PROBLEM 25
DESIGN OF TRANSMISSION SYSTEMS FOR 2 LOAD CHAINS
1. Select proper electric motor and distribute transmission ratio for the
system
1.1.1. System efficiency ƞ
According to Table 3.3, we choose efficiency for the system component as
follows:
Ƞb = 0.95: efficiency of belt drive
Ƞbevel = 0.93: efficiency of bevel gear
Ƞr = 0.96: efficiency of speed reducer
Ƞbr = 0.99: efficiency of bearing
k = 3: number of bearing couple
Ƞc = 0.92: efficiency of chain driver
ηsystem = ηb × ηbevel × ηr × ηbrk × ηc = 0.95 × 0.93 × 0.96 × 0.993 × 0.92 = 0.76
1.1.2. Power calculation
F ×v 3800× 0.50
Preq = 1000 = 1000 = 1,9 (kN)
Preq 1 ,9
Pmotor = η system = 0 ,76 = 2,5 (Kw)
Choose Pmotor = 3,0 (Kw)
Table 1:
Option 1 2 3 4 5 6 7 8 9 10
Force on 3400 3800 4200 2600 3000 4500 5000 5000 5500 3500
a loads
chain F, N
Periphera 0,45 0,50 0,55 0,6 0,4 0,65 0,70 0,55 0,60 0,50
l velocity
v, m/s
Chain 125 80 100 125 100 80 100 80 125 100
pitch pc,
mm
Number 9 9 8 9 10 11 8 9 10 11
of
Sprocket
teeth z
Service 6 5 6 6 7 6 6 6 7 6
time L,
years
Operating 24 41,67 41,25 32 24 44,32 52,5 45,83 28,8 27,27
speed n,
rpm
1.1.3 Select electric motor
We got: usystem = ugear × ubelt
u system
Uchain = u gear
Table 2: Selection of motor speed and distribution of transmission ratios
Motor Motor Overall Belt drive, Gear drive,
speed, rpm ratio, usystem ub ug
DC1 2870 68.88 6.15 11.2
DC2 1420 34.08 3.04 11.2
DC3 970 23.28 2.91 8
DC4 715 17.16 2.86 2.5
1.1.4 Technical specifications
Table 3: Technical specifications
Shaft
Parameters
Motor I II Conveyor
Power (kw) 2,1487 2,0412 1.98 1 , 98
Ratio 2,3 6,3 14 , 49
Rotation 1450 630,43 97 , 03 97,03
speed (rpm)
Torque 14 , 17 31,02 30,92 30,92
(N.m)
2. Design of belt drive (horizontal)
2.1 Parameter of belt drive
Power of driving belt 𝑃1 = 𝑃𝑚𝑜𝑡𝑜𝑟 = 2.1487(𝑘𝑊)
Transmission ratio 𝑢𝑏 = 3.04
Rotation speed of driving belt 𝑛1 = 𝑛𝑚𝑜𝑡𝑜𝑟 = 1450 (𝑟𝑝𝑚)
2.2 Desgin of belt drive
2.2.1 Calculate pulley diameter
Driving pulley diameter:
P1 3.0
D1 = (1100:1300¿ . ∛ n = (1100:1300).∛ 14 5 0 = 141: 166mm
1
Select d1 = 160mm
Driven pulley diameter:
D2 = 𝑢𝑏. d1 (1- ξ) = 3.04. 160. 0,98 = 477mm
Select d2 = 470mm
Actual transmission ratio:
𝑢𝑎𝑐𝑡𝑢𝑎𝑙 =
d2 470
d 1 (1−ξ ) = 160(1−0.02) = 2.997
2.2.2 Calculate velocity of belt
Peripheral velocity of driving belt:
𝑣1 =
π d 1 n1
6 ×10
4 = 11.9(m/s)
2.2.3 Calculate center distance, belt length and contact angle of pulley
Center distance:
15000≥ a ≥ 2( d1 +d2) ↔ 15000 ≥ a ≥ 1260 (mm)
Select a = 2000(mm)
Belt length:
2
π (d 1+ d 2) (d 2−d 1)
L = 2a + 2
+ 4a
2
π (160+470) ( 470−160)
= 2 × 2000 + 2
+ 4 ×2000
= 5001.614186 = 5002 (mm)
Increase belt length 100÷ 400 mm for belt joint ⇒ 𝑆𝑒𝑙𝑒𝑐𝑡 𝐿 = 5402 (𝑚𝑚)
Contact angle of driving pulley:
𝛼1 = 180 -57
d 2−d 1
a
= 171.165° = 2.99 rad
2.2.4. Calculate belt and pulley width
Select belt thickness δ = 5mm that satisfies the condition d1/δ ≥ 30
Correction factors:
Velocity correction factor:
Cv = 1 – cv (0.01v2 - 1) = 1 – 0.04 (0.01 × 11.92 – 1) =0.98
cv = 0.04 when 20m/s ≥ v ≥ 10m/s for all belt
Contact angle correction factor:
𝐶𝛼 = 1 − 0.003(180° − 𝛼1) = 1 − 0.003(180° − 165.465°) = 0.97
Orientation and tensioner correction factor: Co = 1 (the drive is in the horizontal
plane)
Operation correction factor: Cr = 0.8 (light impact load, 2 shifts)
⇒ C = CvCαCoCr = 0.98 × 0.97 × 1 × 0.8 = 0.76048
Allowable calculating stress:
[𝜎𝑡 ] = [𝜎𝑡 ]0𝐶 = 2.25 × 0.76048 = 1.71 (𝑀𝑃𝑎)
Where [σt ]0=2.25 with d1/δ=40
Belt width:
1000 P1 1000 ×2.1487
b≥ δv [σt ]
= 5× 11.9×1.71 = 21.1 (mm)
⇒ Select b = 25mm based on standard
Pulley width: select B = 32mm based on standard
2.2.5. Calculate force acting on belt drive
Initial tension:
𝐹0 = [𝜎0 ]𝑏𝛿 = 1.8 × 32 × 5 = 288 (𝑁)
Where [σ0] ≤ 1.8 MPa for flat belt
Circumferential force:
𝐹𝑡 =
1000 P1
v1 = 180.56 (N)
Tension on the tight side:
𝐹1 = + 𝐹0= 378.28 (N)
Ft
2
Tension on the slack side:
𝐹2 = 𝐹0 -
Ft
2
= 197.72 (N)
Minimum friction force is based on the condition to prevent belt slip:
𝐹0 ≥
fa
F t (e +1)
fa
2(e −1)
⇔ 𝑓𝑚𝑖𝑛 =
1 2 F0+ Ft
a ln( 2 F 0−F t ) = 0.21
2.2.6. Calculate service life of belt
Maximum stress:
𝜎𝑚𝑎𝑥 = + 10-6 𝜌𝑣 2 +
1000 P1 e
fa
δ
vA
× fa
(e −1) d1 E
= 5.16(MPa)
Where:
Belt density ρ = 1200 kg/m3
Belt modulus of elastic E=100MPa
