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MACHINE DESIGN

2 POWER TRANSMISSION BY BELTS

1. INTRODUCTION

(i). There are two types of drives—rigid and flexible.

(ii). Gear drives are called rigid or non-flexible drives where there is direct contact between the
driving and driven shafts through the gears. While in flexible drives, there is an intermediate
link such as belt, rope or chain between the driving and driven shafts. Since this link is flexible,
the drives are called ‘flexible’ drives.
(iii). Thus, Belt drives are the flexible drives.
(iv). In flexible drives, the rotary motion of the driving shaft is first converted into translatory
motion of the belt or chain and then again converted into rotary motion of the driven shaft.
(v). Belts are used to transmit power between two shafts by means of friction. A belt drive
consists of three elements—driving and driven pulleys and an endless belt, which envelopes
them.
1.1. Mechanical power transmission system (M.P.T.S.):

1.2. Advantage of gear drive:

(i). Positive drives
(ii). Life is more
(iii). Higher η is (98-100%)
Disadvantage of gear drive:
(i). Costlier
(ii). Poor damping capacity

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(iii). Not suitable for large centre distance
1.3. Advantages and disadvantages of Belt drives:
Advantages: Belt drives offer the following advantages compared with other types of
drives:
(i). Belt drives can transmit power over considerable distance between the axes of driving
and driven shafts.
(ii). The operation of belt drive is smooth and silent.
(iii). They can transmit only a definite load, which if exceeded, will cause the belt to slip
over the pulley, thus protecting the parts of the drive against overload.
(iv). They have the ability to absorb the shocks and damp vibration.
(v). They are simple to design and have low initial cost.
Disadvantages of belt drives compared to other types of drives are as follows:
(i). Belt drives have large dimensions and occupy more space.
(ii). The velocity ratio is not constant due to belt slip.
(iii). They impose heavy loads on shafts and bearings.
(iv). There is considerable loss of power resulting in low efficiency.
(v). Belt drives have comparatively short service life.
1.4. Applications of Belt drives:
(i). Conveyors
(ii). Flour mills
(iii). Textile Machinery
(iv). Crusher
(v). M/C tool

2. CLASSIFICATION OF THE BELTS

Depending upon the shape of the cross-section, belts are classified as:
(1). Flat belts:
(i). Flat belts have a narrow rectangular cross-section.

(ii). Thin and wider Rectangular cross section belts are preferred.
(iii). The velocity ratio for flat belt is up to 4:1.
There are two types of flat belts:
(i). Leather belt:
• made of the best quality leather obtained from either side of the backbone of a steer.
• They are oak-tanned and mineral, or chrome tanned.
• The main advantage of leather belt is the high coefficient of friction and consequently, high
power transmitting capacity.

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Fig.1: Flat belts

(ii). Fabric rubber belt:
• The fabric rubber belts are made from several layers of canvas or cotton-duck impregnated
with rubber.
• The rubber protects the fabric against damage and increases the coefficient of friction.
(2). V-belts:
(i). V-belts have a trapezoidal cross-section.

Fig.2: Cross section of V Belt

(ii). For V-belts the velocity ratio is up to 7:1.
Note.1:
• The efficiency of flat belt drive is more than V-belt drive but occupy more space due to large
dimensions.
• Flat belts are easy to design and thus are less expensive.
• V-belt drive can operate in any position, even when the belt is vertical while flat-belt
drives are horizontal and not vertical.
• Flat belts are used for the long centre distance while V-belts have short centre distance,
which results in compact construction.
• Round belts can operate satisfactorily over pulleys in several different planes. They are
suitable for 90° twist, reverse bends or serpentine drives. They can be stretched over the
pulley and snapped into the groove very easily.

3. APPLICATIONS

Flat Belts: Flat belts are used in belt conveyors, baking machinery, brick and clay machinery,
crushers, sawmills, textile machinery, line shafts and bucket elevators.
V belts: V-belts are very popular where an electric motor is used as the prime mover
to drive compressors, pumps, fans, positive displacement pumps, blowers and machine tools.
They are also popular in automobiles to drive accessories on petrol or diesel engines.
Round Belts: Round belts are limited to light duties. They are used in dishwasher drives,
sewing machines, vacuum cleaners and light textile machinery.

