Belt Drives

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Belt drives
Updated April 2008

Purpose
To develop the knowledge and skills required to carry out the selection of a wedge belt drive system.

Objectives
At the end of this section you should be able to:
1. Describe the various types of belt drive
2. Select a suitable wedge belt for a given power
transmission
3. Select suitable pulleys and determine the speed of the
driven shaft
4. Determine the centre distance between the pulleys and
pitch length of the belt
5. Determine the number of belts required
6. Determine the radial (overhung) load caused by a belt
drive given the ratio of the belt tensions
7. Finalise the design, including selection oftaper lock
bushes (if used)

Belt drives are widely used for transmitting rotational mechanical power from one rotating shaft to
another. They are light, inexpensive, quiet and capable of transmitting reasonably large amounts of
power. There are several manufacturers/distributors of belt drives in Australia. The data in the manual
was taken from the Fenner Catalogue.

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Belt drive pulleys can be plain bushed or taper bushed for use with taper-lock bushes. All the pulleys
supplied by Fenner are of taper-lock bush type. The advantage of the taper-lock bush is that no key is
required, it is easy to install and does not weaken the shaft (does not cause as much stress
concentration) as a keyed bush.
There are many types of belt drive but for the purposes of this module you need only to be able to
select the wedge belt type. These are a type of vee belt that have largely superseded the older type of
vee belt. They have a deeper profile and are capable of transmitting more torque and power than the
older type.. The two types are interchangeable on the pulleys, so even if a vee belt was originally in
place, it can be replaced by a wedge belt if necessary without changing the pulleys.
The power that can be transmitted by a wedge belt drive depends upon a number of factors, namely:
The angle of contact
The greater this is, the more torque and power can be transmitted. If both pulleys are not of the same
diameter, then the smaller pulley is the one that determines the maximum torque and power that can
be transmitted. Not only does the smaller pulley have a shorter length of contact, but it also has a
smaller angle of contact than the larger pulley, so it will always be the first to slip. In cases where the
pulleys are not the same diameter, the angle of contact will depend also upon the centre distance
between the shafts. The greater the centre distance, the greater the angle of contact. For this reason,
centre distances should not be below the recommended minimum value (sum of the pulley pitch
diameters) unless there are special circumstances.
The wedge angle of the belt (and groove).
Because you will be selecting a standard belt you are not able to change this angle which is usually
34 or 38 depending upon the size of the belt and the size of the pulleys.

The coefficient of friction.

You have little control over this because it is determined by the belt material and the pulley material
(and finish). In practice it is important to keep oil and grease off the belt and pulleys because this will
reduce the friction (and could deteriorate the belt). Why would it not be a good idea to use a rough
surface on the pulley to increase the coefficient of friction?
The pulley diameters.
The larger the diameters, the greater the torque and power. This is simply because for a given belt
tension force, the larger the pulley, the larger the torque (torque = force x radius) and hence the
greater the power for a given speed. This is why it is not a good idea to choose pulleys that are too
small. On the other hand if the pulleys are too large, the belt speed increases, centrifugal tension
increases and the drive takes up more space. So a reasonable compromise is needed when choosing
pulley pitch diameters.
Initial belt tensions.

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The higher the initial tension in the belts, the greater the torque and power that can be transmitted. At
rest, when no power is being transmitted, the belt tensions are equal on both sides of the pulleys. As
the pulleys rotate and transmit power, the belt tension rises in one side (tight side) and reduces in the
other (slack side). However, the sum still stays the same. When the ratio of the belt tensions reaches a
certain limiting value, slipping will occur. Hence the greater the initial tension in the belts, the greater
the torque and power that can be transmitted before slipping occurs.
However, it is not a good idea to have too much tension because this will place high radial loads on
the shaft and bearings and also will reduce the belt life considerably. For this reason, initial belt
tensions should be set carefully. In their catalogue, Penner detail the practical method for pre-setting
the belt tensions. This method requires a belt tension indicator (which is really just a force gauge) that
measures the force at the centre of the belt required to cause a standard deflection (16 inn per m of
span). There is a recommended value for this force that should be adhered to when the belt drive is
initially installed.
As the belt wears, the initial tension needs to be re-set, so the designer should allow for an adjustment
method. Adjustment can be provided by moving one shaft further away from the other or by means of
an adjustable jockey pulley. This pulley should be located on the inside of the drive on the slack side
as close as possible to the larger pulley and should have a diameter at least equal to the smaller pulley.
The size of the belt.
The larger the belt section, the greater the tension that can be carried by the belt and the greater the
torque and power. In the Data Manual, four sizes of wedge belt are given, namely: SPZ, SPA, SPB,
and SPC. These are listed in increasing size, with the SPZ being the smallest and the SPC being the
largest.
The number of belts.
Belt drives with a single belt are the most common but belt drives are often used with 2 to 6 belts in
parallel on multi-grooved pulleys. In the larger sizes up to 8 belts may be used. Clearly, the torque
and power increase in direct proportion to the number of belts.

