UNIVERSITY OF DAR ES SALAAM

COLLEGE OF ENGINEERING AND

TECHNOLOGY

DESIGN OF THE DRIVING MECHANISM FOR A BELT

CONVEYOR

NAME: Mayeka, Luckson Evarist

REG. NO: 2020-04-06273
DEGREE PROGRAMME: BSc. In Mechanical Engineering
SUPERVISOR’S NAME: Prof. Bavo Nyichomba

Date 1/2/2023
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Abbreviation and Acronyms

PDS Product Design Specifications

Kw kilowatts

rpm Revolutions per minute

Mm millimeters

m/s Metres per second

Km kilometers

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1.0 INTRODUCTION

1.1 Background Information

A Small mining company uses a semi-automatic light duty belt conveyor to move their materials
from the production site to the processing unit by using a small engine. Due to the nature of its
working mechanism, the power unit is left running continuously for the 10 working hours shift
while the conveyor is required to move/work only when needed (i.e., an operator can stop the
conveyor during break time for example). Since, there are different types of transmission
systems aimed at transferring power from the driving shaft to the driven shaft, thus different
mechanisms can be used to allow the operation to take place such as using of belts or chains for
transmitting power but also using clutches such as cone clutch or disc clutch in starting or
stopping the operation.

1.2 The Main Objective

An appropriate design of power transmission or driving mechanism and clutch system is required
to carter for the requirements of the belt conveyor whereas the clutch system would allow the
operator to start or stop the conveyor depending on the work or when it is particularly needed.

2.0 LITERATURE REVIEW

The methods employed in information collection is grasped from the class but also from
literature thus including books and Internet were different possible power transmission or driving
mechanisms and clutch system for belt conveyors are discussed. There are variety types of power
transmission or driving mechanism which include the use of chain drives and belts. Through
these, the system can adhere to the transmission of motion from one point to the other point.
Apart from the power transmission, clutches are also used in allowing driving mechanism from
driving shaft to driven shaft either by starting or stopping the motion.

2.1 Design Requirements

The conveyor is installed such that the center distance between the driving and driven shaft is X=
1150 mm, with the engine producing power, P= 9.8 Kw at speed, V= 900 rpm. The desired
conveyor speed is 0.66 m/s and the diameter of the drum which conveyor belt is wrapped around
is 50 mm.

2.1.1 Transmission system:

(a) Use of belts:

There are basically three types of belts but the most used belts are the V-belts and Flat belts. The
V-belts are made of fabric and cords moulded in rubber and covered with fabric and rubber.
These belts are moulded to a trapezoidal shape and are made endless. The included angle for the
V-belts is usually from 30◦ to 40◦. The power is transmitted by wedging action between the belt
and the V-groove in the pulley. The Flat belts are mostly used in factories and workshops, where

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a moderate amount of power is to be transmitted from one pulley to another when the two
pulleys are not more than 8 metres apart.

Advantages of V-belt Drives over Flat belt Drives

(i) The V-belt drive gives compactness due to small distance between centers of pulleys.
(ii) The drive is positive, because the slip between the belt and the pulley groove is negligible.
(iii) It provides longer life, 3 to 5 years
(iv) It can be easily installed and removed
(v) The operation of the belt and pulley is quiet

Disadvantages of V-belt Drives over Flat belt Drives

(i) The V-belt drive cannot be used with larger center distances, because of large weight per unit
length
(ii) The V-belts are not so durable as flat belts
(iii) The construction for pulleys of V-belts is more complicated than pulleys of flat belts
(iv) Since the belts are subjected to certain amount of creep, therefore they are not suitable for
constant speed machines such as synchronous machines.
(v) The belt life is greatly influenced with temperature changes, improper belt tension and
mismatching of belt lengths.

Figure 2.6. V-belt pulley

Figure 2.7. Flat belt pulley

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(b) Chain driven
The chain driven make a use of sprockets whereas chains are mostly used to transmit motion and
power from one shaft to another, when the Centre distance between their shafts is short such as
in conveyors, rolling mills and so on. The chains are used for velocities up to 25m/s and for
power up to 110Kw.