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4. TYPES OF FLAT BELT DRIVE AND GEOMETRICAL RELATIONSHIPS

(i). Open belt drive (O.B.D.):

OBD  Direction of rotation are same  like internal gear
(ii). Cross belt drive (C.B.D.):
CBD  Direction of rotation are opposite = like external gear
(iii). Compound belt drive:
Compound  To obtain higher speed reduction (compound gear train).
(iv). Fast & loose pulley belt drive:
Fast & loose puller = To obtain same as clutch (intermittent service).
Difference between fast & loose pulley:
(a). Fast pulleys are pulley which is having key connection with the shaft & capable of power
transmission hence whenever the driven M/c should be in the running cond. The belt should be
mounted on the fast pulley.
(b). Loose pulley is a pulley which is freely rotating over the shaft (due to absence of key
connection) & it is incapable if power transmission hence whenever the driven M/c has to be
stopped the belt is shifted from the fast pulley to the loose pulley.
This driven function is similar to function to clutch.
(v). Steppe pulley drive:
Stepped  When variable speed is required at the driven shaft. (similar as gear box)

(vi). Quarter turn drive or right-angle drive:

Right angle drive which is used to transmit power between two Nonparallel non intersecting
shaft
Note.2:
• All the type of belt drives are used to transmit power between two parallel shafts except the
right angle drive which is used to transmit power between two Non parallel non intersecting
shaft.
4.1. Open belt drive (O.B.D.):
Let D1 = Diameter of driven pulley
D2 = Diameter of driven pulley or follower pulley
C = Centre distance between two parallel shafts

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V1 = Linear velocity of driven pulley
V = Linear velocity of belt
V2 = Linear velocity of driven pulley

Fig.3: Open Belt drive

θ1 = Angle of contact /lap/ wrap of the belt at driven pulley
θ1 =  - 2β
θ2 = Angle of contact /Lop / wrap of the belt at driven pulley
θ2 =  + 2β
θ1 + θ2 = 2  radian

 D − D1  
 = sin−1  2  radian
 2C  180

 (D − D1 )2
L OBD = 2C + (D1 + D2 ) + 2
2 4c
 Increase & decrease in tension is due to frictional force

Here frictional force is assisting the motion of belt. So, belt will leave with low tension.

Here friction force sup resisting the motion of belt. Belt will leave with high tension.

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From the triangle O1 O2 E
O2E O C – CE
sinβ = = 2 (CE = O1 B)
O1O2 O1O2

D2 D1
–
Sinβ =
O2C − O1B
= 2 2  sin β = D2 − D1
O1O2 C 2C

 D − D1 
 β = sin-1  2 
 2C 
 This drive is not suitable for smaller centre distance it should be medium.
C = less    1  2 β

T1
=e μθ1
 T 1   so power transmission 
T2

Alternatives of open belt drive are

(i). V- belt drive
(ii). Open belt drive with on idler pulley.
Idler Pulley:
Idler pulley should be placed on the slack side nearer to pulley which is smaller M size (Q
15 Min)
 Idler pulley does not transmit any power.
 Purpose of Idler pulley is to increase the angle of contact (θ) at the smaller pulley
when
C < CMin in open belt drive

Fig.4: Idler pulley function

 Centrifugal force is compulsory for functionality bet they are Harmful for power
transition capacity because it decreased the power transmission capacity.
 All lower velocity effect of centrifugal force can be neglected.
Due to centrifugal force:
Total tension in tight side = T 1 + T C
Total tension in slack side = T 2 + T C
T 1 + T C ≤ T max
T max = Per  A = Per  b  t

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From the above diagram:

T 2H = T 2 cosβ 
T 1H = T 1 cosβ 

T 2V = T 2 sinβ 

T 1V = T 1 sinβ 
Force equilibrium:
ΣH = (T 1 + T 2) cosβ
ΣV = (T 1 – T 2) sinβ
H = (T 1 + T 2) cosβ
V = (T 1 – T 2 ) sinβ
V = (T 1 – T 2) sinβ – W

It D1 = D2  β= 0
 θ1 = θ2 = 

4.2. Cross belt drive:

From the triangle O1 O2 E

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O2E O D + ODE
sinβ = = 2
O1O2 O1O2

DE = O1 A
O2D + O1A
sinβ =
O1O2

Fig.5: Cross belt drive

D2 + D1
sinβ =
2C
θ1 = θ2 =  + 2β

 D + D1  
β = sin–1  2 
 2C  180

It 2C   β   θ1 & θ2 
T1
  T1  orT2 
T2

 (T 1 – T 2)   Power transmutation capacity 

Length of the belt:

