1

CHAPTER 2

BELT DRIVE SYSTEM

2.1 Introduction to Belt Drive System

Another method widely used in engineering practice in transmitting power between

shafts is belt drive system. Basic arrangement of a belt drive system consists of driver sheave,
driven sheave and belting material such as ropes, rubber bands or chain. Power is transmitted
from the driver sheave by means of a belt to the driven sheave.

A Belt is a looped strip of flexible material, used to mechanically link two or more
rotating shafts. They may be used as a source of motion, to efficiently transmit power, or to track
relative movement.

A pulley (also called a sheave or block) is a wheel with a groove between two flanges
around its circumference. The groove normally locates a rope, cable or belt. Pulleys are used to
change the direction of an applied force, transmit rotational motion, or realize a mechanical
advantage in either a linear or rotational system of motion.
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2.1.1 Operation of belt drives

The operation of belt drives depends fully on the friction generated from contact surface
between the belt and sheaves. Thus, any slip occurrence on the contact surface will reduce the
efficiency of the power transmitted. Power transmitted from the driver to the driven sheaves also
depends on factor such as;

Speed of the belt itself.

Surface area of contact between the belt and sheaves.
Workspace constraint where belt drive is used. Most belt drive system will have parallel
shaft arrangement, but for a constraint workspace such as in a cars engine, an idler
sheaves maybe used.
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2.1.2 Advantages of belt drive

They are simple.

They are economical.
Parallel shafts are not required.
Overload and jam protection are provided.
Noise and vibration are damped out.
Machinery life is prolonged because load fluctuations are cushioned (shock-absorbed).
They are lubrication-free. They require only low maintenance.
They are highly efficient (9098%, usually 95%).
Some misalignment is tolerable.
They are very economical when shafts are separated by large distances.
Clutch action may be obtained by relieving belt tension.
Variable speeds may be economically obtained by step or tapered pulleys.

2.1.3 Disadvantages of belt drive

The angular-velocity ratio is not necessarily constant or equal to the ratio of pulley
diameters, because of belt slip and stretch.
Heat buildup occurs.
Speed is limited to usually 7000 feet per minute (35 meters per second).
Power transmission is limited to 370 kilowatts (500 horsepower).
Operating temperatures are usually restricted to 31 to 185F (35 to 85C).
Some adjustment of center distance or use of an idler pulley is necessary for wear and
stretch compensation. A means of disassembly must be provided to install endless belts.
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2.2 Choice of Belt Drive System

There are four general types of belts:

a) Flat belts
b) V-belts
c) Film belts
d) Timing belts
Each has its own special characteristics, limitations, advantages, and special-purpose
variations for different applications.

a) Flat belts
Flat belts, in the form of leather belting, served as the basic belt drive from the
beginning of the Industrial Revolution.
They can transmit large amounts of power at high speeds.
Flat belts find their widest application where high-speed motion, rather than
power, is the main concern.
Flat belts are very useful where large center distances and small pulleys are
involved.
They can engage pulleys on both inside and outside surfaces, and both endless
and jointed construction are available.
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b) V-belts
V-belts are the basic power-transmission belt, providing the best combination of
traction, operating speed, bearing load, and service life.
The belts are typically endless, with a trapezoidal cross section which runs in a
pulley with a V-shaped groove.
The wedging action of the belt in the pulley groove allows V-belts to transmit
higher torque at less width and tension than flat belts. V-belts are far superior to
flat belts at small center distances and high reduction ratios.
V-belts require larger pulleys than flat belts because of their greater thickness.
Several individual belts running on the same pulley in separate grooves are often
used when the power to be transmitted exceeds that of a single belt. These are
called multiple-belt drives.

c) Film belts
Film belts are often classified as a variety of flat belt, but actually they are a
separate type.
Consisting of a very thin strip of material, usually plastic but sometimes rubber,
 6

their widest application is in business machines, tape recorders, and other light-
duty service.

d) Timing belts
Timing belts have evenly spaced teeth on their bottom side which mesh with
grooves cut on the periphery of the pulleys to produce a positive, no-slip,
constant-speed drive.
They are often used to replace chains or gears, reducing noise and avoiding the
lubrication bath or oiling system requirement.
They have also found widespread application in miniature timing applications.
Timing belts, known also as synchronous or cogged belts, require the least tension
of all belt drives and are among the most efficient.