Advantages of Chain drives over Belt drives

(i) As no slip takes place during the chain drive, hence perfect velocity ratio is obtained.
(ii) Since chains are made of metal, they occupy less space in width than belts
(iii) It may be used for both long and short distances
(iv) It transmits more power than belts

Disadvantages of Chain drives over Belt drives

(i) The production cost of chains is relatively high
(ii) The chain drive needs accurate mounting and careful maintenance, particularly lubrication
and slack adjustment.
(iii) The chain velocity has velocity fluctuations especially when unduly stretched

Figure 2.5. Chain drive

2.1.2 Clutch Systems:

A Clutch is a machine member used to connect a driving shaft to a driven shaft so as the driven
shaft may be started or stopped at will, without stopping the driving shaft. There are particularly
two main types of clutches namely as the positive clutches and friction clutches.

The positive clutches are used when a positive drive is required. The simplest type of a positive
clutch is a jaw or claw clutch. The jaw clutch permits one shaft to drive another through a direct
contact of interlocking jaws.

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 Figure 2.1. Jaw clutch

A friction clutch has its principal application in the transmission of power of shafts and machines
which must be started and stopped frequently. The force of friction is used to start the driven
shaft from rest and gradually brings it up to a proper speed without excessive slipping of the
friction surfaces.

The friction clutches can be classified into three types namely as;
(i) Disc or plate clutches
A single disc or plate clutch consists of a clutch plate whose both sides are faced with a frictional
material. The pressure plate is mounted inside the clutch body which is bolted to flywheel. Both
the pressure plate and flywheel rotate with the driving shaft.

Figure 2.2. Single disc clutch

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(ii) Cone Clutch
It consists of one pair of friction surface only. In cone clutch, the driver is keyed to the driving
shaft by a sunk key and has an inside conical surface or face which exactly fits into the outside
conical surface of the driven.

Figure 2.3. Cone Clutch

(iii) Centrifugal Clutches

The centrifugal clutches are usually incorporated into the motor pulleys. It consists of a number
of shoes on the inside of a rim of the pulley. The outer surface of the shoes is covered with a
friction material.

Figure 2.4. Centrifugal Clutch

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2.2 Preparation of PDS

Table 2.1. PDS of driving mechanism of belt conveyor

S/N ELEMENT DESCRIPTION

1. Performance (i) There should be a high efficiency in the transmission and
clutch system.
(ii) The transmission and clutch system should possess
minimal breakdown.
(iii) There should be minimal replacements of belts and
clutch system.
2. Environment (i) The system should produce less noise in operation.
(ii) There should be less friction and hence minimal wear in
the belts.
3. Life in service (i) Durable materials for both clutch and belts should be used.
(ii) The system should operate for a long time.
4. Maintenance (i) It should be easy to dismantle or assemble.
(ii) Materials or spares should be available
(iii) Tools and human resource should be available.
(iv) It should be easy to operate and clean.
5. Target product The cost for designing the driving mechanism of belt conveyor
cost should be affordable to the consumer. .
6. Aesthetics The product should be provided with a good appearance and
smooth surface finish. The mild steel shafts should be galvanized.
7. Materials Galvanized Mild steel should be used in the making of the shafts
so as to prevent rusting while the belt pulleys should be durable.
8. Safety (i) There should be protective guards (cages) of the belt pulley
to prevent dangers from occurring.
(ii) There should be negligible slipping between the belts and
the pulley.

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3.0 DEVELOPED CONCEPTS FOR THE DRIVING MECHANISM AND CLUTCH
SYSTEM FOR THE BELT COVEYOR

The driving mechanism and clutch system for the belt conveyor can be generated in various
ways depending on the product design specification as considering to the clutch locking
mechanism and type but also the precise type of belt to be used in the power transmission.

