Belt Drives:

Ratio of tensions, Centrifugal stress in a

belt, Power transmitted, effect of
centrifugal tension on power transmitted,
Simple numerical problems.

Veeresh R. K., Associate Professor

Robotics and AI Engineering.
NMAM Institute of Technology
Nitte, Karkala, India
06-07-2023 1
 Chapter 5: Belt Drives
Power is transmitted from the prime mover to a machine by means of an intermediate
mechanism called drives. This intermediate mechanism known as the drive may be a belt or
Chain or gears.

2
Belt is used to transmit motion from one shaft to another shaft with help of a pulley
preferably if the center distance is long. It is not a positive drive since there is slip in the belt
drive.

Three types of belt drives are commonly used. They are

i. Flat Belt Drive
ii. V-Belt Drive
iii. Rope or Circular Belt Drive

Flat Belt Drive V-Belt Drive Rope or Circular Belt Drive

06-07-2023 3
Flat Belt Drive

When the distance between

two pulleys is around 10
meters and moderate power is
required then flat belt drive is
preferred. This may be
arranged in two ways.
i. Open Belt Drive
ii. Cross Belt Drive

when the direction of rotation of both the pulleys is required in the same direction then we
can use an open belt drive. If the direction of rotation of pulleys is required in the opposite
direction then cross belt drive is used. The pulley which drives the belt is known as the
driver and the pulley which follows the driver is known as driven or follower.
06-07-2023 4
Merits and demerits of flat belt drive

Merits
1) Simplicity, low cost, smoothness of operation, ability to absorb shocks, flexibility, and
efficiency at high speeds/
2) Protect the driven mechanism against breakage in case of sudden overload owing to belt
slipping.
3) The simplicity of care, low maintenance, and service
4) Possibility to transmit power over a moderate long distance

Demerits
1) It is not a positive drive
2) Comparatively large size
3) Stretching of belt calling for resewing when centre distance is constant
4) Not suitable for short tips center distance
5) The belt joint reduces the life of the belt
6) High-bearing load and belt stresses
06-07-2023 5
7) Less efficiency due to slip and creep
Creep and slip-in belts
Creep in Belts
Consider open belt drive rotating in the clockwise direction as shown in the Figure. The
portion of the belt leaving the driven and entering the driver is known as the tight side and
the portion of the belt living the driver entering the driven is known as the slack side.
During rotation, there is an expansion of the belt on the right side and contraction of the
belt on this lack side. Uneven expansion and contraction of the belt over the pulleys, there
will be a relative movement (motion) of the belt over the pulleys, this phenomenon is known
as creep in belts.

06-07-2023 6
Creep and slip-in belts
Slip In Belts
Consider an open belt drive rotating in a clockwise direction, this is the rotation of the belt
over the pulleys and is assumed to be due to a firm friction grip between the belt and the
pulleys. When this frictional grip becomes insufficient, there is a possibility of forward
motion of the driver without carrying the belt with it and there is also a possibility of the
belt rotating without carrying the driven pulley with it, this is known as a slip-in belt.
Therefore, slip may be defined as the relative motion between the pulleys and the belt in it.
This reduces the velocity ratio and is usually expressed as a percentage.

06-07-2023 7
Materials used for belt
Belts used for power transmission must be strong, flexible, durable, and must have a high
coefficient of friction. The most common belt materials are leather, fabric rubber, camel
hair, and woven cotton.

