DTS 1.3-1.4 Problems in Design of Flat Belt

Design of
Transmission
Systems
Dr. K. Kannan
Professor Mechanical Engineering
Anjalai Ammal Mahalingam Engineering College
Kovilvenni – 614 403
Dr. K. Kannan Problems in design of flat belts Lecture No. DTS 1.3
Topic Problem solving in flat belt
Recap Design procedure of flat belt using PSG data book
Learning Outcome
At the end of the lecture, the student will be able to
1. Solve problems in flat belt using PSG data book
2
Example 1: Design a belt drive to transmit 22 kW at 740 rpm to an

aluminium rolling machine, the speed ratio being 3. The distance
between the pulleys is 3 m. Diameter of the rolling machine pulley
is 1.2 m. (AU-Nov 2010)
Given data: P = 22 kW, n = 740 rpm, i = 3, C = 3 m, D = 1.2 m
Belt speed
Diameter of smaller pulley d = D/i = 1.2/3 = 0.4 m = 400 mm
 d n   0 . 4  740
v    1 5 . 49 m/s
60 60
The arc of contact (PSG Data book page7.54)

D d 1 .2  0 .4
  180   60  180   60  164
o o o o o
C 3
The rating of belt at 10 m/s belt speed (PSG Data book page 7.54)
= 0.0289 kW/mm/ply for heavy duty
The power rating for the belt speed v m/s

v
 Power rating for 10 m/s  kW/mm/ply
10
15.49
 0 . 0289   0.04477 kW/mm/ply
10
The number of plies for the belt based on belt speed in m/s for
v = 15.49 m/s and d = 400 mm (PSG data book page 7.52) = 6
The power rating of the belt

= No. of plies x Rating per mm per ply kW/mm
= 6 x 0.04477 = 0.26862 kW/mm
The design power
Load correction factor for rolling mill

(PSG data book page 7.53) = 1.5
Arc of contact factor (PSG data book page 7.54) = 1.064
Rated power  Load correction factor 22  1.5

   31 kW
Arc of contact factor 1.064
The width of the belt

Design Power (kW) 31
   115 . 4 mm
Power rating of the belt (kW/mm) 0 . 26862
The standard width from R20 series (PSG Data book page
7.20) = 125 mm
The width of the pulley (PSG Data book page 7.54)

= 125 + 25 = 150 mm
The length of the belt
D 
2
  d
L  2C  D  d 
2 4C
1 . 2  0 . 4 
2

L  23  1 . 2  0 . 4  
2 43
L  6  2 . 512  0 . 0533  8 . 565 m
Correction of the the length for initial tension (PSG Data book
page 7.53) for 6 plies = 1%
Corrected length = 8.479 m
Design details
Belt selected : Dunlop FORT 949 g Fabric belt
Speed ratio i = 3
Diameter of larger pulley D = 1.2 m
Diameter of smaller pulley d = 0.4 m
Centre distance C = 3 m
Length of the belt L = 8.479 m
Width of the belt = 125 mm
Width of the pulley = 150 mm
Number of plies = 6
Example 2: Design a belt drive to transmit 110 kW for a system

consisting of two pulleys of diameter 0.9 m and 1.2 m, center
distance of 3.6 m, a belt speed 20 m/s, coefficient of friction 0.3, a
slip factor 1.2% at each pulley and 5% friction loss at each shaft,
20% over load. (AU-Nov. 2008, Nov 2012, 2016)
Given data: P = 110 kW, d = 0.9 m, D = 1.2 m, C = 3.6 m, v = 20 m/s,

μ = 0.3, s = 1.2%, Frictional loss = 5%, overload = 20%
Speed ratio
When the slip of the belt is considered
n D  s1  s 2  1 . 2  1 .2  1 .2 
i  1     1    1 .3
N d  100  0 .9  100 
The belt speed v = 20 m/s

The arc of contact

D d 1 .2  0 .9
  180   60  180   60  175
o o o o o
C 3.6
v
10
20
 0.0289   0.0578 kW/mm/ply
10
v = 20 m/s and d = 900 mm (PSG data book page 7.52) = 8

