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Drive Belts

Timing Belts

Important Note:..The notes below are intended to be concise informative guidance notes. Manufacturers literature and the relevant standards
provide the necessary detailed information required for detail design.
I have included links to sites providing good quality information on this topic.

Introduction
Synchronous / Timing belts are basically endless flat belts which pass over pulleys- the belts having grooves which mate with teeth on the
pulleys. These belt drives, unlike flat and vee belt drives are positive. Any slip of the belt relative to the pulleys is minor in degree and is due to
belt stretch, or erosion of the grooves. These belts are used for power transfer and for synchronised drives to ensure that the driven pulley is
always rotating at a fixed speed ratio to the driving pulley.

The first synchronous belts had a trapezoidal tooth profile, and is identified as timing belts. The belt tooth profile is a trapezoidal shape with
sides being straight lines The profile of the pulley teeth which mates with the belt is involute. These belts are based on imperial (inch) pitch
sizes and can provide power transmission up to 150 kW.

The development of the classical timing belt with has a rounded tooth (curvilinear tooth profile) and is identified as as the high torque drive, or
HTD. Advantages of this belt design include..

Proportionally deeper tooth; hence tooth jumping or loss of relative position is less likely
Lighter construction, with consequent reduced centrifugal loss.
Smaller unit pressure on the tooth since area of contact is larger.
Greater shear strength due to larger tooth cross section.
Lower cost as a narrower belts will handle larger load.
Installation tension is reduced resulting in lower bearing loads.

HTD sprockets have metric pitches (3 5 8 14 & 20) and can transmit up to 1000 kW.

The most advanced synchronous belts, has a modified rounded tooth profile with a higher tooth angle and shallower tooth. These belts e.g
Gates Powergrip GT have available pitch sizes of 2mm, 3mm & 5mm and can powers up to transmit up to 600 kW . The belts have the
advantages that they provide a smoother drive at higher accuracy,

A correctly designed and installed synchronous belt drive should operate successfully for between 8000 and 12000 hrs and have an operating
efficiency of about 98%.

Synchronous belts have a number of advantages such that they are often used for applications not requiring shaft synchronization. Their
section and flexibility enable timing belts to operate very well on miniature drives and in applications involving high speeds or small pulleys.
They are extremely efficient when correctly installed. They can also be specified to continuous high loads. For these reasons, synchronous
belts have proved to be cost effective in non-synchronous applications as drives for power saws, motorcycles, and domestic appliances.

The disadvantages of synchronous belt drives are that they are generally more costly compared to other belt drive options and the require
accurate alignment of the pulleys for efficient reliable operation
Construction
Belts
Synchronous belts are made with elastomer e.g natural rubber,neoprene, polyurethane, polychioroprene, core with reinforcement to provide
increased tensile strength. These belts were originally reinforced with steel to provide the necessary strength. In modern drives the most
common reinforcement is glass fiber, but aramid is used if maximum capacity is required. Synchronous belts are often provided with nylon
facings to provide the necessary wear resistance and can include conductive coatings.

Pulleys
Synchronous drive pulleys are often made of ductile or cast iron. Aluminum is a often selected for drives that require low weight. These
applications can include high speed drives with low inertia. Steel(and Stainless Steel )is preferred to iron when the drive will exceed the safe
operating limits for cast iron (2000 mpm) or ductile iron (2500 to 3,000 mpm).
Plastic pulleys e.g. nylon are low-cost options when power requirements are low as in office machines or home appliances such as vacuum
cleaners. Plastic gears may also be acceptable when it is acceptable that the belt service life is short, as in some power tools, or lawn and
garden equipment.

Pulleys are mounted to shafts using pins, keyways or by using proprietory shaft locking bushes such taperlock bushes. Pulleys can have one or
two flanges to ensure the belts are retained in place. For drives with horizontal pulley axes it is normal to have two flanges to retain the belt (two
flanges on one pulley or one flange on each pulley on opposite sides). On pulleys with vertical shaft axes the lower face of each pulley should
include a flange and one pulley should include two flanges.

Relevant Standards
The British Standard for timing belt drives was
BS 4548:1987 :Specification for synchronous belt drives for industrial applications . This standard is still in use but is declared as obsolescent the
current standard in europe for timing belt drives is
ISO 5294:1989: Synchronous belt drives -- Pulleys
ISO 5296-1:1989:1989: Synchronous belt drives -- Belts -- Part 1: Pitch codes MXL, XL, L, H, XH and XXH -- Metric and inch dimensions
This is not equivalent and belts and pulleys to the British Standard are not interchangeable with the ISO standard.