 (D + D1 )2
L CBD =2C + (D1 + D2 ) + 2
2 4C
 Life the ceros belt drive is less due to high wear & tear.
4.3. Comparison between open belt drive & cross belt drive:

Parameter Open belt drive Cross belt drive

1. Direction of
Same direction Opposite direction
rotation of pulleys
Suitable for medium centre Suitable for both smaller & Medium
2. Centre distance
distance C ≥ CMin centre distance
3. Idler pulleys Are required when C ≤ C Min Are not required
 D − D1    D + D1  
4. β sin-1  2  sin-1  2 
 2C  180  2C  180

5. Angle of contact θ1 =  - 2β θ1 = θ2 =  + 2β

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θ2 =  +2β or 2  - θ1

6. Power
transmission Less More
capacity
7. Service life More Less
8. Length of the  (D − D1 )2  (D + D1 )2
2C + (D1 + D2 ) + 2 2C + (D1 + D2 ) + 2
belt 2 4C 2 4C

5. VELOCITY RATIO (V.R.)

N2 Speed of driver pulley

Velocity ratio = =
N1 Speed of driver pulley

N2 D1
V.R = =
N1 D2
Assuming No slip: V 1 = V = V2 i.e. by neglecting slip & belt thickness effect.
If slip and belt thickness is taking into consideration. Then:
N2  D1 + t   S 
V.R = =  1−
N1  D2 + t   100 

Where S = % age of slip in a belt hive or % age of total slip.

S = S1 + S2
Where S1 = % age of slip between driven pulley & belt
S2 = % age of slip between driven pulley surface & belt
5.1. Compound belt drive:
For compound belt drive
If ‘n’ pulleys are there
Nn (D1 + t) (Dn −1 + t)  S 
V.R = =  1 − 
N1 (D2 + t) (Dn + t)  100 
Where
S = S1 + S2 + S3 + S4 -------- + Sn
Total slip in 1st belt drive
Total slip in 2nd belt drive
 Slip is nothing but relative motion between pulley & belt surface

6. SLIP & EFFECT OF SLIP ON VELOCITY RATIO

Fig.6: Showing velocity difference due to slip

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V1 > V > V2
D1N1
V1 =
60

 S   S 
V = V1 − V1  1   V = V1 1 − 1 
 100   100 

 S   S 
V2 = V - V  2  = V 1 − 2 
 100   100 

Putting the value of V:

 S  S 
V2 = V1  1  1 − 2 
100   100 

D1N1  S1   S2  D2N2
V2 = 1 −  1 − =
60  100   100  60

D2N2 D1N1  (S1 + S2 ) S1S2 

= 1 − + 
60 60  100 1002 

S1S2
 Neglected
1002

N2 D1   S1 + S2  
= 1 −  
N1 D2   100  

N2 D1   S1 + S2   D1   S 
VR = = 1 −   = 1 −  
N1 D2   100   D2   100  

It the S   V.R   N2   V2   Power O/P  the η 

Thus: η ≠ 100%
 Slip is defined as the relative motion between the belt & pulley surfaces.
Slip occurs due to insufficient frictional grip between belt & pulley surfaces (I.e. Due to
existence of
air layer between both the surface)
 Slip is a measure of difference of the belt & pulley velocities in presence of slip belt.
Velocities lies between driver pulley & driven pulley velocities (I.e. V 1 > V > V 2)
 Effect of slip is to decrease velocity ratio, o/p velocity o/p power & η of the drive.

7. INITIAL TENSION (T O) AND CENTRIFUGAL TENSION (T C)

7.1. Initial tension (T 0): Initial tension is the tension develop in the belt when it is in the
stationary cond. It is provided in the belt by taking a length of the belt less than actual
required length.
In presence of initial tension, power transmission capacity of belt drive increases hence
it is useful
w.r.t. power transmission capacity of the belt drive.
In order to derive an expression for initial tension, the following assumptions are made:

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(i). The length of the belt is constant.
(ii). The belt has linear elasticity. When the driving pulley begins to rotate, the elongation
on the tight side is proportional to (T 1 – T o) while the contraction on the loose side is
proportional to (T o – T 2). For constant belt length, the elongation on the tight side is equal
to the
contraction on the loose side. Therefore:
(T 1 – T o) = (T o – T 2)

T1 + T2
To = ……………….. (1)
2
7.2. Centrifugal Tension (T c ): Centrifugal tension is the addition tension develop in the belt
in presence of centrifugal force acting on the belt.
In presence of centrifugal tension, transmission capacity of a belt drive decreases thus it
is harmful w.r.to power transmission capacity of the belt drive
 T 
P = (T 1 – T 2) V = T1 1 − 2  V
 T1 