Leather Fabric Rubber Camel Hair

Woven Cotton
06-07-2023 8
Ratio of Belt Tensions
Consider a driven pulley rotating in clockwise direction T
T2 Ꟙθ/2
as shown in Figure
Let T1=Tension on tight side F=µRN
T2=Tension on slack side
θ=Angle of lap θ
P
RN=Normal Reaction Ꟙθ RN
F=Frictional force, F=µRN
Q
Consider a small elemental portion of the belt PQ
subtending an angle Ꟙθ at the center. The portion of the
belt PQ is in equilibrium under the action of the T1 Ꟙθ/2
following forces. T+ꟘT
i. Tension T at P
ii. Tension T+ꟘT at Q
iii. Normal reaction RN
iv. Frictional Force F=µRN
06-07-2023 9
    x
Resolving the forces horizontally T sin  =
T1 Ꟙθ/2  2  T
 
RN = T sin + (T +  T ) sin F=µRN
  
x = T sin  
2 2  2 
   
Since angle is small, hence sin  = θ
P
 2  2
Ꟙθ RN

Neglect T Q
2
  x
=
RN = T  ……….. (i)
sin 

 T + 
 2
  
Resolving the forces Vertically
T2 Ꟙθ/2 x = (T +  T ) sin  
T+ꟘT  2 
 
 RN + T cos = (T +  T ) cos
2 2
T     ……….. (ii)
RN =  sin ce issmall , cos = 1
  2 2 
06-07-2023 10
Equating (i) and (ii)
T
= T 

T
= 
T

Integrating between their respective limits


T
T2

 T =  
T1 0

T1 
=e Where θ in radians
T2

06-07-2023 11
Numerical Problems on Flat Belt drive
1. An open belt drive connects to two pulleys 120 cm and 50 cm diameters, on parallel shafts 4m
apart. The maximum tension in the belt is 1855.3N. The coefficient of friction is 0.3. The driver
pulley of diameter 120 cm runs at 200 rpm. Calculate (i) The power transmitted, and (ii)Torque on
each of the two shafts.
r = Radius of the driven or Follower = 250mm
D = Diameter of the driver = 120cm = 1200mm
C = Distance between the centers of two pulleys =
R = Radius of the driver = 600mm
4000mm
n = Speed of the driver in R.P.M. = 200RPM
µ = Coefficient of friction = 0.3
d = Diameter of the driven or Follower = 50cm = 500mm
T1 = Tension in the tight side of the belt = 1855.3N
(i) The power transmitted
Maximum power transmitted by belt drive P = (T1 − T2 ) v
1000 DDHB 14.5 (a)/291
 dn  X 1200 X 200
Velocity of the belt in m/sec v = v = = 12.566m / sec v =  X 1.2 X 200 = 12.566m / sec
60000 60000 60
T1
We use the relation Ratio of belt tension = e  DDHB 14.3 (a)/290
T2
06-07-2023 12
Angle of contact  =  − 2 D − d 1200 − 500
sin  = = = 0.0875  = 5.02o Fig 14.1 (a)/290
2c 2 X 4000

 = 180 − ( 2 X 5.02 ) = 169.96  = 169.96 X = 2.96rad
180
1855.3
=e 0.3 X 2.96
T2=761.95N P=
(1855.3 − 761.95 ) X 12.566
P=13.73kW
T2 1000

(ii)Torque on each of the two shafts

The torque exerted on the driving pulley
T = (T1 − T2 ) R p T = (1855.3 − 761.95 ) X 600 = 656010 N − mm
The torque exerted on the driven pulley
T = (T1 − T2 ) R p T = (1855.3 − 761.95 ) X 250 = 273337.5 N − mm
06-07-2023 13
2. Design a belt drive to transmit 25 kW from a motor shaft rotating at 1500 rpm to a compressor
running at 500 rpm. The motor pulley is 96mm effective diameter and the center distance between
the shafts is 1.5m.

Given: Power Transmitted=25 kW, n1=1500 rpm, n2=500 rpm. d=96mm, C=1.5m=1500mm.