Basic Timing Belt Parameters

Classical Timing belts
Belt Pitch Widths Available
Meaning
Section mm mm
MXL Extra Light 2,032 3,05 4,826 6,35
XL Extra Light 5,08 6,35 9,652
L Light 9,525 12,7 19,05 25,4
H Heavy 12,7 19,05 25,4 38,1 50.8 76,2
XH Extra heavy 22.225 50.8 76,2 50.8 76,2 101,6 127101,6
XXH Double extra heavy 31,75 50.8 76,2 101,6 127

HTD- Curvilinear
Belt Pitch Widths Available
Designation
Section mm mm
3M 3mm High Torque Drive 3 6 9 15
5M 5mm High Torque Drive 5 9 15 25
8M 8mm High Torque Drive 8 20 30 50 85
14M 14mm High Torque Drive 14 40 55 85 115 170
20M 20mm High Torque Drive 20 115 170 230 290 340

GT - Curvilinear
Belt Pitch Widths Available
Name
Section mm mm
2MR (Gates) 2mm High Torque Belt 2 369
3MR (Gates) 3mm High Torque Belt 3 6 9 15
5MM (Gates) 5mm High Torque Belt 5 9 15 25

Note : The various notes below relate to the classical timing belt drives. For the more advanced drive belt design refer to manufactures
literature... I will include notes on these belt drives at a later date...

Designing a Synchronous Belt System

Belt design procedures can be based on torque calculations or they can be based on power calculations.

Power method
1) The driven speed and the maximum driven torque required (including inertia load, shock loads, friction, etc) are used to calculate the required
driven power

2) From information on the driver, driven equipment and operating period a service factor is obtained - see below

3) A design power is obtained based on the product of the Driven Power required and the service factor .

4) A belt section is initially selected using a graph as typically shown below

5) A drive geometry is derived selecting suitable pulleys, and belt Centre Distance - Some Pulley sizes are provided below

6) A Basic Power for the belt is calculated and a mesh factor is calculated - see below

7) A suitable belt width is selected -Using a table as provided below- Some iteration may be required

Torque Method
The classical MXL belt and the Curvilinear more advanced belt options are designed based on torque levels. The outline method for the MXL
drive is provided below. The method used for the HTD and other modern belt options will be provided at some future date...

The MXL belts operate generally at relatively low belt speeds so the torque levels are similar for the normal range of pulley rotational
speed. Torque ratings can be calculated of each of the MXL belt widths as follows: I have converted an imperial formula to a metric formula and
minor differences with the original formulae results..

Torque ratings of belts Tr (Nm) at P2 PCDs (mm)

Belt width =3.048 mm... Tr = P2(5,03 - 9,5147.10-6.P22).10-3

Belt width =4.826mm... Tr = P2(8,36 - 1,586.10-5.P22).10-3
Belt width =6.35 mm...Tr = P2(11,7 - 2,213.10-5.P22).10-3

To design an MXL belt system using the torque method.

1) The driven speed and the maximum driven torque required (including inertia load, shock loads, friction, etc) are calculated

2) From information on the driver, driven equipment and operating period a service factor is obtained - see below

3) A design torque is obtained based on the product of the torque required and the service factor .

4) A belt section is initially selected (assuming MXL) using a graph as typically shown below

5) A drive geometry is derived selecting suitable pulleys, and belt Centre Distance - Some Pulley sizes are provided below

6) The design torque is divided by the teeth mesh factor (see below) to arrive at an adjusted torque

7) The table below is used to select the belt width which has a torque value equal to or larger than the corrected torque

Torque Rating for MXL Belt (Nm)

No Teeth -> 10MXL 12MXL 14MXL 16MXL 18MXL 20MXL 22MXL 24MXL 28MXL 30MXL
PCD(mm) -> 6.477 7.7724 9.0678 10.3378 11.6332 12.9286 14.224 15.5194 18.1102 19.4056
width =3.05mm 0.033 0.040 0.045 0.052 0.059 0.064 0.071 0.078 0.092 0.097
width = 4.83mm 0.054 0.066 0.076 0.087 0.097 0.108 0.119 0.130 0.151 0.163
width = 6.35mm 0.076 0.090 0.106 0.121 0.136 0.151 0.166 0.182 0.211 0.227