 T   1 
P = T1 1 − 1  V  P = T1 1 −   V = T 1[k] V
T1  e 
 
 T2 

 If T c is neglected [i.e., at lower velocity]

T max = T 1 + T c
T 1 = T max
P = T 1[k] × V = T max [k] V = T max k V
 If T c ≠ 0 i.e. at higher velocity
T 1 = T max – T c
P = (T max – T c) k V …………………... (2)

In 1: V = 15 m/s i.e. T c ≠ 0
In 2: V = 3 m/s i.e. T c ≈ 0 (neglected)
Thus, the belt which is moving with lower velocity will transmit more power. Thus, in
presence of T c, P.T.C. of belt drive decreases

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8. CONDITION FOR MAXIMUM POWER TRANSMISSION (Pmax)

Tmax
(i). Tc =
3

(ii). T 1 = 2T c

Tmax
(iii). Vmax = (at this velocity P.T.C = Pmax )
3m

8.1. Methods of increasing the power transmission capacity:

(i). Idler pulley which increases the angle of contact.
(ii). Increasing the initial tension (best method).
(iii). By changing the material.

9. V-BELT DRIVE

 V-belt are used to transmit power between two parallel shaft which are at smaller centre
distance and rotating in same direction.
 cross section = Trapezoidal cross section

Fig.7: V belt drive

 Grooved pulley is used

  = 38 − 40
Where α = semi cone angle
 No contact from bottom side.

T
Ration of belt tensions: 1 = e sin 
T2

For a given diameters, of pulleys, center distance, materials.


  because sinα < 1
sin 
 T1  T 
 T    1
2 V −belt  T2  flat belt

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T 
Thus  1   T1  Power transmission opacity  .
 T2 

(P.T.C) V-belt > (P.T.C) flat belt

9.1. Practical application:
(i). air compressor
(ii). Automobile radiator fans
(iii). M/c tools like shaper, milling M/c etc.

9.2. V-Belt Designation:

 Standard size represents the manufactured length.

If manufacture length = Normal pitch length  Standard size

Manufactured length > Nominal (N) pitch length  Oversize belt

Manufactured length > Nominal (N) pitch length  Undersize belt

 Nominal pitch length will give the exact length of the belt due to no bending at
centroidal axis.
 Always V-belt are designated by Nominal pitch length.
9.3. comparison between flat belt and V-belts:

Parameter Flat belt V-belt

Thin and wider X–S/C

1. Cross section

2. Pulley Flat pulley grooved pulley

3. Centre distance Medium center distance smaller center distance

T1
4. eμθ (less) eμθ/sinθ (more)
T2

5. P.T.C. Less More

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6. Cost Less costly Costlier

7. Life More Less

8. Idler pulley required when C < Cmin Not required

9. V.R. up to 5 up to 10

10. Slip More rarely occur

11. Noise More due to joint quiet operation (less noise)

12. No. of belts One belt Multiple V-belt are used

 In case of multiple V-belts, even it a single belt gets damage, entire set up, V-belts is
replaced of complete new set of V-belts to ensure uniform tension (uniform power
transmission) in all the belts.

Ptotal
 No. of V-belt =  Cs (Theortically)
Peach belt

Cs = service factor
 Practically:

Total Power to be transmitted  Cs or k a

No. of V-belt =
Rated power  kb  k c

Rated power obtained from manufacturer catalogue.

kb = arc of contact factor (≤ 1)
kc = Length correction factor
Reason of kb and kc = manufactured calculated by assuming
Q1 = 180° and standard size belt
kb = 1 when θ = 180°
kc = 1  standard size

> 1  undersize

< 1 = oversize

10. CREEP OF BELT

There is a peculiar phenomenon in the belt drive, which is called ‘creep’. Creep is a slight
relative motion of the belt as it passes over the pulley. While moving from tight to loose side
over the pulley, the belt element is transferred from the zone of higher tension to the zone of
lower tension. As the tension in the belt is reduced, the belt becomes shortened and creeps
along the surface of the pulley. This causes relative motion between the belt and pulley surface.

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Fig.: creep of belt

10.1. Effect of creep:
(i). Creep results in a decrease in the angular velocity of the driven pulley from that
calculated by considering the ratio of diameters of pulleys.
(ii). The efficiency of the belt drive is reduced by 1 to 2 per cent as a result of creep.

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