The choice of type of belt to be used is important so that the required power can be
delivered efficiently. Some of the factor to be considered in selecting a suitable belt type to be
used for a particular application is;

Speed of driver and driven sheaves.

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Required velocity ratio

Distance between the driver sheave and driven sheave.
Workspace constraint
Total power to be transmitted

2.3 Belt Drive System Arrangement

Power from one shaft can be transmitted to another shaft using some of this arrangement;

a) Open Belt Drive Arrangement

b) Cross-Belt Drive Arrangement

c) Quarter Turn Belt Drive with Idler Sheave

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d) Open Belt Drive with Idler Pulley

2.4 Velocity Ratio of Belt Drive System

Driven pulley
Driver pulley
Slack side

Tight side

Let say; d 1 = diameter of driver sheave

d 2 = diameter of driven sheave

N 1 = Speed of driver sheave

N 2 = Speed of driven sheave

For one complete rotation of the sheave, length of belt per unit time used is;
Length of belt = d
Thus for a total of N rotation per unit time, length of belt used is;
Total length of belt = dN .. (1)
By using the assumptions that belt used is inelastic, thus the length of belt passing the driver and
driven sheave is the same. Also no slip occurs in the system thus total length of belt required for
driver and driven sheave is the same.
d1 N 1 d 2 N 2 .. (2)
Simplify equation (2) to get Velocity Ratio, n
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N 2 d1
n .. (3)
N1 d 2

If the thickness, t of belt is considered, equation (3) becomes

N 2 d1 t
n .. (4)
N1 d 2 t

2.5 Slip in Belt Drive System

Belt drive will slip if friction force on

Driver sheave Driven sheave the surface of contact between belt and
v sheave is reduced. This will cause the
N2 sheave to rotate without holding the belt.
d2 Normally slip is expressed in percentage
d1
slip. Consider a belt drive system with
Belt
slip as figure beside.
N1

Effective speed (rad/s) at the driver sheave, v

v [Original speed] - [Change of speed due to slip]
d1 N 1 d1 N 1 G1
v (5)
60 60 100

Where G1 = Percentage slip at the driver sheave

G 2 = Percentage slips at the driven sheave

By assumption that the belt is inelastic at the no slip condition, thus;

The effective speed of The effective speed of

driver sheave, v = driven sheave,

But the effective speed at driven sheave is reduced due to slip at the driven sheaves surface of

G
contact. Thus; v 2 v v 2
100
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d 2 N 2 G
v v 2 .. (6)
100 100

Put equation (5) into (6), thus results in

N 2 d1 G G2
1 1 .. (7)
N1 d 2 100

If the thickness of belt, t is considered, thus equation (7) becomes

N 2 d1 t G G2
1 1 .. (8)
N1 d 2 t 100

2.6 Angle of Lap

Angle of lap/contact is the enclosed angle in which the belt and surface of pulley are in
contact. Angle of lap is important to determine the right setting of driver sheave and driven
sheave that can produce effective power transmission.

Consider an open belt drive system below;

Let r1 = radius of the big pulley

r2 = radius of the small pulley

= Angle of lap
X = Distance between centres of both pulley
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From the geometry;

O1 M O1 E ME r1 r2
sin . .. (9)
O1O2 O1O2 X

Thus, angle of lap,

180 2 rad .....(10)
180
If considering a cross belt drive system as shown in figure below;

If angle of lap, is the same for both sheave, then from geometry;

O1M O1 E ME r1 r2
sin . (11)
O1O2 O1O2 X
And the angle of lap is

180 2 rad .(12)
180
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2.7 Overall Length of Belt Drive System

Figure above shows an open belt drive system.