Service Factors
When designing belt drives it is normal to apply a service factor to the drive operating load to compensate for allow for different driver type, driven
load types and operating periods. Typical service factor values are included on the linked page Service Factors

Designating Classical Synchronous belts

Synchronous Belt sizes are identified by a standard number. The first digits specify the belt length to one-tenth inch followed by the belt section
(pitch) designation. The digits following the belt section designation represent the nominal belt width times 100. For example, an L section belt
30.000 inches pitch length and 0.75 inches in width would be specified as a 300L075 Synchronous Belt. A similar method is used for designating
metric belt designations
Initial selection of Timing Belt
When the design power has been determined (Power x Service Factor) a synchronous belt can be selected generally using a graph similar to the
one below..This is provided for guidance only and is copied from published graphs generally available.

Power Rating of Timing Belt

This method is based on the method shown in Machinery's handbook. It is preferable to use the calculation tool provided by the belt
manufacturers to size the belts for detail design. Or even better let the suppliers do the design for you...

The Power ratings of belts for the basic belt widths (in brackets) are as identified below..

r = Rpm of faster shaft /1000

P2 = Pitch diameter of smallest Pulley (mm)
Z = P2 . r / 25,4
Pr = Power rating in kW

For Belt (width-mm) = XL (9.652)...... Pr = 0.746.Z.(0,0916 - 7,07.10-5.Z2 )

For Belt (width-,mm) = L (25,4)...... Pr = 0.746.Z.(0,436 - 3,01.10-4.Z2 )
For Belt (width-mm) = H (76,2)...... Pr =0.746.Z.(3,73- 1,41.10-3.Z2 )
For Belt (width-mm) = XH (101,6)...... Pr = 0.746.Z.(7,21 - 4,68.10-3.Z2 )
For Belt (width-mm) = XXH (127)...... Pr =0.746.Z.(11,4 - 7,81.10-3.Z2 )

Determining the timing belt length

1) The Pitch dia of a pulley P = No Teeth on Pulley . Pitch /p

2) The Drop distance d = [ P1 - P2 ] /2
3) The belt contact angle α = arcsin(d /C) ..C= Centre distance
4) The belt fall length = fl = d / tan α
5) The contact length Small Pulley= CL2= P2. p. [90 - α]/180 degrees
6) The contact length Large Pulley = CL1=P1.p. [90 + α]/180 degrees
7) The Belt Length L = 2.fl + CL1 + CL2
8) Total number of teeth on belt = L / Pitch
9) Number of teeth in mesh (small pulley) = CL2 /Pitch. Rounded down to nearest whole number.
Mesh Factor
The horsepower ratings obtained above are based on the smallest pulleys having six or more teeth in mesh. For drives with small angles of lap
on the smallest pulleys the mesh factor is required.

No Teeth
Mesh Factor
in mesh
6 or more 1
5 0,8
4 0,6
3 0,4
2 0,2

Determination of the Belt Width required

1) First establish the design power to be transferred(kW) = Service Factor x Power.
2) Select a suitable belt and calculate the basic power using the belt size, smaller pulley speed, and smaller pulley size.
3) If the basic belt power is less than the design power- change one or more of belt size , pulley size or speed.
3) Divide the Basic power/ Design power to obtain a belt width factor.
4) Use the table below and select a width with a width factor higher than the calculated width factor required

Table of Belt Width Factors -

Belt Belt Width
Section 3,05 4,826 6,35 9,652 12,7 19,05 25,4 38,1 50.8 76,2 101,6 127

MXL 0,43 0,73 1,00 - - - - - - - - -

XL - - 0,62 1,00 - - - - - - - -
L - - - - 0,45 0,72 1,00 - - - - -
H - - - - - 0,21 0,29 0,45 0,63 1,00 - -
XH - - - - - - - - 0,45 0,72 1,00 -
XXH - - - - - - - - 0,35 0,56 0,78 1,00

Typical Pulley Sizes

Below are listed a collection of pulley Dimensions (PCD and OD) for pulleys in the classical timing belt range. In practice there are a vast
number of pulleys available from suppliers on the belt sections shown and on other higher specification sections. Additional data is available
using the links below and preferable by contacting the suppliers.