Design and selection of belt drive systems

In your applied mechanics (or dynamics) you should have learnt how to calculate the maximum
torque and power that can be transmitted by a vee or wedge belt drive, given the coefficient of
friction, angle of contact, groove angle and slack-side tension under load. For the purpose of
mechanical design you will now learn to use the manufacturers catalogue in order to design and select
a belt drive system.
Note The calculation of torque and power based on mechanics principles will usually overstate the
amount of torque and power: This is because this calculation does not consider the stresses in the belt
and the allowable stress that depends upon the belt material and method of construction.

Study guide
http://www.fennerdrives.com/assets/Opm_V_belts.pdf

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http://www.fptgroup.com/downloads/friction_wedgebeltdrives.pdf
Reference: Mechanical Design Data Manual Chapter 3
(Click to read pdf below. Do not print these notes on CADLAB
printers!)
Belt drives notes and example; Belt_notes.pdf
Belt drives data pages; Belt_data.pdf

1. Types of Belt Drives: Read the Preamble on page 50 of the Data Manual. Recognise the various
types of belt drives available.
2. Minimum Diameter: Look at Table 1 on page 56. This gives you the minimum pulley diameter
for a given power and faster-shaft speed.
3. Service Factors. Look at Table 3 on page 56. This gives you a service factor which takes into
account shock loading and the hours per day of operation. You will encounter a similar factor in the
selection of many other mechanical power transmission components. Note that in most cases, the
drive is a speed-reducing one. If the drive is speed-increasing one, then an additional service factor
should be applied (as shown in this table).
4. Power/Speed Graph: Look at the graph on page 57. This shows you where each size of belt can
be used according to the power and speed. You may like to use coloured pencil or highlighter pen to
shade the various lines to make this graph easier to use.
5.

Correction Factors: Given on page 58 and the power ratings given on pages 59 to 64.

6. Pulley Dimensions: Given on pages 65 to 72. These are all for use with taper-lock bushes.
Taper-lock bush details are given on page 73.
7. Read the selection method given in pages 50 to 52. It is not necessary that you work through this
in detail at this stage because it won't mean much to you until you try and work through a problem on
belt selection.
8.

Study the Worked Example on page 54 in conjunction with the selection method.

9.

Work through Exercises 1 and 2 in this section.

Types of belt drives.

Belt drives can be broadly categorised into two groups, positive(no-slip, toothed belts) and nonpositive(slip, friction belts). Traditionally belts have been of the non-positive (friction) type which
include flat belts and vee belts. In recent times toothed belts have become popular for use in electromechanical systems such as video machines, turntables and higher power applications such as servo
drives and camshaft drives. These are not treated here.

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Flat belt and Vee belt drives.

