I L LU S T RAT E D S 0U RC E B 00K

of

M E C H AN I CAL C 0M P 0N E N T S

SECTION 3

BELTS
Unique Belt Applications Leather Belts-Hp Loss and Speed Find the length of Open and Closed Belts Ten Types of Belt Drives Mechanisms for Adjusting Tension of Belt Drives Equations for Computing Creep in Belt Drives Typical Feeders, Take-ups, Drives and Idlers for Belt Conveyors 3-2 3-1 1 3-12 3-14 3-16 3-18 3-22

3-2

Unique Belt Applications

Brent Oman

elt power transmission systems have been in operation in industry for over 200 years, going back to early flat belt drives. These early flat belts were typically composed of leather and cotton or hemp rope, used to transmit power from steam engines or water wheels to early industrial production machinery. Belt technology has increased dramatically, with modern engineered belt systems handling loads and applications with a design flexibility that other power transmission systems cannot match. Modern belt drives can handle a wide variety of loads and speeds that would not have been possible in the past.

An example of an extremely harshly loaded belt application is the supercharger belt drive system used
on the supercharged, nitromethane consuming Top Fuel and Funny Car classes in professional drag racing. The belt drive is used to drive the supercharger, transmitting power from the engine crankshaft. Vehicles in these drag racing classes commonly traverse the 1/4 mile track in under 5 seconds. Belt tensioning is provided by the addition of an idler. The superchargers used to develop such high vehicle speeds can require in excess of 1000 HP to operate, at speeds in excess of 10,000 RPM. Engine acceleration at the start of a race can be nearly 5,000 RPM in 0.2 seconds. Such extreme operating conditions requires a belt with equally extreme capabilities. A polyurethane synchronous belt with high strength aramid tensile cords and a modified curvilinear tooth form is the only belt which can handle such a demanding load requirement. Supercharger drive belts are commonly 14mm pitch (distance from the center of one belt tooth to the center of an adjacent belt tooth) and approximately 3 inches wide.

An example of a Top Fuel or Funny Car supercharger driven from engine crankshaft

Belts & Belting

3-3

While the supercharger drive, racing application is highly visible and glamorous, the same polyurethane belt is used in industry to replace roller chain on a wide variety of applications. Roller chain requires lubrication and regular maintenance in order to perform at its peak level. Roller chain can stretch up to 3% of its length over the life of the chain. The Kigh capacity, polyurethane synchronous belt provides superior horsepower capacity, with virtually no stretch.

Relative Center Distance Take-up R q i e eurd (100 Chain / Poly Chain GT)

.04

PolPcb.i.GT)P

I I I I I I I I

Stretch comparison of high performance polyurethane synchronous belt vs. roller chain. Over time, stretch of flexible power transmission products may require re-tensioning for optimum performance. Note that the high performance polyurethane belt system is virtually free of stretch over the life of the belt drive.

Additionally, no lubrication is necessary with the synchronous belt. The lack of lubrication allows the polyurethane synchronous belt to replace roller chain on applications where cleanliness is necessary to prevent contamination of product. As an example, conveying and paper converting applications are typically very sensitive to grease and contaminants contacting the product being manufactured. Live roller conveyors are used for controlled movement of a great variety of regular or irregular shaped commodities, from light and fragile to heavy and rugged unit loads. The term live roll indicates that the conveyor rolls are connected and driven by a power source. Where roller chain previously had to be used due to its capacity at low speeds, the latest generation of polyurethane, modified curvilinear tooth, aramid tensile cord synchronous belt drives have horsepower capacities in excess of similarly sized roller chain drives.

~~

Horsepower Rating Comparison

O t 40 Roller Chain 16 T Spkl # 50 Roller Chain 12T SpM . O # 60 Roller Chain 11T SpM

--

W8mm PCGT 12mm 2 Spld 8mm PCGT 21mm 25T SpM 8mm PCGT 36mm 25T SpM

Comparison of Horsepower Ratings for roller chain and high performance polyurethane synchronous belts. Note that it is quite possible to replace roller chain with comparably sized belt drives which will eliminate lubrication and maintenance concerns.

3-4

The high capacity synchronous belt allows for driving live roll conveyors by an arrangement of roll to roll belt drives, connecting adjacent rolls. At times, idler rolls are inserted between driven rolls.

Typical conveyor arrangement showing general roll to roll drive configuration

Detail showing motor and gearbox driving sets of live rolls. Note the belt drives connecting pairs of live rolls.

Detail showing head shaft drive and roll to roll drive. The drives can be on opposite sides, the same side, or a combination over the length of the conveyor system.

Belts & Belting

3-5

The major advantages of the polyurethane synchronous belt compared to roller chain are their high load capacity, wide range of operating speeds, lack of lubricant contamination, and virtual elimination of maintenance. The polyurethane synchronous belts can be used to replace roller chain with performance advantages in a wide variety of industries, including lumber, pulp, and paper; packaging; food processing; and sand/gravel/concrete processing. A n additional conveying application for synchronous belts is transporting product on the belts back.