3.1 Concept I: V-belt pulley and cone clutch system

The belt conveyor is operated with the V-belt pulley as the power transmission system from the
driving shaft to the driven shaft while the operator can start or stop the conveyor by using a cone
clutch which is controlled by a handle. The handle is pushed forth to allow engagement and
backwards to disengage the connection of the shafts. The clutch has adjustable springs and
extension support that allow locking mechanism of the handle as it is also located on a pin
support.

Figure 3.1. V-belt pulley and Cone clutch system

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Advantages and Disadvantages of V-belt pulley and cone clutch system

Advantages
(i) The system produces less noise in operation as the use of V-belt pulley is quite in operation.
(ii) The components in the system can be easily installed and removed that is the V-belt pulleys
can be easily maintained.
(iii) The use of V-belts provides a longer life in operation.
(iv) The drive is positive as the slip between the belt and pulley groove is negligible.

Disadvantages
(i) The V-belts are not so durable in operation.
(ii) The belt life is greatly influenced with temperature changes, improper belt tension and
mismatching of belt lengths.

3.2 Concept II: Flat belt pulley and disc clutch system

The belt conveyor is operated with a Flat belt pulley as the power transmission system from the
driving shaft to the driven shaft while the operator can start or stop the conveyor by using a disc
clutch which is controlled by a pedal. The pedal is pressed forth to allow engagement and
released to disengage the connection of the shafts. The clutch has adjustable springs and
extension support that allow locking mechanism of the pedal.

Figure 3.2 Flat belt pulley and disc clutch system

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Advantages and Disadvantages of Flat belt pulley and disc clutch system

Advantages
(i) The flat belt pulley is more durable in operation.
(ii) The flat belts are not greatly affected be temperature changes, improper belt tension and
mismatching of belt lengths in operation.

Disadvantages
(i) It is not safe due to effect of slipping of the belt from the pulley.
(ii) Flat belts do not offer longer life in operation due to friction and wear.

3.3 Selection of Appropriate Concept

The operation of the belt conveyor requires a system which is quite and for this the use of V-belt
pulley and cone clutch become advantageous as the its system is quiet. The system also requires
a controlled easy maintenance of the components that is the installation and removal, in
preference to the two concepts, the use of V-belts allow easy dismantle and assemble thus
become easier to be maintained. The use of V-belts also provides a longer life in operation thus
making it suitable to use V-belt pulley and Cone clutch system in operation. The drive is positive
since the slip between V-belts and the pulley groove is negligible thus providing a credit to use
the V-belt and Cone clutch system.

4.0 DESIGN OF THE TRANSMISSION SYSTEM OF THE BELT CONVEYOR

The transmission system of the belt conveyor consists of the V-belt pulley and Cone clutch
which allow the power transmission from the engine to the conveyor. Thus, there is a need to
design the specification sizes of the V-belt pulley as the driving system but also the Cone clutch
specifications as it provides the starting and stopping operation. The design is done with
relevance to the data from the textbook of machine design.

4.1 Design of Driving/Transmission System

Consider the figure of V-belt pulleys as shown below;

Figure 4.1. V-belt pulleys

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Let;
N1 = frequency of small pulley (rpm)
N2 = frequency of large pulley (rpm)
R1 = radius of the smaller pulley (mm)
R2 = radius of the larger pulley (mm)
Given;
N1 = 900 rpm
Obtaining N2,
Consider;
Velocity of the conveyor = 0.66 m/s
Diameter of the shaft, d= 44 mm
Recall, V = ω × r
0.66 m/s = ω × 22 × 10-3 m
ω= 30 rad/s
2× π × N
From; ω =
60
⸫ N2 = ω × 60 / 2 × π
N2 = 30 rad/s × 60 / 2 × π
N2 = 286.479 rpm
N2 ≈ 290 rpm
For Small V-belt pulley diameter, it can be obtained from Table 20.1 in the textbook of machine
design as shown below;

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Since the power of the engine is 9.8 Kw thus it lies between 7.5 – 75 Kw.
⸫ Diameter of the small pulley, D1 = 200 mm
Recall, Velocity ratio (V.R) = N1 / N2
V.R = 900 rpm / 290 rpm
V.R = 3.10
Say V.R ≈ 3
Thus, Diameter of the large pulley, D2 can be obtained from, V.R = D2 / D1
D2 = D1 × V.R
D2 = 200 mm × 3
D2 = 600 mm