Let r1 = radius of the driver sheave
r2 = radius of the driven sheave
= angle of lap
X = Distance between centres of driver sheave with driven sheave
L = Overall length of belt drive
From the geometry, line O2 M is parallel with line EF and also
O1 M O1 E ME r1 r2
sin
O1O2 O1O2 X

Since, is small, thus sin . This leaves with

r1 r2
rad. . (13)
X
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Again, from the figure above,

Length of curve JE r1 . (14)
2

EF MO2 O1O2 2 O1 M 2 X 2 r1 r2
2
Line

2
r1 r2
EF X 1 . (15)
X

Use Binomial Theorem to expand equation (15), and the final equation is

EF X
r1 r2 2 .. (16)
2X

Length of curve FK r2 .. (17)
2
Total length of belt is
Lopen = 2 [Length of curve JE + Length of line EF + Length of curve FK ]
r1 r2 2

Lopen 2 r1 X r2 . (18)
2 2 X 2

Now consider for a cross belt drive system as below figure. The same procedure previously, only
the difference is that location of line EF is parallel with line MO2 .
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Thus total length of belt is;

Lcross = 2 [Length of curve JE + Length of line EF + Length of curve FK ]

r1 r2 2

Lcross 2 r1 X r2 . (19)

2 2X 2

2.8 Belt Tension in Belt Drive System

Belt tension in a belt drive system can be expressed in terms of ratio between tension on
the tight side and the slack side of the same belt when it was operating. Consider a pulley wheel
with a belt passing around it as shown below. In order for the belt to produce torque on the wheel
(whether or not it is rotating), there must be tension in both ends. If this was not so, the belt
would not be pressed against the wheel and it would slip on the wheel. The belt depends upon
friction between it and the wheel in order to grip and produce torque.

T1

T2

For the belt to produce torque on the wheel, the tension in one end must be greater than
the tension in the other end. Let T1 is larger than T2 and is the angle of lap. Now, consider an
elementary length of the belt on wheel. The tension in one end is T and the other end is T dT .
The angle made by the small length is d .
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T T dT

1. First, resolve T radially and tangentially to the wheel.

T1

d
T1 T cos , and for small angle , thus cos cos 0 o 1
2
T1 T . (20)
d
R1 T sin , for small angle , thus sin
2
d
R1 T .. (21)
2
2. Next, repeat for the other end to resolve T dT
T2

T dT

d
T2 T dT cos T dT .. (22)
2
d d
R2 T dT sin T dT .. (23)
2 2
3. Ignoring the product of two small quantities, total reaction force is
R N R1 R2 Td .. (24)
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4. The resultant tangential force is

TR T2 T1 dT .. (25)
5. As a summary, two important results we have obtained
R N Td And TR dT

6. Now, treat the small piece of belt as a small block about to slip on a flat surface

RN

TR

When the block just about to slip, force TR is equal to friction force, F
TR F R N

dT R N Td

dT
d (26)
T
7. Integrating between limits of 0 and for angle and T T1 and T T2 for
force, thus we get;
ln T1 ln T2

T1
e (27)
T2
Equation (27) is the ratio of belt tension and is used ONLY for flat belt type.
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The derivation for the belt tension ratio for Vee-Belt type can also be derived with the
same approach as previously. Consider a section of a Vee-belt with an included angle of 2 . The
wedging affect increases the reaction force between the sheave and the belt from R to R ' . Since
the friction force is increased, greater power can be transmitted before the belt slips.

Figure: Vee-Belt section

1. Resolving R ' vertically gives an upward force R ' sin on each side of belt
R
R' .. (28)
2 sin

2. Previously, dT R N , but for vee-belt must use dT R '

R
dT R ' .. (29)
2 sin

3. Since there are two faces in contact with the wheel, the friction is doubled. Hence
R R
dT 2 R ' 2 . (30)
2 sin sin

4. Completing the derivation by integrating between limits as before, the results are

T1 sin

e (31)
T2

Equation (31) is the belt tension ratio for the Vee-Belt type ONLY.
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2.9 Maximum Power Transmitted by Pulley

The tension in a belt pulley increases with torque and power. The maximum power that a
pulley system can transmit is limited by the strength of the belt material. If this is a problem then
more than one belt should be used to share the load. If the belt does not break, then the
possibility of belt slipping exists and this depends upon the angle of lap and coefficient of
friction. If the coefficient of friction is the same for both wheels, then slippage will occur first on
the smaller wheel. The power at which the belt slips is not the absolute maximum power that
can be transmitted as more power can be transmitted with slippage occurring by using higher
wheel speed.
The friction between the belt and the wheel is further affected by centrifugal force which
tends to lift the belt off the wheel. This increases the likelihood of slipping. Friction between belt
and pulley can be increased by using a Vee-belt type instead of Flat Belt type since Vee-belt can
grip better.