(1) Diameter of Larger Pulley n1d = n2 D 1500 X 96 = 500 XD D=288mm

 dn1  X 96 X 1500
(2) Velocity (m/sec) v= v= v=7.54m/sec
60000 60000
(3) Length of Belt

(i) Angle of contact in the open belt drive

 D−d 
(a) On a smaller Pulley, rad  S =  − 2sin 
−1
 DDHB 14.1(a)/289
 2C 
−1  288 − 96  
 S =  − 2sin    S = ( − 7.338 ) θS=3.0135rad
 2 X 1500  180
06-07-2023 14
  D−d 
(b) On a Larger Pulley, rad  L =  + 2sin 
−1
 DDHB 14.1(b)/289
 2C 
−1  288 − 96 

 L =  + 2sin  
 L = ( + 7.338 ) θL=3.27rad
 2 X 1500  180
1
L = 4C 2 − ( D − d ) + ( D L + d S )
2
Length of Open belt DDHB 14.2(b)/290
2
1
L = 4 X 15002 − ( 288 − 96 ) + ( 288 X 3.27 + 96 X 3.0135 ) L = 2993.84 + 615.528
2
L=3609.368mm
2
wv 2
(4) Centrifugal Stress c = 6 DDHB 14.3(f)/291
10 Xg
Specific weight of leather =10X10-6N/mm3=10000N/m3
10000 X (7.54) 2
c = σc=0.05795MPa
106 X 9.81

06-07-2023 15
(5) Width of Belt v  e  − 1 
P= ( d −  c )    DDHB 14.6(a)/291
1000  e  0.473

σd=2.06MPa x 7.54 − 7 0.466 x

=
0.473 − 0.466 8−7
For velocity v=7.54 from Table 14.2 (b)/305
x=3.78X10-3
7 7.54 8
7.54  e0.46978 X 3.0135 − 1 
P= ( 2.06 − 0.0579 )  0.46978 X 3.0135  µ=3.78X10-3+0.466=0.46978
1000  e 
P=0.01143kW
25
Area of cross section of belt =
Total Power A= = 2187 mm 2
Power Transmitted per mm2 0.01143

A=bXt Assume t=10mm Then 2187=bX10 b=220mm

06-07-2023 16
(6) Initial Tensions in the Belt T1 + T2 = 2 To DDHB 14.8/291

1 −  c
= e  DDHB 14.3(d)/291
2 −c

2.06 − 0.0579
= e0.46978 X 3.0135 σ2=0.5439MPa
 2 − 0.0579
T1 =  1 A = 2.06 X 2196.4 = 4524.6 N

T2 =  2 A = 0.5439 X 2196.4 = 1194.68 N

4524.6 + 1194.68 = 2 To

To=2592.3N

06-07-2023 17
3. Two parallel shafts whose centre lines are 4.8m apart are connected by an open belt drive. The
diameter of the larger pulley is 1.5 m and that of the smaller pulley is 1m. The initial tension in the
belt when stationary is 3 kN. The mass of the belt is 1.5 kg/m in length. The coefficient of friction
between the belt and the pulley is 0.3. Taking centrifugal tension into account, calculate the power
transmitted, when the smaller pulley rotates at 400 rpm.
D = Diameter of the driver = 1.5m = 1500mm C = Distance between the centers of two pulleys =
R = Radius of the driver = 750mm 4800mm
n2 = Speed of the smaller pulley in R.P.M. = 400RPM µ = Coefficient of friction = 0.3
d = Diameter of the driven or Follower = 1m = 1000mm To = Initial Tension on belt= 3000N
r = Radius of the driven or Follower = 500mm m=Mass of the belt is 1.5kg/m

(i) The power transmitted

Maximum power transmitted by belt drive P = (T1 − T2 ) v
1000 DDHB 14.5 (a)/291
 dn2  X 1000 X 400
Velocity of the belt in m/sec v = v = = 20.94m / sec
60000 60000
T1
We use the relation Ratio of belt tension = e  DDHB 14.3 (a)/290
T2
06-07-2023 18
Angle of contact  =  − 2

D − d 1500 − 1000
sin  = = = 0.05208  = 2.9855o Fig 14.1 (a)/290
2c 2 X 4800

 = 180 − ( 2 X 2.9855 ) = 174.03  = 168.041X = 3.037 rad
180
T1 T1
=e 0.3 X 3.037
= 2.48
T2 T2