This pallet conveyor transports product on the back of a synchronous belt. Typically, the belt span will be supported on a low friction surface. Special high durability backings are available which will reduce wear on the back belt contact surface. Special backings are also available in non-marking constructions.

Another unique product which demonstrates the design flexibility available belts provide is long length synchronous belting. This is a synchronous belt which is available in a continuous length of up to 100 feet, in a variety of pitches and constructions. Rubber trapezoidal tooth profile belts with pitches from .080 to S00 are available; as well as rubber curvilinear tooth profile belts with pitches from 2mm to 8mm. Urethane long length belting with aramid or steel tensile cords is also available in both trapezoidal and modified curvilinear tooth profiles. Long length belting is a cost effective, efficient and low maintenance alternative to chain. It is particularly suited for linear movement applications (automatic doors, automated warehouse or production conveying systems) and positioning applications (machine tools, x-y coordinate machines, printers, office equipment). Synchronous long length belting offers high positioning accuracy, length stability, low maintenance, and simple mechanical attachment using belt clamping fixtures. The clamping fixtures are easily machined, providing an effective method of attaching the ends of the belting to the device or product being positioned.

An example of a clamp groove profile which is used for attaching modified curvilinear tooth profile polyurethane long length belting to a fixture. A top plate is typically used to mechanically clamp the belt into the grooves. The fixture is mechanically attached to the component being positioned by the belt drive.

3-6

It is not uncommon for a pair of long length belts to be used in an industrial manufacturing environment to move a production mechanical device linearly. The belt is typically clamped to the device being positioned. Examples of applications include cutters, knives, print heads, and component movement equipment.

Belt clamp fixture attached to belt. The fixture would be attached to the machine element being positioned by the belt drive.

One of the advantages of synchronous belts is their very high efficiency. Efficiency of any power transmission system is a measure of the power loss associated with the motor, the bearings and the belt drive. Any loss of power is a loss of money. By minimizing the losses in the system, the cost of operating the drive is minimized. Since the passage of the U.S. Energy Policy Act (1992), higher efficiency motors are more often being used by Original Equipment Manufacturers (OEM) to reduce power loss. The U.S. Energy Policy Act is aimed at increasing the efficiency standards for all types of appliances and equipment (including electric motors). However, even a high efficiency motor's advantages can be under-utilized if the most efficient belt drive alternative is not chosen. Synchronous belts are more energy efficient than V-belts, providing a cost effective method of improving the overall system efficiency. Efficiency can be defined by the following formula: Efficiency = HPout/HPin
=

(TORQUEout x RPMout)/(TORQUEin x RPMin)

As this equation shows, energy losses in belt drives can be separated into two categories, torque
and speed loss. Torque loss results from the energy required to bend the belt around the sprocket or sheave. Energy lost as heat (due to friction) also causes torque loss. Speed losses are the result of belt slip and creep. Belt slip is self-explanatory. Creep happens as the belt elongates or stretches as it moves from the slack side to the tightside as tension increases. This causes a slightly longer belt to leave the sheave than what entered. Since V-belts generally have a much thicker cross section than synchronous belts, they use more energy bending around the sheave. Also, V-belts operate through a wedging action with the sheave, thus creating friction. There is generally more heat lost through this wedging action than from the minimal friction generated as a synchronous belt tooth enters and exits the sprocket grooves. V-belt drives, especially if poorly maintained, will slip. But synchronous belts are a positive drive system and do not slip. The V-belt drive will show a decrease in driveN speed (rpm) over time and the synchronous drive will not. Also, due to its low stretch properties, a synchronous belt does not experience creep. Even though properly maintained V-belts drives can run as high as 95-98% efficient at the time of installation, this often deteriorates over time by as much as 5% during operation. Poorly maintained V-belt drives may be up to 10% less efficient. Synchronous belts remain at an energy efficiency of around 98% over the life of the belt.

Belts & Belting

3-7

100
90
I

97.8% Synchronous Belt Drive

80

70

60
Increasing DriveN Torque

Synchronous belts are often used where precise positioning of components is required. Sophisticated machine tool applications, pick and place applications, and printing applications are just a few examples of potential synchronous belt drive applications.

This machining station uses synchronous belts to drive lead screws which position a machining spindle.

3-8

Synchronous belts are used to drive and position components in this pick and place application.

V-belt drives offer robust power transmission systems which can be designed for many unique applications. One example is the use of spring loaded idlers to minimize maintenance by means of automatic tensioning. An additional benefit is that a spring loaded idler provides lower overall drive tensions for drives subjected to large peak loads as compared to the drives average load. This increases the life of the V-belt and drive components. Fixed, manually adjusted, idlers function by forcing the idler into the belt until proper belt tension is achieved and the idler is locked into place. Belt tension in fixed idler drives is not constant, but decreases with time due to sheave wear, belt wear, and belt elongation. When retensioning is required, the idler must be manually adjusted to provide proper tension. With a fixed idler, static tension is imposed on the drive to transmit the peak load. With varying loads, this can result in higher belt tensions, reducing belt life. The spring loaded idler system automatically compensates for sheave and belt wear as well as belt elongation. Spring loading is often designed to provide constant tension over the life of the V-belt drive. Additionally, on applications subject to extremely wide variations in horsepower requirements, properly designed spring loaded idlers produce a constant slack side tension. Since the slack side tension remains constant, the tight side tension increases with increasing loads but drops as the loads decrease. This results in lower overall tensions and longer belt life.

