Design of flexible drive

system
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Drive system for an industrial application employing a belt drive,
a gear reducer, and a chain drive
• Belt, chain and rope drives are called ‘flexible’ drives.
• There are two types of drives—rigid and flexible. Gear drives
are called rigid or non-flexible drives.
• In gear drives, there is direct contact between the driving and
driven shafts through the gears.
• 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.
The advantages of flexible drives over rigid drives are as
follows:
(i) Flexible drives transmit power over a comparatively long distance
due to an intermediate link between driving and driven shafts.
(ii) Since the intermediate link is long and flexible, it absorbs shock
loads and damps vibrations.
(iii) Flexible drives provide considerable flexibility in the location of
the driving and driven shafts. The tolerances on the center distance
are not critical as compared with a gear drive.
(iv) Flexible drives are cheap compared to gear drives. Their initial
and
The maintenance
disadvantagescosts
of are low drives are as follows:
flexible
(i) They occupy more space.
(ii) The velocity ratio is relatively small.
(iii) In general, the velocity ratio is not constant
 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 a endless belt, which envelopes them.

Pitch diameter on a (a) chain sprocket, Types of belts

(b) synchronous belt sprocket, and (c) V-
belt sheave with section view
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.
Material used for Belts

1. Leather belts
2. Cotton or fabric belts
3. Rubber belt
4. Balata belts

Flat Belts

Cross-section of V-belt
Types of Flat Belt Drives

Open belt drive

Crossed or twist belt drive

 (a) Quarter turn belt drive. (b) Quarter turn belt drive with guide pulley

(also known as right angle belt drive)

Belt drive with idler pulleys.

Compound belt drive.

Stepped or cone pulley drive.

Fast and loose pulley drive.

GEOMETRICAL RELATIONSHIPS

The length of the belt (L)

Crossed Belt Drive
Velocity Ratio of a Belt Drive
 Horizontal and Vertical Drives

Belt Creep
ANALYSIS OF BELT TENSIONS Slack side

Tight side
ANALYSIS OF BELT TENSIONS IN V-
BELT

The centrifugal force acting on the belt

can be expressed as
CONDITION FOR MAXIMUM POWER

The belt is given an initial tension Pi in order to transmit power. The initial tension
depends upon the length of the belt, the elasticity of the belt material, the geometry
of pulleys and the center
distance. In order to derive an expression for initial tension, the following
assumptions are made:
(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
(P1 – Pi) while the contraction on the loose side is proportional to (Pi – P2). For
The optimum velocity of the belt for maximum
constant belt length, the elongationpower
on thetransmission
tight side is is
equal toby,
given the contraction on the
loose side. Therefore,
CONDITION FOR MAXIMUM POWER
CONDITION FOR MAXIMUM POWER
Stresses in Belts

(i) Tension on tight side

(ii) Tension on slack side
(iii)Centrifugal force
(iv)Bending of belt over
pulley
(a)Static stress due to tension on tight side ,
=
(b) The centrifugal force produced due to weight of the belt
produces centrifugal stresses = =

(c) Maximum bending stress = ; Where E is the elastic modulus of belt

material
Check the units
= m = mass per unit length, kg/m
v = belt velocity, m/s
w = weight per unit length, N/m
The power transmitting capacity of a belt, it is given by the following relation

σd is the design stress of belt material = 2 MP;

ρ=density of belt material
bt cross-sectional area
µ coefficient of friction between belt and pulley
Pd = design power
Pd= P x C
C= service factor = C1 x C2 x C3 x C4
Service life of belt
The service life calculation based on fatigue strength is given by
(σmax)m N = Constant
σmax is the maximum stress
m is the constant [ For rubber, and fabric belt m=5; For Leather and plastic
m =6]
N is
If thethefatigue
number of stress
life cycles
is assumed to be N cycles, usually taken as 106
e
cycles, and endurance strength is σend, then
(σmax)m N = (σen)m Ne
The number of cycles before failure of the belt is

Where H is the life in hours

Z is the number of bends per one full cycle of the belt
Service life, H=

V/L is the number of full revolutions of the

belt/second
σend is the endurance strength of the belt
material
The layout of a leather belt drive transmitting 15 kW of power is
shown in Fig. The center distance between the pulleys is twice
the diameter of the bigger pulley. The belt should operate at a
velocity of 20 m/s approximately and the stresses in the belt
should not exceed 2.25 N/mm2. The density of leather is 0.95 g/cc
and the coefficient of friction is 0.35. The thickness of the belt is 5
mm. Calculate:
(i) the diameter of pulleys;
(ii) the length and width of the belt; and
(iii) the belt tensions
Design a flat belt drive to transmit 15 kW at 720 rpm to a driven machine
operating at 360 rpm Assume that the belt slips over pulley by 3 percent.
The belt material is chrome-tanned leather. The belt drive operates in damp
and chemical environment.

Diameter of the driving pulley

d=(520-630) =75.4 rad/s

d=(600)= 350 mm; refer to table for the standard size i.e. 355 mm from Table, refer
to handbook.

