DTS 1.1-1.2 Design of Flat Belt

Design of
Transmission
Systems
Dr. K. Kannan
Professor Mechanical Engineering
Anjalai Ammal Mahalingam Engineering College
Kovilvenni – 614 403
1
Dr. K Kannan Design of Flat Belt Lecture No: DTS 1.1
Belt drive, selection of belt drive, types, flat belt,

Topic V belt, round belt, timing belt, belt material, belt
friction, belt joints
Recap Design of machine elements
Learning Outcome
At the end of the lecture, the student will be able to
1. State the factors of belt selection
2. Describe the types of belt drives
3. Define the belt ply
2
The belts, ropes and chains are used to transmit power from one
shaft to another by means of pulleys which rotate at the same
speed or at different speeds.
Belts, ropes and chains are flexible elements used in conveying
system and in transmission of power over comparatively
longer distances.
The amount of power transmitted depends upon the following

factors :
1. The velocity of the belt.
2. The tension under which the belt is placed on the
pulleys.
3. The arc of contact between the belt and the smaller
pulley.
4. The conditions under which the belt is used. 3
The power is transmitted by friction between the belt

and contact surface of the pulley.
Selection of a Belt Drive
Following are the various important factors upon which
the selection of a belt drive depends:
1. Speed of the driving and driven shafts,
2. Speed reduction ratio,
3. Power to be transmitted,
4. Centre distance between the shafts,
5. Positive drive requirements,
6. Shafts layout,
7. Space available, and
8. Service conditions.
4
Types of Belt Drives

The belt drives are usually classified into the following
three groups:
1. Light drives. These are used to transmit small powers
at belt speeds up to about 10 m/s as in agricultural
machines and small machine tools.
2. Medium drives. These are used to transmit medium
powers at belt speeds over 10 m/s but up to 22 m/s,
as in machine tools.
3. Heavy drives. These are used to transmit large powers
at belt speeds above 22 m/s as in compressors and
generators
5
Types of belt drive

1. Flat belt
2. V-belt
3. Round belt
4. Timing belt
6
Flat belts were used early in-line shafting to transmit power in

factories.
They were also used in farming, mining, sawmills, blowers, water

pumps and electrical generators.
The flat belt is a simple system of power transmission. It delivered

high power for high speeds (500 hp for 300 m/min), in cases of
wide belts and large pulleys.
Flat belts are running on crowned pulley. These flat belts stayed
centered on pulleys without any guides or flanges. The key to
keeping them tracking centered on the pulleys is the use of
"crowned pulleys".
A crowned pulley is a pulley that has a slight hump in the middle,
tapering off ever so slightly towards either edge.
7
8
V- belts solved the slippage and alignment problem.

It is now the basic belt for power transmission.
They provide the best combination of traction, speed

of movement, load of the bearings, and long service
life.
The V-belt was developed in 1917 by John Gates of the

Gates Rubber Company. They are generally endless,
and their general cross-section shapes trapezoidal.
9
For high-power requirements, two or more v- belts can be joined

side-by-side in an arrangement called a multi-V, running on
matching multi-groove sheaves.
The strength of these belts is obtained by reinforcements with

fibers like steel, and polyester.
10
11
Multiple V-belt Timing belt
12
Round belts are a circular cross section belt designed to

run in a pulley with a circular (or near circular) groove.
They are for use in low torque situations and may be

purchased in various lengths or cut to length and joined,
either by a staple, gluing or welding (in the case of
polyurethane).
Early sewing machines utilized a leather belt, joined

either by a metal staple or glued, to a great effect.
13
Timing belts, (also known as Toothed, or Synchronous

belts) are a positive transfer belt and can track relative
movement.
These belts have teeth that fit into a matching toothed

pulley.
When correctly tensioned, they have no slippage, run at

constant speed, and are often used to transfer direct
motion for indexing or timing purposes.
14
They are often used in lieu of chains or gears, so there

is less noise and a lubrication bath is not necessary.
Camshafts of automobiles, miniature timing systems,

and stepper motors often utilize these belts.
Timing belts need the least tension of all belts, and are
among the most efficient. They can bear up to 150 kW
at speeds of 5000 m/min.
15
16
Flat belt : thickness 0.75 to 5 mm
Round belt: Ф 10 to 20 mm
V- belt : b= 8 to 19 mm
17
Belt friction
Belt drives depend on friction to operate but, if the
friction is excessive, there will be waste of energy and
rapid wear of the belt.
Factors which affect belt friction include belt tension,