DriveR V-belt drive with spring loaded idler

DriwN

Belts 8t Belting

3-9

Specific design procedures must be followed to properly calculate the required spring forces. However, the long term application benefits greatly outweigh the initial design time required. Examples of V-belt applications which commonly use spring loaded idlers are lawn mower deck drives and agricultural machinery. The driveR and driveN sheaves of a typical V-belt drive are usually in the same plane, but there are occasions which require that the two sheaves be in different planes. Two of the most common two-plane V-belt drives are quarter turn drives, which have the sheaves 90" apart, and eight-turn drives, which have the sheaves at 45 '. Quarter turn drives are more widely used, example applications include irrigation pumps driven by a PTO, agricultural equipment, lawn and garden equipment, and lineshafts.

P I;
Horizontal Shaft

l o p View

I
I

Vertical Shaft

Horizontal Shaft

\e

C T i g h i Side

Vertical Shaft

Quarter drive configuration showing dimensional design considerations.

Specific design considerations must be followed when designing drives operating in more than one plane. Minimum drive center distances, alignment positioning of the two shafts, rotational direction, and belt tensioning are all factors which must be examined in order to obtain optimum belt performance. It is suggested that belt manufacturers be consulted for specific application recommendations when designing a two plane drive. Serpentine drives are commonly defined as those having three or more sheaves or sprockets, in which the belts can drive from either inside or backside surfaces. There are many types of applications for serpentine drives, but several of the more common types include automotive front end accessory drives, roll drives in printing or paper equipment, machine tools, and conveyors. Many belt types can be used, including Micro-V, Double-V, conventional V-belts, and double sided synchronous belts. Double sided synchronous belts not only allow for power transmission from both sides of the belt, but also synchronize shaft speeds. This is typically critical in roll drives used in the paper or printing industry. Double sided synchronous belts are a clean, low maintenance alternative to roller chain for these types of applications.

Double sided synchronous belts provide design flexibility for systems requiring shaft counter-rotation and positive positioning.

3-10

In addition to providing a cost effective means of power transmission, belts can also be supplied in a variety of special constructions which might be required for unique applications. Alternate tensile member types, high or low temperature constructions, non-marking constructions, and special backings are just a few of the special constructions that are available to solve equipment designers problems.

Synchronous belts can be supplied with special backings for unique applications. Product is captured between the backs of two belts and moved in an assembly or conveying process. Similarly, belts with special backings can be used for wire drawing applications or bottling applications.

Information provided: Courtesy of The Gates Rubber Company Author. Brent Oman, Project Application Engineer The Gates Rubber Company

Belts & Belting

3-11

Leather Belts-Hp Loss and Speeds

From 0-10,000 ft/min and 435-3450 rpm, for pulley diameters up to 30 in.
Douglas C. Greenwood

Horsepower ratings and correction factors for various leather belt sizes, tensions, and operating conditions are given by most engineering handbooks or manufacturers catalogs. Such data, however, are usually not corrected for centrifugal force. This chart may be entered at any axis or pulley-speed curve. As shown,

secants parallel to the axcs connect any four value.; in corrcct relationship. In thc sainplc construction, a 12 in. dia pullcy at 1150 rpni givcs a bclt velocity of about 3620 fps at which spccd there is a 12% lip reduction. Consult bclt manufacturer regarding suitability, efficiency and other factors in high-speed applications.

Check with belt manufacturer for speeds in shaded areas.

2000

4000

6000

0000

l0,OOO

B e l t speed. f t /min

3-12

Find the Length of Open and Closed Belts

The following formulas give the answers (see the illustrations for notation): Open length, L = TD (tan e - e ) (D - d ) Closed length, L = (D d ) I. (ran e - e)] . YOUcan find 0 from (for open belts): cos 0 = (D

+ +

COS

e = (D +4 1 2 ~ .

- d ) / 2 C ; (for closed belts)

When you want to find the center distance of belt drives, however, it is much quicker if you have a table that gives you y = cos e in terms of x = (tan 0) 0. Sidney Kravitz, of Picatinny Arsenal, has compiled such a table. Now, all you need do to find C is first calculate x = [ L / ( D d ) ] - T for open drives.

