belt is given as . P= G-%4) View wee cee 247 When a belt is used to transmit power, it experiences bending and tensile stresses at the same time. In order for the belt to be able to transmit the power safely, a proper selection of the cross-sectional area is important. This is especially so, when the material propertics of the belt is known. To estimate the minimum cross-sectional area, equation 2.8 can be used, tT = & A Bo]: occ ee where, Gy material stress property N/mm? A = cross-sectional area (mn?) Tz = tension on tighter size (N). However, based on the power to be transmitted, the cross-sectional area can be obtained with R ef” e : a WEP) ee rites» aya)When 6 belt is in motion, a force P {s imposed on the sides of the pulley, resulting in @ normal, force P,. The normel force 2, = £ Sings while the tractive force F = Qu, = AMP Sing on. nee wee 2610 The tractive force is the one used to move the pulley against the load. 2.3 Plat Belt and Pulley Design. The procedure for designing flat belt drives is as follows: (a) Select the type of belt This is done by calculating the stress imposed on the belt due to the tension of the drive and corpering it with the allowable stress of the belt matericl. For leather belts, kk, design stress G)= Oy (ae) : where @ = design stress (t/mm”) Om = belt material tensile strength (N/mm?) K, = small pulley diameter factor (see Table 2.2) K, = motor type and starting weticd factor (see Table 2.3) Kj, = special operating conditions factor (see Table 2.)) Equation (2.11) also applies for rubber, cotton, canvas and balata type belts.Table 2.3 Motor Type and Stucting Mokoretiod Factor Belt Material] Allowable Tensile Strength N/mm2) ; Motor Type and Factor, pacer pe Startin: Netiiod K eee? a Squirrel cage ond Rubber compensator start 1.5 a Squirrel cage, line Canvas start 2.0 synthetic Slipring and hich Polymer Film torque start Table 2.2 Table 2el. Small Pulley Diameter Factor Operating Conditicn Factor Small Pulley Factor Kp Diameter (mm) Operating Conditions | Factor, K 0 - 100 over'400%"200 Oily, wet or dusty Over 200 - 300 Over 300 - 00 Vertical drive Jerky loads Shock and reversing Over 400 = 750 Over 75010 However for nylon core type, o b= bm hy K, = arc of contact fector. (Table 2.5) After finding b>, compare this with the actual stress in the belt, Oy. If GAS & nen vert material cen be used, if not enother material has to be chosen. ne thickness of the belt can be estimated with equetion.(2s48). ee GRAV were nee tee (2413) where, t = belt thickness, mm. p = motor power, Watts. A = belt cross sections] area, mr’ & = design stress (N/mm?) Y = belt speed. (>) Determine Pulley Diameters Based on the thickness obtained with equation (2.13) and using Table 2.6, the diameter of the smailer pulley can be obtained. Then using the relationship expressed in equation (2.1) the belt speed ¢ean be calculated und checked with belt speed for flat belt. Belt Speed, V = $5... Cart D = pulley diameter (mm) N = pulley speed (rpm) Flat belt have a speed limit of 5 to 30m/s fcr conventional materials while for special fabrics or rubber, high speed of 50m/s can be used but this gives e chorter life.Table 2.5 s Contact Factor Arc of contact 70. “80° -90° 490. 110: dogs Flat Belt Factor V-Belt Factor deg. THO P4180: (160s 170. TBO e190... 200 | rast nent Factor |0.88 0.91 0.94 0.97 1.00 1.05 1,10 0.89 0.92 0.94 0.98 1,00 - - V-Belt Factor Arc of Contact der. 210 220 Ales eS, Flot Belt Factor V-belt Factor1 (c) Find the Centre Distance Based.on the limitations provided by the m:chine the Centre distance of the pulley can be found, The minimum centre distance isuusually restricted to o condition where the arc of contact on the small ley, > is at leest 150°. The centre distance can be evaluated using equation (2.2). The angle of contact on the pulley must be higher than 150° otherwise the design is modified to satisfy this condition Table 2.6 Ratio of Small Pulley Dismeter ta ehpess Tn Fiat Belt Drives Belt Metcrial Rubber ho 30 Leather ei) 25 ; Solid Wooven Canvas 30 oo Woolen 30 25: synthetic 100 50 (ad) Belt Selection The calculated belt dimensions are now checked ageinst standard belts and the closest to the obtained dimensions is chosen. This chosen belt also has to be checked to ensure its fitness into the available space.(e) Service Lite Checking the service 1ife of the belt ts next. Goodyesr Coupany developed equation (2.15), an enpiricnt relation which cun be used to check the serWice .ife of belts lepsp® kpsbint-d22 on gatnct put, a faster approach is to use, N c “en max, total number of cycles of lead applicotion fatigue ductility exponent, index, which is 5 to 6 for flat belt (rubber and canvas), 6 to 11 for V-belts. However, for reasonable life of belts, 2 minimum ratio of diameter of a pulley to thic'ness of belt is about 30, Also excessive flexing of belt should be preven- ted otherwise, the life of the belt will be shortened. 2.3 Quick reference in belt design. The following equations are frequently required in the procedures of belt design. t cross-section of belt. (1, - 14) V+ tronsmitted power 2 4 Tp - mv? 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