DESIGN OF TRANSMISSION SYSTEMS

MEE 4007

Dr. M. Sasikumar
 Module-1
• Flexible power transmitting systems
– Flat Belt
– V Belt
– Chain
Module-2
• Bearings
– Sliding Contact bearings
– Rolling Contact bearings
 Module-3

• Classification of gears
• Design of SPUR gears
• Force analysis
Module-4
• Helical Gears
 Module-5
• Bevel gears

Module-6
• Worm gears

Module-7
• Design of gear box (6, 9, 12 & 18 speed)
– Speed diagram
– Structural diagram
 Introduction
• Types of drives
– AC drives
– DC drives
– Mechanical drives
• Flat Belt
• V Belt
• Rope
• Chain
Type Efficiency Space Centre Noise
distance
(around)
Flat 95 More 10 m Less
V 96 Little less 2m less
Rope 96 More 100 m less
Chain 98 less 50 m more
Gears 99 Least Very less more
 Flat Belt
• Advantages
– Low initial cost
– Absorbs Shock
– Noiseless
– Larger Centre distance

• Disadvantages
– More space
– Inaccurate velocity ratio
– Less Efficiency
– Less life due to fatigue
 Flat Belt
• Materials
– Leather
• Oak tanned leather, preferred in dry areas
– Cotton and canvas
• Layers of woven material held by synthetic resin
– Rubber
• Fabric impregnated with rubber
– Nylon core belts
• Outside leather or rubber
– Balata Belts
• Balata gum
 FLAT BELT
Design Procedure
1. Calculate the minimum Pulley diameter
2. Calculate the design power
3. Select the type of belt and its load rating
4. Correct the load rating of the belt
5. Calculate the width of the belt
6. Calculate the length of the belt
7. Correct the length of the belt
8. Calculate the width of the pulley.
9. Calculate the number of arms in the pulley
10.Determine the cross section of the arm
11.Calculate the thickness of the arm
Effect of belt speed

Speed
A open flat belt drive connects 2 parallel shafts 1.2 m apart. The
driving and driven shaft rotate at 350 rpm and 140 rpm
respectively. The driven pulley diameter is 400 mm. The power
to be transmitted is 1.1 kW. Design the drive.
Types of flat belt Drive

2. Crossed belt drive

Belt drive with idler pulley
• Slip of the belt
• Creep of the belt
• Crowning
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 -..J
V,
0() V ~ BELTS
Data on Standard V-Belt Sections
w
i~ ·\
Cross-section
symbol
Usual load of
drive
Recommended
minimum
pulley pitch
diameter
Nominal
top width
Nominal
thickness
Weight
per
metre
ooooooff
&
0 0 0 0 0 t,..
I,
kW d, mm W,rum T,mm kgf I

¥
A 0.75-5 15 13 8 0.106
B 2-15 125 17 11 0.189
C 7.5-75 200 22 14 0.343
D 22-150 355 32 19 0.596 STANOMIIJ
SECTION OF
I E 30-)90 , 500 38 23
VaELTS

Nomiaal htside lalgth, aominal pitch lengths, permissible length variatlo• ancl correction factor for standarcl sizes of V-Belta
Nominal Pitch Length Pitch Lenath Variation Correction Factor, Fa
Nominal Maximum
inside Cross- Cross- Cross- Cross- Cross- Pitch-length variation in
Section Section Section Section Section Belt Cross-Section Symbols
length
A B C D B limits Jenath within
a matcbecl set
mm mm mm mm mm mm mm A B C D
mm

}
0
m
+ ll.4 1
610 645 0.80
az
en

l
660 696 0.81
- 6.4
711 747 0.82
0
2.5
> 0.84
' 787 823
l +12.5 0.85

J
"'0
8\3 MS
J
Cl'.l
a..., 932 1.S 0.87 0.81
~9 925
tr\
950 0.87
(, 9\4
':!:.
 = \
c:,
=
i5 I ,._, Nominal Pitch Lensth Pitch Lcnatb Variation
Maximum
- ~ F ' - . C , . . o T . l:11•

z en-- cro.- Crou- 0-osa- Crou- Pitch-length variation in

:::::; .imide Section Section Section Belt c.a---&,cuoa Symbo\s

-
lel,pb Secdon Sec:doo limits lenath within
A B C D E
t a matched ect
> mm mm mm A B C D '6
..., mm mm mm mm

l
V1

l
a 0.88 0.83
-i 965 l 001 1008
r:,
991 I 026 0.88
/")
= 1016
l 067
1 OSI
l 102
1 059
1110 I
+14.0
- 8.9 t 2.5
0.89
0.90
0.90
0.84
0.85
1092
l 168
1128
i 204 l 212 J J 0.92 0.87