2.9.1 Maximum Power with No Belt Slip

1. Power transmitted by a pulley is generally given by P Tv where T is the torque at

pulley and v is speed of pulley.

To find the power transmitted for certain belt

Driver Driven
Tight side type, use the belt tension ratio and substitute
N2 into P Tv .

N1 T1 For Flat type belt, maximum power; when the

belt starts to slip is
P T1 T2 v Watt
T2
1
P T1 1 v . (32)
Slack side e
This is the maximum power that can be
transmitted with no slip occurring.
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To find the power transmitted for certain belt type, use the belt tension ratio and substitute into
P Tv .
For Flat type belt, maximum power; when the belt starts to slip is
P T1 T2 v Watt

1
P T1 1 v . (32)
e
This is the maximum power that can be transmitted with no slip occurring

For Vee Belt type, the maximum power that can be transmitted with no slip occurring is

1
P T1 1 v Watt . (33)


e sin

2.10 Effect of Centrifugal Force

Consider the element of belt on the wheel once again;

T
T dT

The length of the curved element is rd

Density of the belt material is
The cross sectional area of the belt is A
The volume is Ard
The mass of the elemental belt strip is dm Ard
mv 2
The centrifugal force is FC
r
1. Since we are dealing with elemental mass, thus the elemental centrifugal force acting on the
tiny mass can be written in
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dmv 2 Ardv 2
dFC Adv 2 . (34)
r r
2. The normal force R N pressing the element to the wheel derived earlier without
centrifugal effect is, R N Td

3. Now the normal force is reduced due to centrifugal force acting outward, so
R N Td Adv 2

R N d T Av 2 .. (35)

4. From relation dT R N , thus substitute it into equation (35)

dT d T Av 2
dT
d
T Av 2 (36)

5. Integrating both sides of equation (36) from T1 to T2 and angle from 0 0 to ,

T1 dT
T Av
T2 2 0
d

T Av e
1
2

T Av
2
2 .. (37)

6. Let Av 2 TC that is the centrifugal force term, then

T1 TC e
.. (38)
T2 TC

We can see the effect of centrifugal force from equation (38). It shows that the tension on
the belt increase due to centrifugal effect. Centrifugal effect tends to lift the belt off the wheel,
thus increase the likelihood for slippage to occur.

Equation (38) represents the belt tension ratio for a Flat Belt type with the effect of
centrifugal force on the system. The effect of centrifugal force can be ignored when belt drive is
operating at low speed, but it must be taken care when it is operating at high speed. Also
centrifugal force effect must be included if mass per unit length of the belt is considered. Note
 21

also that since the angle of lap is smallest on the small wheel, the belt always slips first on the
small wheel (if the coefficient of fiction is the same).
For Vee-belt type, the belt tension ratio when centrifugal effect is considered,

T1 TC


sin
e
(39)
T2 TC

2.10.1 Maximum Power with Centrifugal Effect Included

Equation (32) and (33) earlier states that how a maximum power can be achieved with
condition no slip occurs (offset of centrifugal effect). However, due to the onset of centrifugal
effect, the belt tends to lift off the wheel and thus slippage is likely to occur. This will cause
power to decrease as the speed of belt drive increase. So, the problem here is how to maximize
the full power of the belt drive system by practically taking care of the centrifugal effect and
slippage that occur?

Modify equation (32), now take into consideration the effect of centrifugal force. It will
make the effective tension at tight side to be T1 TC and slack side to be T2 TC .
1
P T1 TC 1 v . (40)
e

Plot graph of power against speed for a given set of parameters as shown below.
 22

The graph shows clearly that the power is increased as the speed increase but a point is
reached when the centrifugal force reduces the grip to such an extend that slippage reduces the
power. Further increase in speed reduces the power as the belt slips more, even though
practically, slips maybe start to occur at a point before reaching the critical speed. At very high
speed, there will be no more grips at all and power drops to zero.