The following discussion on belt drives is limited to flat belts and vee belts where power is
transmitted by friction. These belt drives are subject to creep and even slip, depending on the load
being applied, and hence the drive ratio cannot be considered positive.
Flat belts with long centre distances were common in many industries in the past. A central prime
mover (eg. a steam engine) would generate power and belts would be used to transmit power to
various machines. These types of arrangement can still be found in some textile industries. Today
short centre drives are still in common use but more often vee belt drives are used.
Flat belts were commonly made from leather but today are usually made from rubber (cotton fabric or
cord impregnated and bound together by vulcanised rubber). Leather belts are made from leather
from the butt of the hide. Their ultimate tensile stress varies from 20 to 35 N/mm2.
Flat rubber belting is usually used as it is cheaper, has a higher coefficient of friction, is more resistant
to moisture and is stronger than leather belting. Initial tensions in rubber belts vary from about 2.5 to
4N per ply per mm width. Tensioning the belt results in elongation so belts are made approximately 1
per cent shorter than the theoretical tape line measurement. Belts can be purchased in endless form or
made endless in the field by means of a vulcanised splice. Rubber belts will stretch about 2 per cent
over their nominal life so it is desirable to provide centre distance adjustment. Maximum power
ratings are dependent on belt strength, angle of contact, small pulley diameter, beltspeed in m/sec and
service conditions.
Pulleys are generally made from cast iron or fabricated from steel. Flat belt pulleys are generally
crowned for self centring.
Vee belts
Vee belts are manufactured of rubber, fabric and cord. They provide a quiet, compact and resilient
form of power transmission with minimum shock transmission between drive shaft and driven
shaft/s. The tapered cross sectional shape of a vee belt causes it to wedge firmly into a sheave groove
so that the driving action takes place through the sides of the groove rather than the bottom. Vee belts
operate most efficiently at speeds of about 20-25 m/sec. Design of vee belt drives is done using the
selection procedure shown below (or on pages 51 and 52 of the Belt_notes.pdf)

SELECTION PROCEDURE FOR VEE BELT DRIVES

This selection procedure complies with BS3790.
1. Select service factor.
.
(a) The type of driven machine will determine the duty.
(b) Determine the type of driving machinery and operational hours per day.
(c) Select service factor.

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2. Calculate the Design power rating.

Design power rating = Motor power Service factor
3. Select the belt section.
(a) Mark the RPM of the faster shaft on the horizontal axis.
(b) Trace upwards along the vertical axis to the design power.
(c) At the point were they meet, note the recommended belt section or sections if there is an overlap.
Notes: choose 'B' section belts in preference to 'A' section belts.
In the overlap between 'B' and 'C' sections, 'C' section belts are likely to be more desirable as
fewer belts will be required.
4. Calculate the speed ratio (R). (Maximum ratio of about 6:1 in a single ratio)

5. Select pulley diameters.

(a) Determine recommended minimum motor pulley diameter from the table.
(b) Choose a combination of pulley diameters that gives required speed ratio, keeping in mind (a).
(c) Record catalogue details of pulleys and bushes.
6. Calculate the belt length based on centre distance (C).
If the centre distance is not fixed then use:

To determine belt length use:

Choose a suitable belt and record belt actual belt length and identification number.
7. Calculate the accurate centre distance (CA) based on the belt selected.

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8. Determine the basic power per belt for 'A', 'B' and 'C' section belts respectively.
Each page has the basic power per belt table on the left hand side and a table on the right hand side for
calculating additional power which depends on the belt speed ratio.
(a) Record basic (rated) power per belt from left hand table.
(b) Record approximate belt speed from left hand table
(c) Record additional power per belt from right hand table.

Power/belt = Basic power/belt + Additional power/belt

9. Determine the Arc of contact correction factor.
Refer Table 5
(a) Calculate (D-d)/C
(b) Record correction factor
(c) Record arc of contact ()
10. Determine the belt length correction factor.
Refer Table 6 .
11. Calculate the number of belts required.

Number
of
belts

Design power rating (step 4)

=

----------------------------------------(Power/belt(step 8)arc factor(step 9)length factor(step 10))

12. Summarise results.

Gather the data that is required for a bill of materials/materials list.

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(a) Pulley catalogue numbers and required dimensions.

(b) Taper lock bush catalogue numbers and required dimensions.
(c) check bore sizes against shaft sizes.
13. General arrangement drawing.
The centre distance CA has a negative tolerance to allow for initial installation of belts over pulleys.
CA has a positive tolerence to allow for take up as the belts are tensioned and for adjustment after
wear. At the centre of the span tensioning is satisfactory if the belt can be depressed 16mm/meter of
centre distance. For installation and take up allowances see DESIGN DATA MANUAL.

WORKED EXAMPLE
Problem 1:
Design a vee belt drive to transmit power from an A.C. squirrel cage, delta start, motor rotating at
1440 rev/min and rated at 11kW to a fan rotating at 720 rev/min. Centres are to be near to, but not
more than, 750mm apart and the driven pulley is not to exceed 355mm outside diameter. The drive is
to run a minimum of 18 hours per day.
Data:
Motor: A.C. squirrel cage, delta start; 11kW ; 1440RPM
Fan: 720RPM
Centre distance 750mm
Driven pulley 355mm O.D.
operating hours 18 hours per day

Solution:

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1. Service factor (S.F.).