Velocity ratio = 1/2; Therefore diameter of driven

pulley 710 mm as per Table. By calculation 690
mm.
Pitch line velocity v= = 13.38 m/s The length of the belt (L)

Centre-distance
Center distance C ≥ (1.5 -2.0) (d+D)
C ≥ (1.75) (d+D)
C ≥ (1.75)
(355+710) L= 5389 mm
C=1850 mm

σd=design stress= 2 MPa

= 1690
µ=0.4
ρ =10 x103 N/m3
Pd = P x C
Pd =30 kW
The power transmitting capacity of a belt, it is given by the following relation

= eµϴ==3.25

bt=1764 mm2

b=1764/8=220 mm, say 225 mm

P = Design power

T1 =3206 N
(a)Static stress due to tension on tight side , = 1.78 MPa
=
(b) The centrifugal force produced due to weight of the belt
produces centrifugal stresses = = =0.18 MPa

(c) Maximum bending stress = ; Where E is the elastic modulus of belt

material =30 MPa
σb=0.67 MPa

=
=1.78+0.18+0.67=2.63 MPa
 Service life, H=

Ne=106 cycles and Z=2, σen =6 MPa; m=6

=7888 h
V-BELTS

V-belts are an extremely common power transmission device, used on applications

as diverse as blowers, compressors, mixers, machine tools, etc. One or more V-
belts are used to drive accessories on an automobile and transfer power from the
internal-combustion engine. V-belts are made to standard lengths and with
standard cross-sectional sizes, as shown in Fig.
Dimensions for standard V-
grooved pulleys
(a) Standard V-belts cross
sections with dimensions in
millimeters;
(b) Typical single-belt, showing
reinforcing cords and wear-resistant
exterior; (c) double V-belt, used for
higher power transmission than single
belts. Up to five belts can be combined
in this fashion.
Nominal inside length, nominal pitch
lengths and permissible length
variations for V-belts
The V-belts are designated by the symbol of
the cross-section followed by inside length of
the belt. The inside length of a belt can be
calculated by subtracting a fixed length from
the pitch length of the belt. For example, a V-
belt of cross-section A having pitch length of
1051 mm is designated as A-1051-IS. Where
the inside length 1016 mm is computed by
subtracting 35 mm from the pitch length.
Selection of Cross-section of V belt
Refer Table 14.14 Page 314
The number of belts required for a given application is calculated by
the following relationship:
Number of belts required

where P= drive power in kW

P = drive power to be transmitted in kW

Ks = is the correction factor according to service
(Table 14.19)
KL= is the correction factor for length (Table 14.20)
Kd = is the correction factor for arc of contact (Table
14.21)
Refer Table 14.16, Page 314 & Table 14.22
Refer Table 14.15
Page 314
Refer Table 14.19 Page 322
Nominal pitch length of belt

Center distance for a given belt length and diameters of

pulleys
The following data is given for an open-type V-belt drive:
diameter of driving pulley = 200 mm
diameter of driven pulley = 600 mm
groove angle for sheaves = 34°
mass of belt = 0.5 kg/m
maximum permissible tension in belt = 500 N
coefficient of friction = 0.2
contact angle for smaller pulley = 157°
speed of smaller pulley = 1440 rpm
power to be transmitted = 10 kW
How many V-belts should be used, assuming each belt takes its proportional part of the
load?
It is required to design a V-belt drive to connect a 7.5 kW, 1440 rpm
induction motor to a fan, running at approximately 480 rpm, for a
service of 24 h per day. Space is available for a centre distance of
about 1 m. Refer Table 14.19 Page 322

Step I
Correction factor according to service (Ks)
In this application, an induction motor is
driving a fan of 7.5 kW capacity for 24 hours
per day. From Table 14.19, Page 322 the
correction factor according to service (Ks) is
1.3.
Step II
Design power
Design power, Pd = Px Ks(transmitted
power)= 1.3(7.5) = 9.75 kW
Step III, Based on the amount of power to be transmitted, find the cross-
section of the belt

Therefore, for this application, the cross-section of V-belt is B.

Step IV
Pitch diameter of smaller and bigger pulleys From Table 14.16, the minimum pitch diameter
for the smaller pulley is 200 mm.
Determine the recommended pitch diameter of the
smaller pulley from Table. It depends upon the cross-
section of the belt. Calculate the pitch diameter of the
bigger pulley by the following relationship:

d = 200 mm and D =
3(200) = 600 mm

The above values of D and d are compared with the preferred pitch diameters given in Table. In case of non-standard
value, the nearest values of d and D should be taken from Table 14.22, Page 326-327
Step V
Pitch length of belt

Step VI
Preferred pitch length
From Table, the preferred pitch length for B section belt is 3294 mm and inside
length =3251 mm , Refer Table 14.17, page 316, Col.3

Step VII
Correct center distance

Take L =3294, Find revised C = 950.64 mm

Step VIII
Correction factor for belt pitch length (KL), From Table 14.20, Page 324 (B-section
and 3251 mm inside length length),

KL= 1.08
Step IX
Correction factor for arc of contact (Ka)
Table 14.21, Page 325

Ka is approximately 0.94.
Step X
Power rating of single V-belt
From Table (1440 rpm, 200 mm pulley, B section) (speed ratio = 3) Table 14.15, Kd, Page 314

(de) equivalent pitch diameter = d x Kd = 200 x 1.14 = 228 mm

V = πde N/60 = 17,19 m/s

Power rating = 4.92 kW, Refer 14.18, Page 318