Centrifugal Force on the belt

w' v 2 mgv 2
Tc = Tc = Where W=mg DDHB 14.3(e)/291
g g

Tc = mv 2 Tc = 1.5 X (20.94) 2 TC=657.72N

06-07-2023 19
We know that initial tension
T1 + T2 + 2Tc
To =
2
T1 + T2 + 2 X 657.72 T1 + T2 = 4684.56
3000 =
2
2.48T2 + T2 = 4684.56

T2=1346.13N T1=3338.42N

Power Transmitted

P=
( 3338.42 − 1346.13) X 20.94
P=41.71kW
1000

06-07-2023 20
4. A nylon core flat belt 200 mm wide weighing 20 N/m, connecting a 300 mm diameter pulley to a
900mm diameter driven pulley with a shaft spacing of 6m transmits 52.2 KW at a belt speed of 25
m/sec.
i. Calculate the belt length and angle of the wrap
ii. Calculate the belt tension based on the coefficient of friction 0.38

Given: b=200mm, w=20N/m, d=300mm, D=900mm, C=6m=6000mm, P=52.2kW, v=25m/sec.

Assume open belt drive

Length of Belt

(i) Angle of contact in the open belt drive

 D−d 
(a) On a smaller Pulley, rad  S =  − 2sin 
−1
 DDHB 14.1(a)/289
 2C 
−1  900 − 300  
 S =  − 2sin    S = ( − 5.732 ) θS=3.041rad
 2 X 6000  180
06-07-2023 21
  D−d 
(b) On a Larger Pulley, rad  L =  + 2sin 
−1
 DDHB 14.1(b)/289
 2C 
−1  900 − 300   = (  + 5.732 )

 L =  + 2sin   L θL=3.242rad
 2 X 6000  180
1
L = 4C 2 − ( D − d ) + ( D L + d S )
2
Length of Open belt DDHB 14.2(b)/290
2
1
L = 4 X 6000 − ( 900 − 300 ) + ( 900 X 3.242 + 300 X 3.04155 )
2
2
L = 11985 + 1915.1325
2
L=13900mm
Belt Tensions
20 X ( 25 )
' 2 2
wv
Centrifugal Force on the belt Tc = Tc = DDHB 14.3(e)/291
g 9.81

TC=1274.2N

06-07-2023 22
 v  e  − 1 
P= (T1 − Tc )    DDHB 14.6(a)/291
1000  e 

25  e0.38 X 3.041 − 1 
55.2 = (T1 − 1274.2 )  0.38 X 3.041 
1000  e 

T1=4496.627N=Tension on the tight side

T1 − TC 4496.627 − 1274.21 0.38 X 3.0415

= e  =e
T2 − TC T2 − 1274.21

T2=2288.665N =Tension on the Slack side

06-07-2023 23
V-Belt Drive
When the distance between the shaft is less, then V-
belts are preferred. These are endless and of
trapezoidal cross-section as shown in the figure. It
consists of a central layer of fabric and moulded in
rubber or rubber-like compound. This disassembly is
enclosed in an elastic-wearing cover. The belt will have
a contact at the two sides of the groove in the pulley.
The wedging action between the belt and the groove
will increase as the coefficient of friction making the
drive a positive one.

06-07-2023 24
 Difference Between Flat Belt Drive and V-Belt Drive
Sl No Flat Belt Drive V-Belt Drive
1. Narrow rectangular cross-section Trapezoidal cross section
2. Low-velocity ratio (up to 4:1) High-velocity ratio (up to 7:1)
3. Adjustable velocity ratio possible using a Fixed velocity ratio
stepped pulley
4. The efficiency of a flat belt drive is more Low efficiency
than V Belt Drive
5. The design and construction of flat belt The design and construction of V-belt
drive is simple and inexpensive and easy drive are complex and costlier
to maintain
6. They have large dimensions and consume V-belt has a short centre distance
much higher space for the operation which results in a compact
construction.
06-07-2023 25
Numerical Problems on V-Belt drive
1. A V-belt is to be arranged between two shafts whose centers are 3000 mm. The driving pulley is of
850 mm effective diameter and is to be supplied with 75 kW at 960 rpm. The follower pulley is to run
at 480 rpm. Determine the number of belts required for the following particulars.
Area of belt section=400 mm2
Weight of belt= 0.01 N/cm3
Safe working tensile stress=2.1 N/mm2
Coefficient of friction=0.27
Groove angle of pulley=40O
Also, find the initial tension required in each belt.