y values*
Y 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 1.00000 0.95332 0.92731 0.90626 0.88804 0.87175 0.85690 0.84318 0.83039 0.81839 30705 .79630 .78606 .77629 ,76693 .75795 .74931 .74098 .73295 .72518 .71767 ,71038 .70332 .69646 .68980 .68332 .67701 .67086 .66487 .65902 .65331 .64774 54230 .63698 .63177 .62668 .62169 .61681 .61202 ,60733 50274 .59822 .59380 58946 .58520 .58101 .57690 .57286 .56889 .56499 0.56116 0.55738 0.55367 0.55002 0.54643 0.54289 0.53941 0.53598 0.53260 0.52927 ,52600 52277 .51958 .51645 51336 .51031 50730 ,50433 SO141 .49852 .49567 .49286 ,49009 .48735 .48465 .48198 .47935 .47675 .47417 .47164 08 . .46913 .46665 .46420 .46179 .45940 .45703 .45470 ,45239 .45011 .44785 09 . A4562 .44342 A 1 2 3 .43908 .43694 .43483 A3274 .a068 .42863 .42661 .O . 1 .2 . 3 A .5 .6 .7 .8 .9 1 0.42461 0.40568 0.38850 0.37284 0.35848 0.34526 0.33304 0.32170 0.31115 0.30130 2 .29208 .28344 .27531 ,26766 26043 25359 .24712 24098 .23515 ,22960 3 22431 21926 21445 .20984 .20544 20121 .I9717 .19328 .I8955 .18596 4 .I8251 .I7918 .17598 .17289 .16991 .16703 .16424 .16156 .15895 . 1 5 W 5 0.15400 0.15163 0.14935 0.14712 0.14497 0.14287 0.14084 0.13886 0.13694 0.13508 6 .13326 .13149 .12977 .12810 .12646 .I2487 .E332 .12181 .I2033 .11889 7 .11748 .11611 .I1477 .11346 .11217 .11092 .lo970 .lo850 .I0733 .lo618 8 .lo506 .I0396 .lo289 .lo183 .lo080 .09979 .09880 .09783 .09688 .09594 9 .09503 .09413 .09325 .09238 .09153 .09070 .OS988 .08908 .08829 .08751 0 1 2 3 4 5 6 7 8 9 10 0.08675 0.07980 0.07389 0.06879 0.064360.06046 0.05701 0.05393 0.05116 0.04867 20 ,04641 .04435 .04246 .04073 .03914 .03766 .03629 .03502 .03384 .03273 30 .03169 .03072 .02980 .02894 .02812 .02735 .02663 .02594 ,02528 .02466 40 .02406 .02350 .02296 .02244 ,02195 .02148 .02103 .02059 .02018 .01978 50 0.01939 0.01903 0.01867 0.01833 0.01800 0.01768 0.01737 0.01708 0.01679 0.01651 60 ,01624 .01598 .01573 .01549 .01525 ,01502 ,01480 .01459 .01438 .01417 70 ,01397 .01378 .01359 .01341 .01323 ,01310 .01289 .01273 ,01257 .01241 80 .01226 .01211 .01197 .01183 .01169 .01155 .01142 .01129 .01117 .01104 90 .01092 .01080 .01069 ,01057 .01046 .01036 .01025 .01015 .01004 .00994 100) 100 0.00985 (see note below for x IIf x = (tan$) $; then y = cos $ .

x 00 . 01 . 02 . 03 . 04 . 05 . 06 . 07 .

~f x

> 100, calculate C from c = L - - (Df d ) for both open and closed belts- s 2 4

>

Belts & Belting

3-13

x=Then

L
D f d

for closed drives

e=------I2Y

for closed drives

Example: L = 60.0,D = 15.0, d = 10.0, x = (L - d ) / ( D - d ) = 2.575, y = 0.24874 by linear interpolation in the table. C = (D - d ) / 2 y = 10.051.
.e..

Morton P. Matthews letter on fractional derivatives (PE-July 22 63, p 105) drew several interesting comments from readers. Heres what Professor Komkov of the University of Utah had to say on the subject. He pointed out that the question raised by Mr Matthew is well known in mathematics, but very little
publicized. The definition of fractional derivatives goes back to Abel, who developed around 1840 this fascinating little formula:

(r (n) is the Eulers Gamma Function).

An elementary proof of this formula is given for example in Courants Differenrial
and Zntegrul Calculus, Part 11, page 340. Abel claimed that the formula works for al real values of S,although there is no guarantee that the range of values obtained l can be bounded. For a negative S Abels operator D8 becomes an integral operator:

Al results quoted by Mr Matthew may be easily obtained by application of Abels l

Formula. . There exists a generalization to partial differential equations of the fractional derivative. This is the so-called Riesz Operator. In one dimensional case it becomes Abels derivative of fractional order. Details of the Riesz technique are explained, for example, in Chapter 10 of Partial Differential Equations by Duff. Unfortunately I know of no textbook which devotes more than a few pages to the subject of fractional derivatives. However, there exists a large number of papers on the subject in mathematical journals. I remember reading one by Professor John Barrett in the Pacific Journal of Mathematics (I think it was 1947) which discussed the equation:

*+
dz.

~y = 0 where 1 5 s

There are some interesting applications in engineering and science for this theory. I was interested some years ago in formulation of elasticity equations for some plastics. I have never completed that investigation but I have established that in some cases, the behavior of plastics may be better simulated by assuming stress-strain relationship to be of the type:

where s is some number between 0 and 1, than by the usual assumption of linear superposition of Hookes law and Newtonian Fluid properties. In case of some rubbers s worked to be close to 0.7.