On determining the belt length, L;

Recall, L = π (R1 + R2) + 2x + (R1 – R2)2 / x
Given;
x= 1150 mm
R1 = 100 mm
R2 = 300 mm
⸫ L = π (100mm + 300mm) + 2 (1150 mm) + (100mm – 300mm)2 / 1150mm
L= 3591.42 mm

From Table 20.3 in the textbook of machine design, the length of the belt can be chosen
depending on the type of belt as shown below;

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Since the belt type is type C, therefore the length of the belt, L ≈ 3713 mm.

On determining the groove angle (2β), consider the Table 20.2 in the textbook of machine design
as shown below;

⸫ The groove angle (2β) of type C belt in degrees = 38◦

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Belt basic power rating (Pb)
Total belt basic power rating (Pb) = basic power rating + power rating based on speed ratio
From the table below;

For the shaft speed (900 rpm) and small pulley diameter (200mm), the basic power rating =
8.83Kw and the power rating based on speed ratio = 0.45Kw
⸫ Pb = 8.83Kw + 0.45Kw
Thus, Pb = 9.28Kw

Belt power rating (Pr)

Pr = Pb × C1 × C3
Whereas;
Pb = belt basic power rating
C1 = belt length correction factor
C3 = Arc of contact correction factor

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From the tables below;

From table 7 above, given D= 600mm, d= 200mm and center distance (CC) = 1150 mm thus the
Arc of contact correction factor (C3) = 0.97 while for the type C belt from table 8, the belt length
correction factor (C3) = 1.02
⸫ Pr = 9.28Kw × 0.97 × 1.02
Thus, Pr = 9.181632Kw

On determining the number of belts (N)

N = design power/power rating of selected belt
N = Pd/Pr
But, Pd = drive power (Pr) × service factor (C2)
Given, the drive power = 9.8Kw

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From the table below;

For medium duty operating with soft starts for a duty time of 10h/day and under, the service
factor (C2) = 1.1
⸫ Pd = 9.8Kw × 1.1
Pd = 10.78Kw

Thus, N = 10.78Kw / 9.181632Kw

N = 1.174
N≈1

Therefore, 1 type C belt is needed.

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Consider a small V-belt pulley below in determining the sizes of the key to be fitted on it;

Figure 4.2. Small V-belt pulley

Let, R1 = radius of the small V-belt pulley

Since the diameter of the driving shaft is 30 mm, the relevance width and thickness of the key
can be obtained from Table 13.1 in the textbook of machine design as shown below;

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From the table above, Considering d= 30 mm, ⸫ width, w = 10 mm and thickness, t = 8 mm
Since the shaft is of mild steel, thus crushing stress, σ c = 70 MPa and shearing stress, Ʈs = 42
MPa
Given, T = 103.9812295 Nm

Determining the length of the key due to crushing stress and shearing stress;
For Shearing Stress,
T = l × w × Ʈs × d / 2
103.9812295 × 103 Nmm = l × 10 mm × 42 N / mm2 × 30 mm / 2
L = 16.505 mm
Say length of the key, l = 18 mm

For Crushing Stress,

T=l×t/2×σc×d/2
103.9812295 × 103 Nmm = l × 8 mm / 2 × 70 N / mm2 × 30 mm / 2
L= 24.757 mm
Say Length of the key, l = 30 mm

For safety, take the length of the key, l = 30 mm

Consider the large V-belt pulley below in determining the sizes of the key to be fitted on it;