Given: C=3000mm, d=850mm, P=75kW, n1=960rpm, n2=480rpm, A=400mm2, w=0.01N/cm3,

σ1=2.1N/mm3, µ=0.27 , 2α=40.

(1) Diameter of Larger Pulley n1d = n2 D 960 X 850 = 480 XD D=1700mm

06-07-2023 26
  dn1  X 850 X 960
(2) Velocity (m/sec) v= v= v=42.726m/sec
60000 60000
(3) Capacity

(i) Angle of contact in the open belt drive

 D−d 
(a) On a smaller Pulley, rad  S =  − 2sin 
−1
 DDHB 14.1(a)/289
 2C 
−1  1700 − 850  
 S =  − 2sin    S = ( − 16.288 ) θS=2.8573rad
 2 X 3000  180
−1  D − d 
(b) On a Larger Pulley, rad  L =  + 2sin   DDHB 14.1(b)/289
 2C 
−1  1700 − 850   =  + 16.288

 L =  + 2sin   L ( ) θL=3.4259rad
 2 X 3000  180
 S 0.27 X 2.8573
 L 0.27 X 3.4259
e sin 
=e sin 20
= 9.54 e sin 
=e sin 20
= 14.94
The06-07-2023
smaller Value is the Capacity Capacity=9.54 27
 wv 2
(4) Centrifugal Stress c = 6 DDHB 14.3(f)/291
10 Xg
Specific weight of belt =0.01N/cm3=10000N/m3
10000 X (42.726) 2
c = σc=1.86MPa
106 X 9.81

 sin 
(5) Power transmitted per belt v  e − 1
P= ( 1 c )   
T − T DDHB 14.6(a)/291
1000 sin 
 e 

T1 =  1 XA = 2.1X 400 = 840 N TC =  C XA = 1.867 X 400 = 744.4 N

 0.27sinX 2.8573 
42.726  e 20
− 1
P= ( 840 − 744.4 )  0.27 X 2.8573  P=3.656kW
1000 sin 20
 e 
06-07-2023 28
(6) Number of V-Belts

𝐓𝐨𝐭𝐚𝐥 𝐏𝐨𝐰𝐞𝐫 𝐓𝐫𝐚𝐧𝐬𝐦𝐢𝐭𝐭𝐞𝐝 75

𝐢= i= = 20.5
𝐏𝐨𝐰𝐞𝐫 𝐓𝐫𝐚𝐧𝐬𝐦𝐢𝐭𝐭𝐞𝐝/𝐛𝐞𝐥𝐭 3.656

(7) Initial Tension T1 + T2 = 2 To DDHB 14.8/291


1 −  c
= e sin  DDHB 14.3(d)/291
2 −c

2.1 − 1.861 0.27 X 2.8573

=e sin 20
σ2=1.886MPa
 2 − 1.861
T1 =  1 XA = 2.1X 400 = 840 N T2 =  2 A = 1.886 X 400 = 754.421N

840 + 754.421 = 2 To To=796.64N

06-07-2023 29
Rope Drive
When power is to be transmitted over a long distance then belts cannot be used
due to the heavy losses in power. In such cases ropes can be used ropes are used
in elevators, main hoists, cranes, oil well drilling, aerial conveyors, lifts, and
suspension bridges.