contact angle and the materials from which the belt and
pulleys are made.
18
Belt tension
Power transmission is a function of belt tension.
However, also increasing with tension is stress
(load) on the belt and bearings.
The ideal belt is that of the lowest tension which

does not slip in high loads.
Belt tensions should also be adjusted to belt type, size,

speed, and pulley diameters.
Belt tension is determined by measuring the force to

deflect the belt a given distance per inch of pulley.
19
Belt wear
Fatigue is the culprit for most belt problems. This wear
is caused by stress from rolling around the pulleys.
High belt tension; excessive slippage; adverse

environmental conditions; and belt overloads caused
by shock, vibration, contribute to belt fatigue.
20
Belt material
o Leather: Oak tanned or chrome tanned.
o Rubber: Canvas or cotton impregnated with rubber
For greater tensile strength steel
reinforcement is used.
o Plastics
o Fabric: Canvas or woven cotton.
Belt thickness can be

built up with number
of layers.
The number of layers
is known as ply.
21
Flat belt
Flat belt are made of urethane and also of rubber
impregnated fabric reinforced with steel wire or nylon
card to take tension load. The surface of the flat belt
may have a friction surface coating. Flat belt are quiet,
efficient at high speed and can transmit large amount of
power over a long distance.
V- belt
V-belt is made of fabric and cord, usually cotton, rayon
or nylon and impregnated with rubber. V-belts are
used for shorter distance, less efficient than flat belt,
and made only in certain length and have no joint.
22
Timing belt
Timing belts are made of rubberized fabric and steel
wire and have teeth that fit into the grooves cut on
the periphery of sprockets.
 Timing belt does not slip or stretch

 The timing belt transmit power at constant
angular velocity ratio.
 No initial tension is necessary
 The cost of the belt is high.
23
Belt joints
When the endless belts are not available, then the belts are cut
from big rolls and the ends are joined together by fasteners.
The various types of joints are
1. Cemented joint,
2. Laced joint, and
3. Hinged joint.
The cemented joint made by the manufacturer to form an

endless belt, is preferred than other joints.
24
The laced joint is formed by punching

holes in line across the belt, leaving a
margin between the edge and the holes.
Metal laced joint is made like a staple
connection.
The points are driven through the flesh
side of the belt and clinched on the inside.
Hinged joint: Metal hinges may

be fastened to the belt ends and
connected by a steel or fibre pin.
25
26
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Please post your comments
Contact: k.kannan@aamec.edu.in
WhatsApp: 944261659
28
Design of
Transmission
Systems
Dr. K. Kannan
Professor Mechanical Engineering
Anjalai Ammal Mahalingam Engineering College
Kovilvenni – 614 403
29
Types of flat belt, velocity ratio, slip and creep of

Topic
belt, length of flat belt, design procedure of flat belt
Belt drive, selection of belt drive, types, flat belt,

Recap V belt, round belt, timing belt, belt material, belt
friction, belt joints
Learning Outcome
At the end of the lecture, the student will be able to
1. Explain the design procedure of flat belt using PSG data book
30
Advantages of belt drive
1. Belts absorb shock and vibration in the driving

machine due to sudden over load.
2. No casing is required as in gear drive.
3. Belt drives can be used for transmission of power
between shafts at short and long distances
4. The flexibility of belts permits transmission of
power between non-parallel shafts also.
5. Flat belt efficiency is nearly 98% .
6. Comparatively cheaper than chain or gear drive
31
Disadvantages of belt drive

a. Slip and creep in the belt make the belt drive less
efficient than the chain or gear drive.
b. Belt drive requires more space comparing with
chain or gear drive.
Types of flat belt drives
1. Open belt drive
2. Closed or twisted belt drive
3. Quarter turn belt drive.
4. Belt drive with idler pulleys.
5. Compound belt drive
6. Stepped or cone pulley drive
7. Fast and loose pulley drive.
32
Types of flat belt drives
Open belt drive

33
Cross belt drive
It rubs against each other and there will be excessive wear and
tear. In order to avoid this, the shafts should be placed at a
maximum distance of 20 b, where b is the width of belt and the
speed of the belt should be less than 15 m/s. 34
35
Belt drive with idler pulleys
A belt drive with an idler pulley (also known as jockey pulley drive):
It is used with shafts arranged parallel and when an open belt drive
can not be used due to small angle of contact on the smaller pulley.
This type of drive is provided to obtain high velocity ratio and
when the required belt tension can not be obtained by other
means. 36
Compound belt drive