3-14

Ten Types of Belt Drives

Although countless types of belt drives are possible, these ten will solve most industrial applications. These pertain to power transmission only; the tooth type of timing belt is not included. For each drive are given: design pitfalls; speed and capacity ranges; and suggestions for application.
George

R. Lederer

Fig.1 OPEN DRIVE

( V,

Flat or Poly V Belts)

Fig. 2 THREE PULLEY DRIVE

( V, Flat or

Poly V Belts)

Fig.4 REVERSE BEND IDLER ( Poly V, V, or Rot 6elts)

FIG. 1-Can be either horizontal ( A ) , or vertical (B). Used on equipment ranging from washing machines to oil well pumps. Ideal for high capacity drives; allows wider range of speed ratios than any other type. Provisions must be made for takeup. No minimum or maximum center distance limits other than available belt lengths. FIG. 2-Limited in capacity to 8-10 hp because of small high-speed pulleys and limited provisions for take-up. Usually used with one unit hingemounted, as in automotive fan belt drives. Large belts would stretch beyond capacity of hinged unit to take up slack. where several units are driven from a central shaft. The Vv belt that resembles two v-belts joined back-to-back was developed especially for this drive. For Vv operation all pulleys must be grooved. For regular V-, Poly-V or flat-belt operation, only those driven by the belt face are grooved, others are Bat and are-driven by the back of the belt. Driving capacity range from 15-25 hp. Sheaves are small, speed is slow and belt flex is extremely high, which affects belt life. FIG. &Used where driver and driven sheaves are fixed and there is no provision for take-up. Idler
FIG. 3-Useful

Fig.3 SERPENTINE DRIVE

(Poly V,V, or Flot Belts )

is placed on the slack side of the belt near the point where the belt leaves the driver sheave. Idler also gives increased wrap and increased arc of contact. Applications range from agricultural jackshaft drives to machine tools and large oil field drives. Idler can be spring loaded to keep belt tight if drive is subject to shock. For maximum belt life, the larger the idler, the better. FIG. %--Driver and driven sheaves are at right angles; belt must travel around horizontal sheave, turn, go over vertical sheave and return. Bend must be gradual to prevent belt from leaving sheave. Minimum center distance for V-belrs is 5.5 in. x (pitch dia of largest sheave + width of sheave). For Poly-V, minimum center distance = 13 X pitch dia of small sheave or 5.5 x (pitch dia + belt width). For flat belts it is 8 X

Belts & Belting

3-15

(PolyV,V, or Flot Belts)

Fig.5 QUARTER-TURN DRIVE (OPEN)
(Poly V,V, or Flot Belts)

w ._

E.-3

s
Fig.7 CROSSED BELT DRIdE (Flat Only)

Fig. 8 ANGLE DRIVE (EIGHTH TURN 1

(Poly V, V, or Flot Belts)

(pitch dia -+ width). V-belt sheaves must be deep grooved and close matching is essential. Speed usually ranges from 3,000-5,000 rpm; hp from 75-150. FIG. &Similar to Open Quarter-Turn but has higher capacity with shorter centers and increased wrap. Tracking is a problem with flat belts. With Poly-V drive, speed ratio is unlimited. Angle of entry (angle between belt and a line perpendicular to face of the sheave) is limited to 3 deg or less. FIG. ?-Limited to flat belts because either V-belt or Poly-V would rub against itself and burn or wear rapidly. Desirable only where the direction of rotation must be reversed such as on planers, woodworking tools in general and line shaft drives. FIG. 8-Used where driver and driven sheave cannot be on the same plane. Has same center distance and angle of belt entry limitations as Quarter-Turn. Drive can be open if take-up can be accomplished at either end or it can be fitted with a reverse bend idler, but not an inside idler. Angle between shaft can be from zero to 90 deg. FIG. 9-Especially developed for drill presses and special applications where driver and driven sheaves are at right angles to each other and yet on the same plane. Can operate around a corner or from one floor to another. The center sheave is 90 deg from the driver and driven sheave and acts as an idler. Twists affect belt life.

11;

Fig.9 MULE DRIVE

(Poly V, V, or Flot Belts)

Fig.IO VARIABLE SPEED DRIVE

( V Belts

Only)

FIG. 10-Sheaves must be grooved to change the pitch diameter for variable or adjustable pitch operation. With two sheaves and one belt, it is possible to have a range of four different speeds. Widely used on propulsion drives and cylinder drives on agricultural combines and machine tools. Drive has same high capacity and advantage as standard open drive, with wider speed range. They are mostly single belt drives 1% to 2 in. wide. Small pulleys are not advisable. Most applications require special vari-speed cylinder or traction belt.

3-16

Mechanisms for Adjusting Tension of Belt Drives

Sketches show devices for both manual and automatic take-up as required by wear or stretch. Some are for installations having fixed center distances; others are of the expanding center take-up types. Many units provide for adjustment of speed as well as tension.
Joseph H. Gepfect

Fig. I-Manually adjusted idler run on slack side of chain or flat belt. Useful where speed is constant, load is uniform and the tension adjustment is not critical. Can be adjusted while drive is running. Horsepower capacity depends upon belt tension.