'I 0.93 0.88

l 219 1 255 1262 'I 0.80
0.94 0.89
1 295
\ 372
1 331 1 339
1 415
l 351
I + 16.0 II 0.96
0.90
0.90

I
l 397 1 433 1440 - 9.0
0.96 0.90
1422
1413
1458
l 509
1466
l 5.0
0.97
I 580 0.98 0.92 0.82
) 560 1 567

}
151.4
0.99
) f,00 I 636
0.99
l 626 l 661 + 17.8 1.00 0.94
1651 1687 ) 694 - 12.5 1.00 0.95 0.85
\ 727 l 763 I 770 I 783
1.01 0.95
177& 1814 1 821

l 905 1941 I 948 I 961

+17.8
- 12.5 I
I
1.02 0.97
0.98
0..87

i
1.03
1 981 2 017 2024 I 1.04

I
2032 2068 7.5 o.98 ll-89
2101 2 113 +30 . 1.04
2057 2093 I.OS 0.\)9 0.90
2 215 - 16
2159 2195 2202 0.91
1.06 1.00
2216
2438
2 322
2474
2 329 2 342
2494 J 1.08 o.n

ii
 ""
0\
0 Nominal Pilch Length Pitch Length Variation C<rrrcction Factor, F •
Nominal Maximum
inside Cross- Cross- Cross- Cross- Croa- Pitch-length variation in
Section Section Section Section Section Belt Cross-Section Symbols
leo,th E
limits length within
A B C D a matched set
mm mm mm mm A B C D E
mm mm mm mm
2 507 l L02
2 464 l
2 583 I 1.03
2 540 +34
2 703 2 7IO 2 723 I I.IO 1.04 0.94
2667 - 18
2 845 2880 2 888 2 90 1 I 1.11 1.05 0.95
3 048 3 084 3 091 3 104 3 127 J_ 1.13 1.07 0.97 0.86
3 150 3 205 0.97
lI IO
3 251 3 287 3 294 3 307 3 330 +38 1.14 1.08 0.98 0.87
3 404 3 459 >-I -21 II 0.99
3 658 3 693 3 701 3 713 3 736 J 1.11 1.00 0.90

4013 4056 4 069 4092

+43
-24 j 1.13 1.02 0.92

}
0.92
4 115 4 158 4171 4194
+43 l 1.14 1.03
4 394 4 437 4 450 4 473 I l.15 1.04 0.93
-24
4 572 4 615 4 628 4 651 I 1.16 1.05 0 .94

l
4953 4 996 5 009 5-032 1.18 1.07 0.96
+49 12.5 0.96 0.94
5 334 5 317 5 390 5 413 s~6 1.19 1.08
6 045 6 IOI 6 124 6 137 J -28

+56
II 1.11 1.00 0 .96

6 807 6 863 6 886 6 899 -32 j

1.14 1.03 0.99

J
+56
7 569 7 625 7 648 7 661
-32 1 1.16 I.OS 1.01

8 331 8 387 8 4IO 8 423 +65 15 1.19 1.07 1.03

Cl 9093 9 149 9 172 9185 -37 1.21 1.09 1.05
m
C/l
ci 9 934 9 947
+6S 1 1.23 1.11 1.07
z 9 855 -37 I
Cl
10 6 17 JO 696 10'709 +76 I 1.24 1.12 1.09
> 12 141 12 220 12 233 -43 I 1.16 1.12
13 744 I 3 757 +89 17.5 1.18 1.14
-c 13 665
C/l
IS 189 15 268 15 281 - -50 1.20 1. 17
Cl
+105
I
-I
m \61\3 16192 16 805 I 1.23 1. 19
('""> -59 J
-:r.
 pcSI·gnation:
nd
A y.be It d cross-section
as C 3048/ 120 of nominal inside length of 3048 mm ( 120 inches) shall be
C a IS :2494.
designate

1 st th
should be amped wi Grading No. SO if the measured pitch length is ~qual to the
The _be Its pitch length. • A deviation
111 1na d h of
d. 2.5 mm in length from nominal pitch length is to be
represent
no ed by one unit an t e gra mg number will increai.e or decrease• as the length is
or less.
111 ore

Example:

A belt of designation C 3048/1 20 IS : 2494 having

an actual pitch length of 3104 should be marked
(3048/120-50
Jf the actual pitch length is 3101.5, it should be marked
C3048/ 120-49
If the actual pitch length is 3109, it should be marked
C3048/ 120-52
Reco mmended standard pulley pitch diameters, mm . R-20 series (80 mm-2500 mm) .
Diameter of larger pulley,
D, diameter of larger pulley, mm
D=d.n 1 .'1 d, diameter of ;mailer pulley, mm
n, n1 , RPM of smaller pulley
n2, RPM of larger pulley
'1~0.98 , efficiency (assumed)