At the peak point, gradient is zero. Differentiate Power with respect to velocity
dP
0
dv
This will result with
T1 3TC .. (41)
And the critical velocity that gives maximum power is
1
T1 2
vP ... (42)
A
3

2.11 Initial Tension of Belt Drive System

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Practically, setting of the tension on the driver and driven sheave is done when the belt drive is
not operating and still has some tension on it. This initial setting is called initial tension of the
belt. By setting the belt with some initial tension, it will increase the gripping ability of the belt
to the pulley. Let say;
TA = Initial tension of belt (N)

T1 = Tension on the tight side of belt (N)

T2 = Tension on the slack side of belt (N)

= Belts length constant
When power is transmitted, the tension on the tight side increase from TA to T1 while on the
slack side is reduced from TA to T2 . If the belt is assumed to obey Hookes Law and the length
of belt does not change, thus

Increase in length on Decrease in length on

the tight side = the slack side

Thus an equation can be developed that is

T1 TA TA T2
For the case of centrifugal force effect is neglected, equation above becomes
T1 T2
TA (43)
2
For the case where centrifugal effect is considered, then
T1 T2 2TC
TA (44)
2

2.12 Creep on the Belt Drive System

When power is transmitted by a belt or rope, there is always a difference between the peripheral
speed of the driving pulley and that of driven pulley. Because of different tensions on the two
 24

sides of the pulley, the stretch in the belt will be different. The portion of the belt, leaving the
follower and approaching the driver is stretched more than the portion of the belt, leaving the
driver and approaching the follower. These uneven extensions and contractions of the belt due to
varying tension will cause a relative motion of the belt on the pulley. This relative motion is
called creep of belt.
Consider one metre length of belt when unstressed. Because of tension T1 on the tight side, the
length of the belt is (1 + x1) metre, where x1 is the stretch. Similarly, due to tension T2 on the
slack side, the length of the belt is (1 + x2) metre, where x2 is the stretch. Obviously x1 is greater
than x2. A length (1 + x1) metre has approached the driver, but only (1 + x2) metre has moved off
the driver. Thus, the length of belt that leaves the driver pulley is less than that which has
approached it. But in the case of driven pulley, the length of belt leaving the driven pulley is
more than that, approaching it. Thus, there is some relative motion of the belt on the pulley, and
the belt is said to creep. The effect of creep in belt is to reduce the speed of the follower and
reduce the power output. Considering creep, the velocity ratio is given by
v1 T T
1 1 2 .(45)
v2 AE
Where A = Cross section of the belt ( m 2 )
E = Young Modulus of the belt material ( N / m 2 )
v2 = Velocity of driven pulley (m/s)

v1 = Velocity of driver pulley (m/s)

2.13 Applications.

Example 1
A flat belt type is used for a belt drive system connecting two pulleys 1.2m apart. The driver
pulley with diameter 40 cm is rotating with speed 350 rpm, while diameter of driven pulley is
 25

100 cm. Coefficient of friction of the contact surface between belt and pulley is 0.3. Maximum
allowable tension is 600N. Find;
a) Power transmitted by the belt
b) Initial tension of the belt.
c) If the flat belt is now replaced by a Vee-Belt with groove angle of 30 0 , find the
power transmitted by this belt.

Solution
a) For ideal case where mass of belt is neglected, there is no centrifugal force effect.
Since belt is inelastic, then no creep effect is happening.
For an open belt arrangement,
r1 r2 0.5 0.2
sin
X 1 .2

14.5 0

Thus, 180 2 180 214.5 2.635 rad
180 180
If given maximum allowable tension T1 600 N, this will give
T1 600
T2
0.3 2.635 272 N
e e
Power transmitted is
2 350
P T1 T2 v 600 272 0.2 , use v wr
60
P 2.4 kW.
b) To find the initial tension,
T1 T2 600 272
TA 436 N
2 2
c) If now using Vee-belt type
T1 600
T2 0.3 2.635
123.5




N
sin e sin 30
e
Thus power transmitted is
 26

2 350
P T1 T2 v 600 123.5 0.2
60
P 3.5 kW.
We can see that more power is delivered using Vee-belt rather than flat belt type.