Medium duty, 18 hr/day
S.F = 1.3
2. Design power rating (D.P.R.).

3. Select vee belt section.

Can use either 'A' or 'B' section
choose 'B' section.

4. Calculate the speed ratio (R).

5. Select pulley diameters (d)&(D).

see - Recommended minimum standard pulley diameters for electric motors.
Motor RPM=1440;Power=15kW
Minimum Diameter Motor pulley=118mm
Maximum O.D. driven pulley=355mm
Try D=315mm: d=D/R=315/2=157.5mm
Available combinations (D=315mm)
for d=150mm : R=2.1:1
for d=160mm : R=1.97:1
closest R=1.97, d=160mm, D=315mm
6. Calculate belt length (L).

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Find L based on the centre distance (C) and the pulley pitch diameters d and D.

Choose next smallest belt to this dimension to give centre distance< 750mm.
Select B2250,Cat No 240B0225 belt
(section 1711mm).

7. Accurate centre distance (CA).

8. Determine the power per belt.

Power per belt

basic power per belt for small pulley

+
Additional power per belt for speed ratio

by interpolation from tables

Power per belt

=

4.254
+
0.402

Power per belt = 4.656kW

9. Arc correction factor.
(D-d)/CA=(315-160)/748=0.2072

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correction factor=0.97
10. Belt length correction factor.
for belt B2250
correction factor=0.98
11. Number of belts
Number
of
belts

step 4
-------------------(step 8 * step 9 * step 10)

Number
of
belts

14.3
-------------------(4.656 * 0.97 * 0.98)

Number of belts = 3.23 (round off to 4 belts)

12. Summary of Results.
pulleys and bushes:
Motor pulley

Fan pulley

PCD=160mm

PCD=315mm

Cat No 013B0224

Cat No 013B0334

No of grooves = 4

No of grooves = 4

Taper lock bush No 2517

Taper lock bush No 3535

Maximum bore 60mm

Maximum bore 90mm

Pulley type - 3

Pulley type - 8

Outside diameter = 169mm

Outside diameter = 324mm 355mm

4 matched belts B2250, Catalogue number 240B0225.

Belt Assignment
Write out your working fully.
Question 1. A 50 mm diameter lineshaft (medium duty) is to rotate at 400 10 rev/mm. Power is
transmitted by a belt drive using a motor with frame size B14-132M-4 and direct-on-line (DOL) start.

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The drive operates for 10 hours per day. Centre distance between the motor and the shaft is to be as
close as possible to 600 mm.
(Motor Frame Sizes - Metric: Foot mounted / Flange mounted or refer to the imperial standard Nema used in the US).
Determine:
(a) Wedge belt section required (use the largest feasible)
(b) Pitch diameter of the pulleys at the motor and lineshaft
(c) Speed of the lineshaft (to the nearest rev/mm) at full load
(d) Wedge belt length
(e) Centre distance between the motor and the lineshafi (to the nearest mm)
(f) Number of belts
(g) Catalogue number of the pulleys and taper bushes at the motor and lineshaft.
Question 2. A conveyor is driven by a belt drive from a 3 phase 8 pole electric motor with star-delta
start. At full load the output power of the motor is 20 kW and the speed of the conveyor shaft is to be
250 10 rev/mm. Service can be described as heavy duty and the conveyor will operate for 8 hours
per day. The conveyor shaft is 60 mm in diameter and space restrictions limit the conveyor pulley to a
maximum diameter of 600 mm. The ratio of the belt tensions under load is expected to be 8:1.
Determine:
(a) Motor type
(b) Wedge belt section required (use the largest feasible)
(c) Pitch diameter of the pulleys at the motor and compressor shaft (use the largest feasible)
(d) Speed of the conveyor (to the nearest rev/mm) at full load
(e) Wedge belt length
(f) Centre distance between the motor and the conveyor (to the nearest mm)
(g) Number of belts
(h) Catalogue number of the pulleys and taper bushes at the motor and conveyor shafts
(i) Overhung load on the motor and conveyor shafts.

Now do it the easy way!

Use Fenner's automated belt drive selector on their website;
http://www.fptgroup.com/drivedesigner/
They also provide a selector for Synchronous Drives (timing belts).
http://www.fptgroup.com/downloads/synchro_htd.pdf

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