MXL XL L H XH XXH
Teeth PCD OD Teeth PCD OD Teeth PCD OD Teeth PCD OD Teeth PCD OD Teeth PCD OD
10 6,47 5,96 10 16,17 15,67 10 30,32 29,56 10 40,43 39,08 18 127,34 124,54 18 181,91 178,87
11 7,11 6,61 11 17,79 17,29 11 33,35 32,59 11 44,47 43,12 20 141,49 138,68 20 202,13 199,09
12 7,76 7,25 12 19,40 18,90 12 36,38 35,62 12 48,51 47,16 22 155,64 152,83 23 232,45 219,30
14 9,06 8,55 13 21,02 20,52 13 39,41 38,65 13 52,55 51,20 24 169,79 167,01 25 252,66 239,50
16 10,35 9,84 14 22,64 22,14 14 42,45 41,68 14 56,60 55,25 26 183,94 181,15 26 262,76 259,72
18 11,64 11,13 15 24,26 23,76 16 48,51 44,72 15 60,64 59,29 28 198,08 195,30 30 303,19 300,15
20 12,94 11,78 16 25,87 25,37 17 51,54 47,75 16 64,68 63,33 30 212,23 209,45 34 343,62 340,56
21 13,58 13,07 17 27,49 26,99 18 54,57 50,78 17 68,72 67,37 32 226,38 223,60 40 404,25 401,19
22 14,23 13,72 18 29,11 28,61 19 57,61 56,84 18 72,77 71,42 40 282,98 280,19 48 485,10 482,07
24 15,52 15,02 20 32,34 31,84 20 60,64 59,88 19 76,81 75,46 48 339,57 336,78 60 606,38 603,32
28 18,11 17,60 21 33,96 33,46 21 63,67 62,91 20 80,85 79,50 60 424,47 421,67 72 727,66 648,41
30 19,40 18,90 22 35,57 35,07 22 66,70 65,94 21 84,99 83,54 72 509,36 506,58 90 909,57 906,53
32 20,70 20,19 24 38,81 38,31 24 72,77 72,00 23 92,98 91,63 84 594,25 591,46
36 23,29 22,78 25 40,43 39,93 25 75,80 75,04 25 101,06 99,71 90 636,70 0,00
40 25,87 25,37 26 42,04 41,54 26 78,83 78,07 26 105,11 103,76 96 679,15 676,35
42 27,17 26,67 28 45,28 44,78 28 84,89 84,13 28 113,19 111,84 120 848,93 846,15
 44 28,46 27,94 30 48,51 48,01 30 90,96 90,19 30 121,28 119,93
48 31,05 30,53 32 51,74 51,24 32 97,02 96,26 32 129,36 128,01
60 38,81 38,30 36 58,21 57,71 36 109,15 108,39 33 133,40 132,05
72 46,57 46,05 40 64,68 64,18 40 121,28 120,51 34 137,45 136,10
42 67,91 67,41 42 127,34 126,58 35 141,49 140,14
44 71,15 70,65 44 133,40 132,64 36 145,53 144,18
48 77,62 77,12 48 145,53 144,77 38 153,62 152,27
50 80,85 80,35 50 151,60 150,83 40 161,70 160,35
54 87,32 86,82 54 163,72 162,96 42 169,79 168,44
60 97,02 90,52 60 181,91 181,15 44 177,87 176,52
72 116,43 115,93 72 218,30 220,57 48 194,04 192,69

Links to Belt Design

1. DANotes Vee Belt Drives.. ..A definitive theoretical and practical review with various
useful tables
2. Helixtech.. ..A software package for belt /chain drives - costly
3. Wyko.. ..Vee belt supplier (Fenner) -limited information available online
4. Mitcalc.com ..Excel based software providing coded belt calculations( very
reasonably priced. I recommend this product
5. Timing belt selection and Troubleshooting ..Very useful notes
6. Stock Drive Produces/Sterling Instruments ..Supplier -Technical library includes
comprehensive design downloads for timing belts
7. Gates-Europe ..Leading timing belt drive supplier- Catalogue download available
8. HPC Gears ..Timing Belt Supplier - Some Formulae -Power ratings for HTD belts
included
9. Fennerprecision ..Timing Belt Supplier - Some Calculators

Drive Belts

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