= 8 x 0.0578 = 0.4624 kW/mm
The design power

The type of application is not given so we take normal load.
Then the load factor = 1
Load correction factor
= Load factor x friction loss factor x over load factor
= 1 x (1+0.05) x (1 + 0.2) = 1.26

Rated power  Load correction factor 110  1 . 26

   135 . 88 kW
Arc of contact factor 1 . 02
Width of the belt

Design Power (kW)

Power rating of the belt (kW/mm)
135.88
  293.86 mm
0.4624
Take the standard width from R20 series (PSG Data book page
7.20) = 315 mm

= 315 + 38 = 353 mm

D 
2
 d
L  2C  D  d 
2 4C
1 . 2  0 . 9 
2

L  2  3.6   1 . 2  0 . 9  
2 4  3 .6
L  7 . 2  3 . 297  0 . 00625  10 . 5 m
page 7.53) = 0.5%
Design details
Speed ratio i = 1.3
Centre distance C = 3.6 m
Number of plies = 8
Example 3: A compressor is driven by a 15 kW motor, running at

960 rpm, through an open belt drive. The speed of compressor
pulley is 480 rpm. The centre distance of the drive is 2.5 m. Select
the flat belt drive. Neglect the effect of slip. (AU-Nov 2016)
Given data: P = 15 kW, n = 960 rpm, N = 480 rpm, C = 2.5 m
Speed ratio
Speed of smaller pulley n 960
i     2
Speed of larger pulley N 480
Diameter of smaller pulley is not given:

For medium duty application we may take d = 400 mm
Then, diameter of larger pulley D = i x d = 2 x 400 = 800 mm

 d n   0 . 4  9 60
Belt speed v    20 . 1 m/s
60 60
D d 0 .8  0 .4
  180   60  180   60  170 . 4
o o o o o
C 2.5

v
10
20.1
 0 . 0289   0.0581 kW/mm/ply
10

= 6 x 0.0581 = 0.3486 kW/mm
The design power

Load correction factor for compressor
Rated power  Load correction factor 1 5  1.3

   1 8 . 75 kW

Design Power (kW) 18.75
   53 . 79 mm
The standard width from R20 series = 56 mm

= 56 + 13 = 69 mm
D 
2
 d
L  2C  D  d 
2 4C
0 .8  0 .4 
2

L  2  2 .5   0 .8  0 . 4  
2 4  2 .5
L  5  1 . 884  0 . 016  6 . 9 m
page 7.53) = 1%
Corrected length = 6.831m
Design details
Speed ratio i = 2
Width of the belt =56 mm
Number of plies = 6
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19
Thank you for watching
Please post your comments
Contact: k.kannan@aamec.edu.in
WhatsApp: 944261659
20
Design of
Transmission
Systems
Dr. K. Kannan
Professor Mechanical Engineering
Anjalai Ammal Mahalingam Engineering College
Kovilvenni – 614 403
Topic Problem solving in flat belt
Recap Design procedure of flat belt using PSG data book
Learning Outcome
At the end of the lecture, the student will be able to
1. Solve problems in flat belt using PSG data book
22
Example 4: A fan running at 360 rpm is driven by a 10 kW, 1440 rpm

motor. The belt drive is open type and space available for a centre
distance of 2 m approximately. The diameter of the driven pulley is
1000 mm. select a flat belt drive for this system (AU-May 2014)
Given data: P = 10 kW, n = 1440 rpm, D = 1 m, N = 360 rpm, C = 2 m
Speed ratio
Speed of smaller pulley n 1440
i     4
Speed of larger pulley N 360
Diameter of smaller pulley d = D/i = 1/4 = 0.25 m = 250 mm
 d n   0 . 25  1440
Belt speed v    18 . 84 m/s
60 60

D d 1  0 . 25
  180   60  180   60  157 . 5
o o o o o
C 2
= 0.023 kW/mm/ply for medium duty
v
10
18.84
 0 . 023   0.043332 kW/mm/ply
10

= 5 x 0.043332 = 0.21666 kW/mm
The design power

Load correction factor for fan

   1 0 .96 kW

   50 . 58 mm
The standard width of the belt from R20 series (PSG data book
page 7.20) = 56 mm