37
Stepcone pulley drive Fast and loose pulley drive
38
A fast and loose pulley drive is used when the driven or machine
shaft is to be started or stopped whenever desired without
interfering with the driving shaft.
A pulley which is keyed to the machine shaft is called fast pulley

and runs at the same speed as that of machine shaft.
A loose pulley runs freely over the machine shaft and is incapable
of transmitting any power.
When the driven shaft is required to be stopped, the belt is

pushed on to the loose pulley by means of sliding bar having belt
forks.
39
Velocity Ratio of a Belt Drive

It is the ratio between the velocities of the driver and the
follower or driven
Let d = Diameter of the driver,
D = Diameter of the follower,
n = Speed of the driver in rpm.,
N = Speed of the follower in rpm.,
Length of the belt that passes over the driver in one minute
=πdn
Similarly, length of the belt that passes over the follower in one
minute
=πDN
Since the length of belt that passes over the driver in one minute
is equal to the length of belt that passes over the follower in one
minute, therefore
πdn=πDN
40
Then, the velocity ratio
Diameter of larger pulley D

i  
Diameter of smaller pulley d
Speed of smaller pulley n
 
Speed of larger pulley N
When the thickness of the belt is considered
n D t
i  
N d t
41
Slip of the Belt

when the frictional grip becomes insufficient some forward
motion of the driver without carrying the belt with it may occur.
This is called slip of the belt and is generally expressed as a
percentage.
Belt slipping will to reduce the velocity ratio of the system.

Let
s1 % = Slip between the driver and the belt, and
s2 % = Slip between the belt and follower,
When the thickness and slip of the belt is considered
n D t  s1  s 2 
i   1  
N d t  100 
42
Creep of Belt
When the belt passes from the slack side to the tight side, a
certain portion of the belt extends and it contracts again when the
belt passes from the tight side to the slack side.
Due to these changes of length, there is a relative motion between

the belt and the pulley surfaces. This relative motion is termed as
creep.
The total effect of creep is to reduce slightly the speed of the

driven pulley or follower.
The creep is very small generally it is neglected in the calculation.
43
Length of an open and cross Belt Drive
D 
2
  d
L  2C  D  d 
2 4C
D 
2
  d
L  2C  D  d 
2 4C
44
Analysis of Flat Belt Drive

D = Diameter of larger pulley (m)
d = Diameter of smaller pulley (m)
C = Center distance (m)
θ = Angle of contact
1  D  d 
Smaller pulley :  d    2 sin  
 2C 
1  D  d 
Larger pulley :  D    2 sin  
 2C 
 dn
Belt Speed : v  m/s
60
45
T1  T 2  v
Power transmitted P  kW
1000
T1 & T2 : Tension on tight & slack sides
T1  T c 
Ratio of tensions  e
T2  Tc
Neglecting centrifugal tension
1000  P
T1  T1 
 e  1 
T2 v  1   
 e 
46
Design procedure of Flat Belt using PSG data book

1. From the data given, determine the speed ratio
Diameter of larger pulley D

i  
Diameter of smaller pulley d
Speed of smaller pulley n
 
Speed of larger pulley N
When the thickness of the belt is considered
n D t
i  
N d t
47
When the thickness and slip of the belt is considered
n D t  s1  s 2 
i   1  
N d t  100 
s1 % = Slip between the driver and the belt, and

s2 % = Slip between the belt and follower
 d n
2. Determine the belt speed v  m/s
60
Most efficient power transmission is obtained from flat belts

at speed of 17.5 to 22.5 m/s
(PSG Data book page 7.53)
48
3. Determine the arc of contact (PSG Data book page7.54)

D d
  180   60
o o
where C = Center distance
4. Take the rating of belt at 10 m/s belt speed

= 0.023 kW/mm/ply for light duty
= 0.0289 kW/mm/ply for heavy duty
5. Determine the power rating for the belt speed v m/s

v
 Power rating for 10 m/s  kW/mm/ply
10
49
6. Fix the number of plies for the belt based on belt speed in m/s
Light duty = 3,4,5 ply
Heavy duty = 6, 8 ply
Minimum pulley diameter in mm for given speed and belt plies

(PSG data book page 7.52)
No. of Minimum belt speed m/s

plies 10 15 20 25 30
3 90 100 112 140 180
4 140 160 180 200 250
5 200 224 250 315 355
6 250 315 355 400 450
8 450 500 560 630 710
50
7. Calculate the power rating of the belt