Elevators Main Hoists Cranes Oil Well Drilling

Aerial
06-07-2023
Conveyors Suspension Bridges30
Two types of ropes are commonly used they are (i) Fibre Rope, (ii) Metallic Ropes. Fibre
ropes are made of Manila, Hemp, Cotton, Jute, nylon choir etc., and are normally used for
transmitting power. Metallic ropes are made of steel, aluminium alloys, copper, bronze, and
stainless steel, and are mainly used in elevators, cranes, oil well drilling, aerial conveyors,
and suspension bridges.

06-07-2023 31
Use of Rope Drive and Chain Drive in Robotic Application

Rope Robotics' wind turbine Chain in Logistic Robotics

blade repairs

06-07-2023 32
Numerical Problems on Rope drive
1. Select a wire rope to lift a load of 10kN through a height of 600m from a
mine. The weight of the bucket is 2.5kN. The load should attain a maximum
speed of 50m/min in 2 seconds. Take Fu=500.8d2
From Table 14.25/328 select the most commonly used type of rope 6X19
Following Data Selected from Table 14.32/337
Weight per meter length =36.3X10-3d2 N/m where d in mm
Wire diameter dw=0.063d, mm
Area of c/s A=0.38d2, mm2
Sheave diameter D=45d, mm
From Table 14.33/338 for 600m depth, Select a FoS, n=7

(1) Total Load 𝐖 = 𝐋𝐨𝐚𝐝 𝐭𝐨 𝐛𝐞 𝐥𝐢𝐟𝐭𝐞𝐝 + 𝐖𝐞𝐢𝐠𝐡𝐭 𝐨𝐟 𝐒𝐤𝐢𝐩

W = 10000 + 2500 = 12500 N
06-07-2023 33
(2) Total Weight of Rope 𝐖𝐑 = 𝐖𝐞𝐢𝐠𝐡𝐭 𝐩𝐞𝐫 𝐦𝐞𝐭𝐞𝐫 𝐥𝐞𝐧𝐠𝐭𝐡𝐗𝐋𝐞𝐧𝐠𝐭𝐡 𝐨𝐟 𝐑𝐨𝐩𝐞

WR = 36.3 X 10−3 d 2 X 600 WR=21.78d2

W + WR 
(3) Inertial Load due to Acceleration Wi = Ma =   a
 g 
v
v = u + at Since u=0 v = at a= 0.834 0.834
t a = a= a=0.417
50 2 2
a= = 0.834
60
12500 + 21.78d 2 
Wi =   0.417 Wi = 531.34 + 0.926d 2
 9.81 
dw
(4) Bending Load Fb =  b A = KA DDHB 14.20(b)/298
D
0.063d
Fb = 82.8 X 10 X 0.38d
3 2
Fb=44.05d2
45d
06-07-2023 34
(5) Starting Load Ws = 2 W + WR  Ws = 2 12500 + 21.78d 2 

Ws = 25000 + 43.56d 2

(6) Maximum Load Assume Impact Load is neglected

Maximum Load on the rope Fmax = W + WR + Wi + Pb

Fmax = 12500 + 21.78d 2 + 530.83 + 0.9249d 2 + 44.01d 2
Fmax = 13030.83 + 66.7149d 2
(7) Diameter of Rope Fa  Fmax Fu
 Fmax DDHB 14.20(c)/298
n
508.8d 2
 13030.83 + 66.7149d 2

7
d  51.96mm
From Table 14.25/328 for6X19 rope standard diameter d=54mm
06-07-2023 35
Numerical Problems on Chain drive
1.

06-07-2023 36
06-07-2023 37
06-07-2023 38
06-07-2023 39
 Review Questions
1. Explain the concept of slip and creep in belt drive.
2. List the merits and Demerits of flat belt drive.
T1
3. Derive the equation = e 
T2
Where T1=Tension in the tight side of the belt
T2=Tension in the slack side of the belt
µ=Coefficient of friction between belt and pulley
θ=Angle of contact in radians

06-07-2023 40
 THANK YOU
06-07-2023 41