= 56 + 13 = 69 mm
The length of the open belt drive (PSG Data book page 7.53)
D 
2
  d
L  2C  D  d 
2 4C
1  0 . 25 
2

L  22   1  0 . 25  
2 42
L  4  1 . 9625  0 . 0703  6 . 033 m
Correction of the the length for initial tension for 5 plies (PSG
Data book page 7.53) = 1%
Design details
Belt selected : Dunlop HI SPEED 878 g Fabric belt
Speed ratio i = 4
Diameter of larger pulley D = 1 m
Centre distance C = 2 m
Number of plies = 5
Example 5: A compressor is to run by a motor pulley running at

1440 rpm, speed ratio 2.5. Choose a flat belt drive. Centre distance
between pulleys is 3.6 m. Take belt speed as 16 m/s. Load factor is
1.3. Take 5 ply, flat Dunlop belt. Power to be transmitted is 12 kW.
High speed load rating is 0.0118 kW/mm/ply width at v = 5 m/s.
Determine the width and length of the belt. (AU-Nov 2014)
Given data: n = 1440 rpm, i = 2.5, C = 3.6 m, v = 16 m/s, Load

factor = 1.3, 5 plies, Dulop belt, P = 12 kW, Load rating = 0.0118
kW/mm/ply at v = 5 m/s
Given Speed ratio i = 2.5
Minimum smaller pulley diameter
v  60 16  60
d    0 . 212 m
 n   1440
Diameter of larger pulley D = i x d = 2.5 x 212 = 530 mm


D d 0 . 53  0 . 212
  180   60  180   60  174 . 7
o o o o o
C 3.6
Given rating of belt at 5 m/s belt speed= 0.0118 kW/mm/ply
The power rating for the belt speed v = 16 m/s

v
5
16
 0 . 0118   0.03776 kW/mm/ply
5
The given number of plies for the belt = 5


= 5 x 0.03776 = 0.1888 kW/mm
The design power

Load correction factor for compressor - given = 1.3

   15.23 kW

   80 . 69 mm
page 7.20) = 90 mm

= 90 + 13 = 103 mm
The length of the open belt drive (PSG Data book page 7.53)
D 
2
 d
L  2C  D  d 
2 4C
 0 . 53 
2
  0 . 212
L  2  3 .6    0 . 53  0 . 212 
2 4  3 .6
L  7 . 2  1 . 16494  0 . 00702  8 . 372 m
Correction of the the length for initial tension for 5 plies (PSG
Data book page 7.53) = 1%
Design details
Belt selected : Dunlop Fabric belt
Speed ratio i = 2.5
Diameter of larger pulley D = 530 mm
Diameter of smaller pulley d = 212 mm
Number of plies = 5
Example 6: It is required to design a leather crossed belt drive to

connect 7.5 kW, 1440 rpm electric motor to a compressor running a
480 rpm. The distance between the centers of the pulleys is twice
the diameter of the bigger pulley. The belt should operate at 20
m/s approximately and its thickness is 5 mm. Density of leather is
950 kg/m3 and permissible stress is 5.6 MPa. (AU-Nov. 2004)
Given data: Crossed belt drive, P = 7.5 kW, n = 1440 rpm, N = 480
rpm, C = 2D, v = 20 m/s, t = 5 mm, Density of leather is 950 kg/m3
and permissible stress is 5.6 MPa.
Speed ratio
When the thickness of the belt is considered
D t n 1440
i     3
d t N 480
Minimum smaller pulley diameter

v  60 20  60
d    0 . 265 m
 n   1440
D t
Diameter of larger pulley i   3  D  t  3  d  t 
d t
D  0 . 005  3   0 . 265  0 . 005 
D  0 . 805 m
Centre distance C = 2 D = 2 x 0.805 = 1.61 m

D d 0 . 805  0 . 265
  180   60  180   60  220
o o o o o
C 1.61
Length of the crossed belt drive (PSG Data book page 7.53)
D 
2
  d
L  2C  D  d 
2 4C
 0 . 805 
2
  0 . 265
L  2  1 . 61    0 . 805  0 . 265 
2 4  1 . 61
L  3 . 22  1 . 6799  0 . 178  5 . 078 m
Tension on the belt