Selection of centre distance, C

D
Speed ratio, i = d 2 3 4 5 6 to 9
=::____d_d---:;c;..-t_o---,-s---1-.2---1.-0--~o~.9=s--:o~.9~- . o.ss
Ri:,commen e D ra I •

c min =0.55 (D+d)+ T T. nominal belt thickness, mm

C.... =2 (D+d) L nominal pitch length of belt, mm
, (to be selected from table-pages 7 59 and 7.60)
'ff (D-d)2
L=2C + T (D+d)+ 4C c, Centre distance, mm

Centre distance for a given belt length and

diameters of pulleys C =
. L D+d
where A = - -
4 - 'ff -8-
( D - d )2
B= --8-

f
O the centres for two transmis~ion pulley~:
Minimum allowances for I hc a djusu,,ent
. 1 centre distance mmus
· 1·5 "11.. of L
Lower limiting value == Nom1na I centr:: distance plus 3 '/4', of L
. .. alue == Nomina
Higher hm111ng v .. ·on the belts may be stretched to 0.5 % to I% of L
- he initial tensi •
lnitiar tension: In order to give t .

DESIGN DATA - PSG TECH 7.61

 FORMULAE FOR TRANSMITTING CAPACITIES

The maximum power in kilowatt which the V-Belts of sections A, B, C, D and E c

shall be calculated from the following formula : an trans .
11111

Belt Mallimum
cross-section Formula value of d. in
symbol the formula
mm
where
A
19.62
. )
kW .., ( 0.45S-0·09 --d- -0.765 x l0- 4 S2 S 125

j
. .
kW, maximum Pow .
at 180° arc ofer in k\V
for a belt of con1ac1
B kW=_(o.19s-o.o9 _ ~-
.8
-1.32 x10-•s•)s 175
.
S,
length

belt speed, m/s

average
I

142.7 )
C kW • ( 1.47S-o.oe _ _ d- -2.34 x J0-4S 2 S 300 d.. equivalent pitch
• meter =d xF dia.
P b
7
D kW -= ( 3.22S-0·09 - ~ - -4.78 x JO-' s• )s 425 dP, pitch diameter of the
• smaller pulley. mm

Fb, the small diameter factor

E 952
kW-= ( 4.58S-0.09_d_7.05 x t0- 4 S2 ) S 700 to account for variation
• of arc of contact, from
table below

Small dia. Small dia.

Speed ratio range, D/d Speed ratio range, D/d
factor, Fb factor, F0
1.0 to 1.019 I.OQ I.223 to 1.274 1.08
1.02 to 1.032 1.01 1.275 to 1.340 l.{)(J
1.033 to 1.055 1.02 · 1.341 to 1.429 I.IO
1.056 to 1.081 1.03 . 1.43 to I.562 I.II
1.082 to 1.109 1.04 1.563 to 1.814 . 1.12
I.I I to 1.142 1,05 1.815 to 2.948 1.13
1.143 to 1.178 1.06 2.949 and over 1.14
1.179 to 1.222 1.07

Matched ~ets
Number of
consecutive
Nominal
grading numbers
belt length
any of which may
mm
be used to make
a matched set
610-1168 2
1219-1778 3
1905-2464 4
2540-4013 5
4115-6807 6
7569-9093 7
9855 and over 8

GTECH
DESIGN DATA. pS
7.62

C
 D-d o, pitch diameter.of laraer PUllt)
Arc of contact angle = 2 cos-1 - 2C
d, pitch diameter of SotaJ(er PULi
0-d
c, .
centre d ,stance C)'

=l80°-60°C

Correction ,actor
It fior arc of contJct, F,

Arc ot contact on Correction factor

smaller pulley (Proportion Qf ~goo rating)
(in deirees) V-V V-Flat
180 1.00 0.75
177 0.99 0.76
114 0.99 0.76
171 0.98 0.77
169 0.97 0.78
166 0.97 0.79
I
163 0.96
160 0.79
0.95 0.80
157 0.94
154 0.81
0.93 0.81
151 INC01flf,C'r
0.93 0.82
148
0.92 0.83
145
0.91 0.83
142
0.90 0.84
139
0.89 0.85
136
0.88 0.85
133
0.87 0.86
130
0.86 0.86
127 INCORl#ICT
0.85 0.85
123
0.83• 0.83
120
0.82
117 0.82
0.8(
113 0.81
0.80
110 0.80
0.78
0'.78
106
0.77
103 0.77
0.75
99 0.75 CORRECT
0.73
95 0.73
0.72
91 0,72
0.70
87 0.70
0.68
83 0.68
0.65
0.65

NoTE I-Arcs of contact · below I 20° should not be used unless full drive
. deta ils are first
submitted to the V-drive manufacturer concerned for· confirmation.