Fig. 2 S p r i n g or weight loaded idler run on slack side of flat belt or chain provides automatic adjustment. For constant speed but either uniform or pulsating loads. Adjustments should be made while drive is running. Capacity limited by spring or weight value.

Driver

Fig. 5-Screw type split sheave for V-belts when tension adjustment is not critical. Best suited for installations with uniform loads. Running speed increases w i t h take up. Drive must be stopped to make adjustments. Capacity depends directly upon value of belt tension.

Fig. (i-Split sheave unit for automatic adjustment of V-belts. Tension on belt remains constant; speed increases with belt take up. Spring establishes maximum torque capacity of the drive. Hence, this can be used as a torque limiting or overload device.

Fig. 9-Spring actuated base for automatic adjustment of uniformly loaded chain drive. With belts, it provides slipping for starting and suddenly applied torque. Can also be used to establish a safety limit for the horsepower capaeity of belts.

Fig. l-ravity aetuated pivoting motor base for uniformly loaded belts or chains, only. Same safety and slipping characteristies as that of Fig. 9. Position of motor from pivot controls the proportion of motor weight effeetive in produeing belt tension.

Belts & Belting

3-17

- base h 'Matar
Fig. 3-Screw-base type unit provides normal tension control of belt or chain drive for motors. Wide range of adjustments can be made either while unit is running or stopped. With split sheaves, this device can be used to control speed as well as tension. Fig. &Pivoting screw base for normal adjustment of m.otor drive tension. Like that of Fig. 3, this design can be adjusted either while running or stopped and will provide speed adjustment when used with split sheaves. Easier to adjust than previous design.

be

Fig. 7-Another manually adjusted screw type split sheave for V-belts. However, this unit can be adjusted while the drive is running. Other characteristies similar to those of Fig. 6. Like Fig. 6, sheave spacing can be changed to maintain speed or to vary speed.

Fig. 8-Special split sheaves for accurate tension and speed control of V-belts or chains. Applicable to parallel shafts on short center distances. Manually adjusted with belt tension screw. No change in speed with changes in tension.

shaft mounted

Weigh?

Fig. 11-Torque arm adjustment for use with shaft mounted speed reducer. Can be used as belt or chain take up for normal wear and stretch within the swing radius of reducer; or for changing speed while running when spring type split sheave is used on motor.

Fig. 12-Wrapping type automatic take-up for flat and wire belts of any width. Used for maximum driving capacity. Size of weight determines tension put on belt. Maximum value should be established to protect the belt from being overloaded.

3-18

Equations for Computing Creep in Belt Drives

Don't confuse slippage caused by overloading with creep found in all belt drives. These equations give the creep rate and power loss in various pulley systems
Peter L. Garrett

HEN a belt is transmitting power there exists a tension TI on the tight side that is greater than the tension T, on the slack side. This is due to friction between belt and pulley. By the rules of equilibrium, the maximum possible tension ratio, TJ T,, that can be transmitted without slip is given by the following equation (refer to figure below): e

where T , = tension at tight side, lb T, = tension at slack side, Ib e = natural logarithm base = 2.718

are listed in the table of belt and rope properties on page 89. The relationship between the drivFor velocities substantially below the speed of sound this equation has ing torque, T, and the belt tension is been confirmed by tests. For those 7 = (TI - Tz)RB (2) sufficiently curious to note the effect where Rs = radius of pulley B plus of extremely high speeds, Eq 1 can one half the belt thickness. be modified to include the Mach Therefore, the initial belt tension number, M. and ratio T J T , can be increased to prevent slip without affecting the = e (1A) torque equation (or, more specifically, the difference in tensions, TI - T 2 ) . m a The limiting factors in this case are Any load greater than e'' in Eq 1 the belt stress and bearing loads. Yet even when there is no slip the will cause belt slippage, loss of synchronism and serious wear. Coeffi- belt inexorably creeps backward over cients of friction for belts and ropes the pulleys, an effect that is particup

6 '

= coefficient of friction = angle of wrap, radians

(a)

(&@)

DUAL-PULLEY DRIVE

Belts 8t Belting

3-19

larly obvious if the drive never reverses. For zero slip, one revolution of pulley A will pull 2aRA inches of belt at tension T,. However, as the belt approaches point 1, the tension drops to a lower value, Tz, and the belt contracts by an amount d equal to

where A = area of belt cross section, in.' L = segment of belt length, in. E = modulus of elasticity, psi F = tensile loading If L = 1 in., then

and of the slack side

(5)
Hence

K=AE
or

K
where K = spring constant of belt. Typical K values are included in the table of properties on page 89. This change in length causes localized slippage between belt and pulley with consequent power dissipation. Thus, pulley A unwinds only (2aRA - d ) inches of belt per revolution, and the belt creeps backward an amount equal to d inches each revolution. The K factors Factor K in Eq 3 is the spring constant of the belt in units of force per unit strain. Thus

= =

($)(0.020)(30 X lo6) 150,000 lb/in./in.