Power transmitted P = (T1 – T2) v = (T1 – T2) x 20 = 7500
T1 – T2 = 375

Ratio of belt tension T1 
0 .3  220
 e  e 180
 3 . 1624
T2
T 1  3 . 1624 T 2
Solving the equations of belt tension

T1 – T2 = 375
3.1624 x T2 – T2 = 375
T2 = 173.4 N and T1 = 548.4 N
Mass of the belt per metre length
m = density x cross sectional area of the belt = density x b x t
m = 950 x b x 0.005
Centrifugal tension
Tc = m v2 = 950 x b x 0.005 x 202 = 1900 b
Maximum tension
Tmax = σ x cross sectional area = σ x b x t
T1 + Tc = σ x b x t
548.4 + 1900 b = 5.6 x 106 x b x 0.005
548.4 + 1900 b = 28000 b → b = 0.021 m = 21 mm
page 7.20) = 22.4 mm

= 22.4 + 13 = 35.4 mm
Design details
Belt selected : Dunlop Fabric belt
Speed ratio i = 3
Diameter of larger pulley D = 805 mm
Diameter of smaller pulley d = 265 mm
Width of the belt = 22.4 mm
Width of the pulley = 35.4 mm
https://www.yout
ube.com/channel/
UCWHfEnMwFBA-
lXfyIhuiRAg?view_
as=subscriber
38
Thank you for watching
Please post your comments
Contact: k.kannan@aamec.edu.in
WhatsApp: 944261659
39

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Design of

Topic Problem solving in flat belt

Recap Design procedure of flat belt using PSG data book

Example 1: Design a belt drive to transmit 22 kW at 740 rpm to an

Given data: P = 22 kW, n = 740 rpm, i = 3, C = 3 m, D = 1.2 m

The arc of contact (PSG Data book page7.54)

The power rating for the belt speed v m/s

The power rating of the belt

The design power

Load correction factor for rolling mill

Rated power  Load correction factor 22  1.5

The width of the belt

The width of the pulley (PSG Data book page 7.54)

The length of the belt

Example 2: Design a belt drive to transmit 110 kW for a system

Given data: P = 110 kW, d = 0.9 m, D = 1.2 m, C = 3.6 m, v = 20 m/s,

The belt speed v = 20 m/s

The arc of contact

The power rating for the belt speed v m/s

The power rating of the belt

The design power

Arc of contact factor (PSG data book page 7.54) = 1.02

Rated power  Load correction factor 110  1 . 26

Width of the belt

The width of the pulley (PSG Data book page 7.54)

The length of the belt

Example 3: A compressor is driven by a 15 kW motor, running at

Given data: P = 15 kW, n = 960 rpm, N = 480 rpm, C = 2.5 m

Diameter of smaller pulley is not given:

Then, diameter of larger pulley D = i x d = 2 x 400 = 800 mm

The power rating for the belt speed v m/s

The power rating of the belt

The design power

Rated power  Load correction factor 1 5  1.3

The width of the belt

The standard width from R20 series = 56 mm

The width of the pulley (PSG Data book page 7.54)

Please post your comments

Topic Problem solving in flat belt

Recap Design procedure of flat belt using PSG data book

Example 4: A fan running at 360 rpm is driven by a 10 kW, 1440 rpm

Given data: P = 10 kW, n = 1440 rpm, D = 1 m, N = 360 rpm, C = 2 m

Diameter of smaller pulley d = D/i = 1/4 = 0.25 m = 250 mm

The arc of contact (PSG Data book page7.54)

The power rating of the belt

The design power

Rated power  Load correction factor 1 0  1.2

The width of the belt

The width of the pulley (PSG Data book page 7.54)

Example 5: A compressor is to run by a motor pulley running at

Given data: n = 1440 rpm, i = 2.5, C = 3.6 m, v = 16 m/s, Load

Diameter of larger pulley D = i x d = 2.5 x 212 = 530 mm

The arc of contact (PSG Data book page7.54)

Given rating of belt at 5 m/s belt speed= 0.0118 kW/mm/ply

The power rating for the belt speed v = 16 m/s

The given number of plies for the belt = 5

The power rating of the belt

The design power