Example 2
Now, using the same data as example 1, treat now the belt is elastic, given that mass per unit
length is 0.4 kg/m, cross section of belt is 320 mm 2, and modulus of elasticity of 300 MN/m 2,
find the power delivered by the system.

Solution
Since mass/length is considered, the centrifugal effect must be considered, thus

2 350
2

Centrifugal force term is TC Av 2 m wr 2 0.4 0.2 21.5 N
60
From the belt tension ratio
T1 TC e
T2 TC
T
600 21.5 21.5 284.5
N
e 0.3 2.635
2

Thus, the power delivered is

2 350
P T1 T2 v 600 284.5 0.2
60
P 2.31 kW.

Also since the belt is elastic, thus the belt can extend its length and creep can happen. When
creep happen, v1 v 2 , thus;
v2 T T2
1 1
v1 AE
 27

v2 1
600 284.5 7.33 7.31

323 10 6 300 10 6
m/s.

TUTORIAL BELT DRIVE SYSTEM

1. An induction motor shaft, running at 1200 rpm, drives a workshop main shaft by a flat
belt drive. The diameter of the pulley on the motor shaft is 40 cm and that on the main
 28

shaft is 70 cm. Another pulley of diameter 45 cm drives a countershaft, having a pulley

65 cm keyed to it. If there is 3% slip on each drive, determine the speeds of the counter
shaft.
[Ans: 446.7 rpm]

2. Two parallel shafts are connected by cross belt, running over pulley 30 cm and 50 cm
diameter respectively. The centre distance between the shafts is 5m. It is desired to alter
the direction of rotation of the driven shaft without altering that of the driving shaft. State
if the same belt can be used. If not, what is the remedy?

3. A driving shaft has a pulley of 80 cm and is rotating at 160 rpm. A counter shaft is to be
driven at 320 rpm by means of an open belt. The distance between the centre lines of the
shafts is 2.5 metres and the coefficient of friction is 0.3. Determine the width of the belt
required to transmit 4 kW of power, if tension is not to exceed 110 N/cm widths.
[Ans: 9.17 cm]

4. An open belt drives connects two pulleys 120 cm and 50 cm diameter, on parallel shafts 4
metres apart. The mass of belt per metre length is 0.9 kg and maximum tension is not to
exceed 2000 N. The coefficient of friction is 0.3. The 120 cm pulley, which is the driver,
runs at 200 rpm. Because of belt slip on one of the pulleys, the velocity of the driven
shaft is only 450 rpm. (a) Calculate the torque on each of the two shafts, (b) the power
transmitted and (c) the power lost in friction. (d) What is the efficiency of the drive?
[Ans: 656.9 Nm, 273.7 Nm, 13.75 kW, 0.86 kW, 93.7%]

5. A belt drives system having open belt type with each pulley having diameter of 200 mm
and 800 mm makes use of Vee type belting. The belt have groove angle of V 60 with
distance between the shafts centre of 1metre. The cross section of the belt is 750 mm 2 and
coefficient of friction between belt and pulleys surface of 0.4. Given also that density of
 29

belt material is 1.2 Mg/m3. Maximum allowable tension is limited to 1200 N. Calculate
the power transferred if the driver pulley rotates at speed of 1200 rpm.
[Ans: 11.54 kW]
6. A flat type pulley with diameter of 200 mm rotating at speed of 1750 rpm drives another
pulley with diameter of 800 mm using open belt type arrangement. Distance between the
shafts centre is 1 metre and mass of belt material is 0.5 kg/m with maximum permissible
tension required is 800 N.
(a) If coefficient of friction between belt and pulleys contact surface is 0.3, find the
maximum tension for the belt.
(b) If the belt used have cross section of 400 mm 2 and Young modulus, E of 500
MN/mm2, find the maximum speed of driven pulley and maximum power
transferred
[Ans: 402.4 N, 7.36 kW]

7. The hand-brake shown in Figure 1 below is used on a wall crane. The brake drum is 600
mm diameter; the lifting drum is 400 mm diameter and carries a load of 4 kN. If = 0.3,
find the least force at the end of the 0.6m lever to support the load.
[Ans: 47.4 N]