For laminated belts, the calculations are more complex. Belt manufacturers usually can give you the K factor for a belt, but it is a simple matter to obtain the value by test if they do not. For example, 30 in. of belting elongates YS in. under a 20-lb load. What is the K factor?

Strain

deflection length

Velocity V , can be considered as the nominal belt velocity, and V , as being equal to V , minus the creep rate, or

=-

'Is
30

1 = -in./in. 240

v,= v* - VIC
-=
VI

vz l - c

(7)

K=-

lb in&

K = - 20 1/240
= 4800 lb/in./in.

These units for K simplify calculations with belts of different length. The K factor is constant for all belts of a particular material and cross section. It can be calculated easily for belts of uniform material and measurable section. For example, for a steel band with a '/4 x 0.020-in. cross section

where creep factor, C, is the fractional loss in speed due to elastic effects. Combining Eq 6 and 7 gives

VeIocity relationships Returning to Eq 3, this relationship can be put into terms of velocity. During a specific time, At, pulley A
will have rotated through an angular displacement of ea. Hence the velocity of the tight side is Since the torque load is equal to = (TI T,)RB,then -

F K = FL/AE

RA~A VI = At

(4)

(9)

MULTIPLE-PULlEY DRIVE

3-20

SYMBOLS
c = CREEP FACTOR, DIMENSIONLESS
d = CHANGE IN BELT LENGTH, IN.
K = SPRING
t

=TIME, SEC

r =TENSION, LB
v = LINEAR VELOCITY OF BELT, IN./SEC
Vc = CREEP RATE, INJSEC

CONSTANT OF BELT,

LB/(IN./IN.)
L

= SEGMENT OF BELT LENGTH, IN. = MACH NUMBER-THE RATIO OF

THE VELOCITY OF A MOVING BODY TO THAT OF SOUND

=ANGLE OF WRAP, RADIANS

0 = FINITE ANGULAR DISPLACEMENT, RADIANS

T

=TORQUE OF LOAD, LB-IN.

P = POWER, LB-IN./SEC.
R

p = FRICTION COEFFICIENT

=PULLEY RADIUS THICKNESS, IN.

BELT

SUBSCRIPTS A, E, AND c REFER TO PULLEYS A, E, AND c, RESPECTIVELY.

Factor 1 / K is frequently referred to as the compliance of the belt, in units of strain per pound. Thus from Eq 9 it can be noted that creep is directly proportional to the product of load and compliance.

tion of the multiple-pulley drive on previous page) :

STEEL-TAPE DRIVE

Power losses
Ignoring windage and hysteresis losses (the energy converted into heat by the belt during the stretch and relaxation cycles), the power relationships are where of tangency and ends short of the other line of tangency.

Driven pulley Pin = TiVl - T2Vz

Paul

Pulley A (driver) Similar to Eq 12:

(10)
(11) Hence
v = V2(l - CC) s

Piosa= T I ( V I- Vs)
Pulley B (1st driven)
(20)
v = 2

Vz(T1 - T z )
Pout

The power loss is

P ~ o a r= P i n

Thus

vl(1- C B )
-

(21)

Piost = Ti(V1 Driving pulley

Pout

vz)

Therefore (12)

vs = Vl(1 - c B ) ( 1
and

cc)

(22)

Pulley C (2nd driven)

TIVI - T2Vz

(13)

From this it can be concluded that the creep with respect to the driving Pout = TlV1 - TZVI (14) pulley speed will increase as we go Hence, subtracting Eq 14 from Eq from pulley to pulley through the 13, the power loss is equal to driven series of belts. Therefore it is P r o s s = Tz(v1 - Vz) (15) not possible to have a reversible drive Because TI is greater than T2, com- with a constant ratio between any two paring Eq 15 with Eq 12 shows that pulleys if there are more than two the power loss ut the driven pulley pulleys in the chain (not counting is slightly greater than the loss at the idlers), driver. Power loss-multiple pulleys

An ideal driving pulley will recover the power T,V, and its power output will be

V = Vl(1 - C l ) (1 - Cz) * (1

- Cn-I)

(23)

Pi, = TsV2 - TsVt P r = V3(T - Ts) m a PI,, = T (v 2 - V d z

To add the power losses of the two driven pulleys, note that T,> T,>T,, and VI> V,> V,;hence

Belt creep-multiple pulleys Employing the same analytical approach to arrangements with three or more pulleys results in the following equations (refer also to the illustra-

The power loss is due to friction i n the areas, where the belt must slip to transmit the difEerence in tension. For all drivers and loads, this area of slippage begins at the unreeling line

Thus, the power losses of all the driven pulleys together i s slightly greater than the loss at the driver.