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 Figure 4.3. Large V-belt pulley
Let, R2 = radius of the large V-belt pulley
Since the conveyor drum diameter is 50 mm, a shaft of diameter, d = 44 mm is connected at the
conveyor.
Given the velocity of the conveyor, v = 0.66 m/s
P = 9.8 Kw
Considering Table 13.1 in the textbook of machine design as shown above;
Width, w = 14 mm and thickness, t = 9 mm
Assume the power loss in the system is negligible.
From; T = P / ω
But ω = V / r
⸫ T = Pr / V
T = 9.8 × 103 Kw × 22 × 10-3 m/0.66 m/s
T = 326.667 Nm
Thus, torque transmitted, T = 326.667 Nm
For mild steel shaft, the crushing stress, σ c = 70 MPa and the shearing stress, Ʈs = 42 MPa
Determining the length of the key due to crushing stress and shearing stress,
For Shearing Stress,
T = l × w × Ʈs × d / 2
326.667 × 103 Nmm = l × 10 mm × 42 N / mm2 × 44 mm / 2
L = 35.35 mm
Say length of the key, l = 36 mm

For Crushing Stress,

T=l×t/2×σc×d/2
326.667 × 103 Nmm = l × 8 mm / 2 × 70 N / mm2 × 44 mm / 2
L= 53.03 mm
Say Length of the key, l = 55 mm

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For safety, take the length of the key, l = 55 m
4.2 Design of Clutch System

Consider a pair of frictional surfaces of a cone clutch as shown in figure below;

Figure 4.4. Friction Surfaces as a frustrum of a cone

Let;
Pn= Intensity of pressure with which the conical friction surfaces are held together (i.e., Normal
pressure between the contact surfaces)
R1= Outer radius of friction surface
R2= inner radius of friction surface
R= mean radius of friction surface = R1 + R2 / 2
α= semi-angle of the cone (also called face angle of the cone) or the angle of the friction surface
with the axis of the clutch
μ= Coefficient of friction between the contact surfaces, and
b= width of the friction surfaces (also known as face width or cone face)

From the standards;

α= 12.5◦

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w= 280N is selected as the axial load, since the human hand can exert a push or pull of about
250N to 350N easily.
To obtain the mean radius of the friction surface, R
Consider; T= μ × w × R × cosec α
Given that the Torque, T= 103.9812295 Nm
But the coefficient of friction between the contact surfaces, μ can be obtained from Table 24.1 in
the textbook of machine design which is illustrated below.

Since the Operating condition is dry and a maximum temperature is considered, take the material
of friction surfaces as powder metal on cast iron or steel whose coefficient of friction between
the contact surfaces, μ= 0.4
⸫ R= T / (μ × w × cosec α)
R= 103.9812295 Nm / (0.4 × 280N × cosec 12.5◦)
R= 0.200943369 m
R= 200.943369 mm
R≈ 200 mm

To obtain the face width,

Recall, face width, b = D/6
⸫ b= 400mm / 6

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b= 66.67 mm
For safety, choose the face width, b = 70mm
To get R1 and R2 of the cone clutch, consider the following;
R1 = R + b/2 sin α
R1 = 200mm + 70mm/2 sin 12.5◦
R1 = 207.575 mm
Say R1 = 210 mm

Also, R2 = R – b/2 sin α

R2 = 200mm – 70mm/2 sin 12.5◦
R2 = 192.4246 mm
Say R2 = 195 mm

Consider the actuating spring in the cone clutch as shown below;

Figure 4.5. Actuating spring

Let,
d= diameter of a spring wire
D= Coil mean diameter
C= Spring index, C= D/d
Kw= Wahl’s stress factor

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Ws= Axial load, Ws= 280N

Consider the material of the actuating spring is a hard-drawn spring wire whose allowable shear
stress at an average service is 350MPa which can be illustrated from table 23.1 in the textbook of
machine design as shown below;

Taking the Spring index, C= 7

From; Kw= (4C – 1 / 4C – 4) + (0.615 / C)
Kw= (4(7) – 1 / 4(7) – 4) + (0.615 / 7)
Kw= 1.21286
From;
Ʈmax= 8WsDKw / πd3
But D= Cd
Ʈmax= 8WsCdKw / πd3
Ʈmax= 8WsCKw / πd2