= No. of plies x Rating per mm per ply kW/mm
8. Determine the design power

Rated power  Load correction factor

Arc of contact factor
Arc of contact factor (PSG data book page 7.54)
Arc of
90 120 130 140 150 160 170
contact 180
Correction
1.68 1.33 1.26 1.19 1.13 1.08 1.04 1.00
factor
Arc of
190 200 210 220 230 240 250
contact
Correction
0.97 0.94 0.91 0.88 0.86 0.84 0.82
factor
51
Load correction factor (or) service factor (PSG data book page 7.53)
Load
Load classification correction
factor
Normal load (where peak load is known) 1.0
Screens, centrifugal pump and fans, evaporators,
Steady load agitators, belt conveyors, light machine tools, 1.2
laundry machines, printing and textile machinery
Heavy duty fans and blowers, brick work
Intermittent machinery, reciprocating pump and compressors,
1.3
load saw mill and paper mill machinery, heavy machine
tools, stokers, elevators and line shafts
Vacuum pump, tube and ball mills, crushing
machinery, disintegrators, stamp presses grinders,
Shock load 1.5
hammers, mills and calenders, automatic
machinery
52
9. Calculate the width of the belt
Design Power (kW)

 mm
Power rating of the belt (kW/mm)
Take the standard width from R20 series

1.00 1.12 1.25 1.40 1.60 1.80 2.00 2.24 2.50 2.80
R20
3.15 3.55 4.00 4.50 5.00 5.60 6.30 7.10 8.00 9.00
10. Take the width of the pulley

53
Pulley width (PSG data book page 7.54)

Pulley to be wider than
Belt width
the belt width by
Up to and including 125 mm 13 mm
Above 125 mm up to and including 250 mm 25 mm
11. Determine the length of the belt

D 
2
  d
Open drive : L  2C  D  d 
2 4C
D 
2
  d
Crossed drive : L  2C  D  d 
2 4C
Correct the length for initial tension
(PSG Data book page 7.53) 54
Correct initial tension is obtained by cutting the belt shorter

than the actual steel tape measurement around the pulley on
the following basis: (PSG data book page 7.53)
Belt of 3 plies – 1.5 % or 15 mm per metre length shorter
Belts of 4, 5 and 6 pies – 1 % or 10 mm per metre length shorter
Belt of 8 plies – 0.5 % or 5 mm per metre length shorter
12. Write down the design details
55
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Thank you for watching
Please post your comments
Contact: k.kannan@aamec.edu.in
WhatsApp: 944261659
57

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Design of

Belt drive, selection of belt drive, types, flat belt,

Recap Design of machine elements

The amount of power transmitted depends upon the following

The power is transmitted by friction between the belt

Types of Belt Drives

Types of belt drive

Flat belts were used early in-line shafting to transmit power in

They were also used in farming, mining, sawmills, blowers, water

The flat belt is a simple system of power transmission. It delivered

V- belts solved the slippage and alignment problem.

They provide the best combination of traction, speed

The V-belt was developed in 1917 by John Gates of the

For high-power requirements, two or more v- belts can be joined

The strength of these belts is obtained by reinforcements with

Multiple V-belt Timing belt

Round belts are a circular cross section belt designed to

They are for use in low torque situations and may be

Early sewing machines utilized a leather belt, joined

Timing belts, (also known as Toothed, or Synchronous

These belts have teeth that fit into a matching toothed

When correctly tensioned, they have no slippage, run at

They are often used in lieu of chains or gears, so there

Camshafts of automobiles, miniature timing systems,

Flat belt : thickness 0.75 to 5 mm

Factors which affect belt friction include belt tension,

The ideal belt is that of the lowest tension which

Belt tensions should also be adjusted to belt type, size,

Belt tension is determined by measuring the force to

High belt tension; excessive slippage; adverse

Belt thickness can be

 Timing belt does not slip or stretch

The cemented joint made by the manufacturer to form an

The laced joint is formed by punching

Hinged joint: Metal hinges may

Please post your comments

Types of flat belt, velocity ratio, slip and creep of

Belt drive, selection of belt drive, types, flat belt,

Advantages of belt drive

1. Belts absorb shock and vibration in the driving

Disadvantages of belt drive

Types of flat belt drives

Open belt drive

Cross belt drive

Belt drive with idler pulleys

Compound belt drive

Stepcone pulley drive Fast and loose pulley drive

A pulley which is keyed to the machine shaft is called fast pulley

When the driven shaft is required to be stopped, the belt is

Velocity Ratio of a Belt Drive

Then, the velocity ratio

Diameter of larger pulley D

When the thickness of the belt is considered

Slip of the Belt

Belt slipping will to reduce the velocity ratio of the system.

When the thickness and slip of the belt is considered

Due to these changes of length, there is a relative motion between

The total effect of creep is to reduce slightly the speed of the