NoTE 2-lt should be noted that the advantage of using V-Ftat drives d1mm,sbes
. . . '..°creas1.nglJ'
p,acti•I
for arcs of contact greater than 133°, and the use of such drives is usually not found to"'
for arcs of contact grea1t·1 titan 151°.
7.68
pSG 1£CH
DESIGN DATA-
 Correction factors for industrl a1service, Fcx

_ Type of Drivina Unita

~MSq~n; Normal Tor- AC Moton·1 Hilb rof-
chto Uiml Cap, Syn- que, High S1 ip R~oo-
llOUI and Split Phase Induction, Single Pb~
Series Wound and Slip
Rin1 .
DC Moton; Shunt DC Motors· Series
Wound, Multiple Cylin- Wound and Compound
der ~nteroal Combuation Wound. Single Cylio~er
Type of O.iven MacbiDM , Bnamee 0YCr 600 RPM internal CombtJtt1on
'tY of Enames. Multiple Cy!in-
der Internal Combusuon
~nlll)CS unckr 600 RPM,
Line Shafts, Clutches,
Brakee, Direct on-line
startina
Upto Over Over Upto Over Over
10 hr IO hr to 16 hr & JO JO hr to J6br&
16 hr continuous hr J6 hr contioUOUI
service service

l.l 1.2 1.3

Agitators for liquids, blowers and 1.0 I.I 1.2
Light.duty exhausters, centrifugal pumps and
compressors, fans upto 7.5 kW
(10 hp), and light-duty conveyors.

1.2 1.3 1.2 1.3 1.4

Belt conveyors for sand, gram etc; 1.1
Medium· dough mixers; fans over 7.5 kW (10
duty
hp); generators; line shafts; laundry
machinery; machine tools; punches,
presses and shears; printing machi-
nery; positive displacement rotary
pumps; and revolving and vibrating
screens.

elevators, 1.2 1.3 1.4 1.4 1.5 1.6

Heavy-duty Brick machinery, bucket
exciters, piston compressors, conve•
yors (drag-pan-screw), hammer oiills,
paper mill beaters, piston pumps,
positive displacement blowers, pulve-
r.iz.ers, saw mill and wood-working
machinery and textile machinery.

1.3 1.4 1.5 1.5 1.6 1.8

Extra-heavy- Crushers (gyratory-jaw-roll), mills
duty (bail-rod-tube), hoists and rubber
(calenders-extruders-mills).

'Non 1-Tbe table gives only a few examples of particularly representative machines.

'Non 2-If an idler pulley is used, the following values must be added to the service factor:
Idler pulley on {inside : 0 .Jdler pulley on {inside : 0.1
the slack side outside: 0.1 the tight side outside : 0.2

'
DESIGN 7.69
DATA· PSG TECH
 P dm·e power, kW
- ---1 - - --- - ------
·~
_F• • correct ion fact or according to service
kW, ratings of the V-bclt
Fe, correction fact o r for length
Fd, correctio n facto r for a rc of c·ontact

DIMENSIONS OF STANDARD V- GROOVED P~LLEYS

Minimum
Groove Pilch distaooc Minimum Centre to Ec!ge or
Cross width down ro Pulley pitch diameter Angle A depth below centre Tolerance pulley to
lp pitch line Tolerance
Scc1ion dµ pitch line distance of OD firs{ groove on
b Tolerance h grooves e• centre f
mm mm ± 1/2° e r
mm mm mm mm mm
Under 75 mm to 67 mm
A . II 3.3 32°
••Recommended min. 75 mm and under 125 mm
34° 8.7 15 ±0.3 10 +2
125 mm and over
Under 125 mm to I 17 mm
38° J -1
32°
H 14 4.2 ••Recommended min. 125 mm an<l under 20D mm 34° 10.8 19 ±0.4 +1
200 mm and over
Under 200 mm to I 75 mm
38° J 12.5
-\
34°
C 19 5.7 ••Recommended min . 200 mm and under 300 mm 36" 14.3 25.5 ±0,5 17 +2
.300 mm and over
Under 355 mm to 300 mm
38° J -1
-:, 34°
D 27 lU ... Recommended min. 355 mm and under 500 mm 36° 19.9
J
Il 37
,:, ±0.6 24 +3
500 mm and over 3go
5 -I
E 32 9.6 23.4 44.5 ±0.7 29 +4
-I
"'I he to lerance ~ on dimension 'e' apply to the di stance between the centres of any two grooves whether consecutive or not.
•• The pitch diameter marked with two asterisks is the recommended minimum for standard use, but the largest possible pulley~ should be used
fo r long belt life, provided that the belt speed does not exceed 25 metres per second.
\ h e "'a\uc s gi ven above h a v e been calculated s ubject t o certain approximations. fro 1n the f o llo wing fo rn1ulae : -
\")=- O 3 \ P c -:-.: \.35 I P f """' 0 .9 I P h = 0 . 7 I P+ I (ex p r e ssed i n n1illimctres )