Example-teel-tape drive To show the use of the design equa-

Belts & Belting

3-2 1

TYPE FLAT BELT

MATERIAL LEATHER WOVEN COTTON WOVEN HAIR BALATA RUBBER STEEL

COEFFICIENT OF FRICTION, (I (ON CAST IRON PULLEYS! 0.25 0.2 0.2 0.3 0.2 0.15 TO 0.35 TO 0.3 TO 0.3 TO 0.4 TO 0.3 TO 0.25

DENSITY LB/IN.: 0.035 0.035 0.035

0.04

MODULUS OF ELASTICITY, PSI 20,000 40,000 30,000 50,000 30,000 30 X 10 35,000 VARIABLE VARIABLE
From G H. Rvder

WORKING STRENGTH (MAXIMUM TENSION), PSI 300 TO 300 TO 300 TO 400 TO 400 TO 10,000
400

0.045 0.28 0.04 0.2802 LB/FT 0 IN.=OIA 1.502 LB/FT

D IN.=DIAMETER

500 400 400 500 500

1
WIRE ROPES

FABRIC SET IN RUBBER STRANDED COTTON STRANDED STEEL WIRE

0.25 TO 0.35 0.2 TO 0.3

0.15 TO 0.25

200

4000

tions, assume that the three-pulley drive, at left, employs a 0.020 x %-in. steel tape. To avoid overstressing the tape, the drive uses 2-in.-dia pulleys. Pulley A drives the belt system. Pulley B is coupled to an indicator with a OS-in.-lb load. Pulley C is coupled to a mechanism with a fj-in.-lb load. Other design specifications are: Coefficient of friction for steel tape (see table), p = 0.2. Angle 0 for pulley A = 160 deg. Belt speed, VI = 20 in./sec. Tension, TI, by preloading the belt = 10 lb. Thus

It has been shown that the design is adequate at the driver pulley. The two driven pulleys will now be examined, Pulley C-major load To determine the minimum angle of wrap at pulley C , it is convenient and conservative to ignore the tension drop across the %-in.-lb load. In other words, assume that TS = T1 = 10 lb To support this contention, note that for the equation

5.5 in.-lb (1 in. X 150,000 lb/in./in.) 10-5

cn = 3.7 x

where the value for K was previously computer on page 87.

v z v1
Pima

1
1 - 3.7

10-5

= 1.000?037

10 T = (0.020) (0.25) I

2000 psi

This amount is sufficient for proper belt seating, yet within the 10,000-psi limit (from the table) for the steel belt. Calculations for the tape tensions are as follows:

= (15.5)(20)(1.000,037 - l j = 310(0.37)(10-4) = 0.011 in.-lb/sec It is safe to assume that the power when 6, = 0, T J T , = 1. But at any losses for both driven pulleys are very positive value of 0, TJT, > 1, or T, nearly equal to the loss at the driver. > Ti. Hence, the total power loss is apReturning to the analysis of pulley proximately 0.022 in.-lb/sec. C, the maximum possible torque is Input power = 20 in./sec x 5.5 lb 5 in.-lb, or 5 lb at the 1-in. radius. = 110 in.-lb/sec; therefore the effiHence the actual T, tension will be ciency of the tape drive is

Ti(Vz - VI)

Te

T + 5 Ib s

10

+ 5 = 15 lb

Tz= TlePBA
T2 = 10 e(0.2)
0.79)

17.5 lb

110 - 0.022 110 1 - 0.00022 or 99.98%

I

This value is the maximum permissible tension at the high-tension side of the drive-the belt will slip with higher tensions. (The actual T, value will depend on the driven loads and should be less than 17.5 Ib.) Thus the tension drop available for work is

p6c =

In 1.5

= 0.405

BC =0.405/0.2 = 2.02 rad = 115 deg A wrap angle of less than 115 deg may cause slippage at pulley C. Pulley B-minor load In a similar manner
,POB

0.5

+ 10
10

This example shows why X-Y curve plotters and other instruments often use steel tapes for drives. The low creep rate resulting from the high modulus of steel permits use of a band that is not indexed to any pulley in the drive and can still indicate position repeatably.

(Tz - T i ) m s x

17.5 - 10 = 7.5 lb

Because R = 1 in., the maximum torque that can be transmitted is ( 1 ) (7.5) = 7.5 in.-lb, which is greater than the 5.5 in.lb total load requirement.

OB = 0.25 = 15 deg The power loss at the driver is

3-22

Typical Feeders, Take-ups, Drives

and Idlers for Belt Conveyors

FEEDERS

Spiral Feeder

Horizontal and Inclined Apron Feeder

Self-contained Apron Feeder

Hopper

Crusher Feeder

Batch Feeder

Crusher Products Feeder

TAKE-UPS

Horizontal Counterweighted Automatic

$ 1

I 1
L-1

Screw Take-up

Ver tica I Counterweighted

Autornotic

DRIVES
210 Oconfacf

Snub

Plain

Belts 81 Belting

3-23

IDLERS

Self-Aligning Return Idler (Positive Type)

Self-Aligning Return Idler (Inclined Pivot Type)

Troughing and Return Idler

Flat Belt and Return Idler

Self-Aligning Idler ( Positivefype)

Self-Ali ning Idler

( Frict-onType)

il

Impoct Absorelon Idler