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350 × 106 N/m2 = 8 × 280N × 7 × 1.21286 / π × d2
d= 4.16 × 10-3 m
d= 4.16 mm
Say diameter of the spring wire, d= 5 mm

Recall; D= Cd
D= 7 × 5 mm
D= 35 mm
⸫ The coil mean diameter, D= 35 mm

Taking the solid length of the spring to be 80 mm

Thus, the number of coils for square ends can be obtained from,
Ls= (n + 3) d
80 mm= (n + 3) 5 mm
n= 13
⸫ The number of coils, n= 13 coils

To get the free length of the spring;

Recall, Lf = n’d + δmax + 0.15δmax
Lf = (n + 2) d + δmax + 0.15δmax
But δmax = 8FD3N / d4G
Given, G = 210 GPa
δmax = 8 × 280N × (35 × 10-3 m)3 × 13 / (5 × 10-3 m)4 × 210 × 109 N / m2
δmax = 9.51 × 10-3 m
δmax ≈ 10 mm

⸫ Lf = (13 + 2) 5 mm + 10 mm + 0.15 (10 mm)

Lf = 86.5 mm

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Say Lf = 88 mm
Thus, the free length of the spring, Lf = 88 mm

To get pitch, P;
P = Lf / (n’ – 1)
P = Lf / ((n + 2) – 1)
P = 88 mm / 14
P = 6.285714286 mm
Say Pitch, P = 6.5 mm

Consider the driven shaft from the power transmitted by the engine as shown below;

Figure 4.6. Driven shaft

Let,
P= power to be transmitted
W= angular velocity of the shaft
T= torque to be transmitted
d= diameter of the shaft

Given;

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Engine Power (P)= 9.8 kw
Speed (N)= 900 rpm
Required to find the diameter of the shaft
From;
T= π/16 × Ʈall × d3
Where; Ʈs is the shear stress of the shaft material
Take the factor of safety, F. S = 1.5
⸫ Ʈall = Ʈs / F. S
But for mild steel; Ʈs = 42 MPa
Ʈall = 42 MPa / 1.5
Ʈall = 28 MPa

Consider, P= Tw
P= T × 2 × π × N / 60
T= 60P / (2 × π × N)
T= 60 × 9.8 × 103 / (2 × π × 900)
T= 103.9812295 Nm
Torque, T= 103.9812295 Nm

Required diameter, d of the shaft;

Consider, T= π/16 × Ʈall × d3
103.9812295 Nm = π/16 × 28 × 106 N/mm2 × d3
d= 0.02664336 m
d= 26.64336 mm
d≈ 27 mm
Say, diameter of the shaft, d= 30 mm

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Consider the spline keys in the cone clutch as shown below;

Figure 4.7. Spline keys in Cone clutch

Let;
d= shaft diameter
t= key thickness
w= width of the key
l= length of the key
Ʈ= shear stress of the key material
σ c = crushing stress of the key material

Since the shaft is of mild steel, thus the key should be of the same material.
Taking Ʈs = 42MPa and σ c = 70 MPa
Consider 4 splines are equally distributed on the shaft with width, w = 2.5 mm and thickness, t =
2.5 mm.

Given Torque, T = 103.9812295 Nm

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Assuming T is equally distributed to the 4 splines;
⸫ For each spline; Ti = 103.9812295 Nm / 4
Ti = 25.9953 Nm
Say Ti = 26 Nm

Consider the length of the spline key due to the effect of crushing stress and shear stress;
For Crushing stress,
T=l×t/2×σc×d/2
26 × 103 Nmm = l × 2.5 mm / 2 × 70 N / mm2 × 30 mm / 2
L= 19.80952 mm
Say Length of the spline key, l = 25 mm

For Shearing Stress,

T = l × w × Ʈs × d / 2
26 × 103 Nmm = l × 2.5 mm × 42 N / mm2 × 30 mm / 2
L = 16.50793 mm
Say Length of the spline key, l = 20 mm

For safety, Consider the length of the spline key, l = 25 mm whose width, w = 2.5 mm and
thickness, t = 2.5 mm.

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