ME 2352 DESIGN OF

TRANSMISSION SYSTEM
III YEAR VI SEM

UNIT I TRANSMISSION
SYSTEMS USING
FLEXIBLE ELEMENTS

Selection of V belts and pulleys

selection of Flat belts and pulleys
Wire ropes and pulleys
Selection of Transmission chains and
Sprockets.
Design of pulleys and sprockets.

BELT DRIVE
1. A belt is a looped strip of flexible
material, used to mechanically link two
or more rotating shafts.
2. They may be used as a source of motion,
to efficiently transmit power, or to track
relative movement. Belts are looped
over pulleys.
3. In a two pulley system, the belt can
either drive the pulleys in the same
direction, or the belt may be crossed, so
that the direction of the shafts is
3
opposite.

1. Fundamentals
Advantages of a Belt Drive System

Easy and economical installation.

No lubrication required.
Clean & low maintenance.
Elasticity of belts helps shock load
dampening.
Quiet, smooth operation.
Long life expectancy when well designed.
Good mechanical efficiency.

4
MASKA 2009-

Belts vs. Chains

Belts
Chains
Use When:
Speed:
Dis:

Advs:

High Speed, Low T

2500 < Vt < 7000
ft./min.
Must design with
standard lengths, wear,
creep, corrosive
environment, slip,
temp., when must have
tension need idler
Quiet, flexible, cost

High T, Low Speed

V < 1500 ft./min.
Must be lubricated,
wear, noise, weight,
vibration

Strength, length
flexibility
5

Open belt drive

Cross belt drive

FLAT BELT

TIMING BELT
ROUND BELT

V-Belts and V-Belt Drives

The function of a belt is to
simply transfer rotation from
the powered pulley to one
or more driven pulleys. The
belt must be designed and
manufactured to transfer
this torque efficiently and
reliably.

V-Belts and V-Belt Drives

V-Belts work
using the
principle of the
wedge

V-Belts and V-Belt Drives

V-Belts are available
in thousands of sizes
and configurations
Primary function is
to transmit power
from a primary
source (motor) to a
secondary driven
unit

10

V-Belt Characteristics

Less expensive than other forms of power transmission

Start, stop and run smoothly
Operate noiselessly and without lubrication
Absorb objectionable and harmful vibrations
Clean and requires minimum maintenance
Rugged and long lasting
Provide a wide selection of speed ranges
Cover an extremely wide horsepower range
Easy to install and simple to replace
Relatively unaffected by moisture, abrasive dusts,
or extreme
variations in temperature

11

V-Belt Drive Terms

12

Types of Belts

Classical or Multiple V-Belts

Fractional Horse-Power or Light Duty V-Belts
Narrow or Wedge Multiple V-Belts
Double Angle or Serpentine V-Belts
Banded Belts
V-Ribbed Belts
Variable Speed Belts
Trapezoidal Synchronous or Timing Belts
High Torque Synchronous belts
Specialty Type Belting
13

Two Major Belt

Categories
V-Belt - works on the
principle of the wedge and
relies on tension to create
friction on the sidewall of the
sheave to transmit power

Synchronous or timing
belt - relies on accurate and
smooth meshing of the teeth
on the belt with the grooves
of the sprocket
14

Two Major Types of VBelts

Wrapped Molded which
has a fabric cover and is
molded into a V-shape

Raw Edge which is

cured and then cut into a
V-shape
15

Wrapped V-Belt
Construction
1. Protective fabric cover
impregnated with rubber
2. Tension Section synthetic rubber
compounded to stretch as
belt bends
3. Cords - synthetic fiber
cords carry the power and
minimise stretch
4. Compression Section synthetic rubber compound
to support cords evenly and
compress as belt bends
16

Raw Edge V-Belt

Construction
1. Tension Section - specially
woven stress-relived fabric
2. Cords - synthetic high
modulus cord to carry high
loads with minimal stretch
3. Compression Section Stiflex rubber compound and
precision molded cogs
increase flexibility and
supports cords
4. Raw Edge Side Walls provide uniform anti-slip
surface, greater flexibility
and allow more cord

17

Advantages
Raw Edge vs. Wrapped
Performs up to 4%
more efficiently
Generates less heat
build up
Allows smaller pulley
diameters
Increased power
ratings
Provides longer life

18

Narrow or Wedge
Multiple Belts

Power Wedge Cog V-Belts

Raw Edge
Increased HP Capability

Super Power Wedge V-Belts

Wrapped Molded
Increased HP Capability

19

V-belt Drive Design

Process

Need rated power of the driving motor/prime mover. BASE sizing

on this.
Service factor based on type of driver and driven load.
Center distance (adjustment for center distance must be provided
or use idler pulley) nominal range D2 < C < 3(D2 + D1)
Power rating for one belt as a function of size and speed of the
smaller sheave
Belt length (then choose standard size)
Sizing of sheaves (use standard size). Most commercially available
sheaves should be limited to 6500 ft/min belt speed.
Belt length correction factor
Angle of wrap correction factor. Angle of wrap on smaller sheave
should be greater than 120 deg.
Number of belts
Initial tension in belts

20

Key Equations

Belt speed (no

slipping) =

Speed
ratio =

D11 D22
b R11 R22

2
2
Pitch dias of
1 D2
sheaves

Pitch
2 D1
dia in

rpm

inches

Belt speed
ft/min

D1n1
b
12

21

Key Equations
Belt length:

2
( D2 D1 ) 2
L 2C ( D2 D1 )

4C

Center Distance:
Where,

B B 2 32( D2 D1 ) 2
C
16

B 4 L 2 ( D2 D1 )
Recommended D2 < C <
3(D2+D1)

Note: usually belt length

standard (use standard belt
length table 7-2), then calculate C
based on fixed L

22

Key Equations cont

Angle of contact of belt on each
sheave
D2 D1
1 180 2 sin

2C
1

D2 D1
2 180 2 sin
2C
1

Note: Select Ds and Cs so maximum contact (1 + 2 =

180). If less then smaller sheave could slip and will need
reduction factor

23

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.
24

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.
25

Various Types of Belts

26

FLAT BELT & PULLEYS

Flat Belt
arrangement
Open loop

27

Flat Belts
Closed loop (reversing)

28

Flat Belts
Fy = 0, and for small
angle

d/
2

Fx = 0, and for small

angle

Low speed
application
For relatively high speed application, the centrifugal
force acting on the belt creates the tension Pc
Where m is mass per unit length of belt V is
Torque that can be transmitted by a
Initial belt
the
belt
linear
velocity,

the angular speed,

flat belt
tension
and r the pulley radius.
29

V-BELT & PULLEYS

30

Timing (toothed) Belts

Transmits torque by virtue of

positive engagement, provides a
constant angular velocity ratio (no
slip or creep).
Can transmit high torque and
power.
Can be operated at high speed, up to
16,000 ft/min.
Requires minimal initial tension, just enough
to prevent tooth skipping when starting or
braking.
Refer to manufacturers catalog for belt selection
procedures.

31

Belts
Belt drive is specially suited for applications where the center
distance between rotating shafts are large.
Advantages

Eliminates the need for a more complicated

arrangement of gears, bearings, and shafts.

Runs relatively quiet.

Reduce the transmission of shock and vibration between sha

Simple to install.

It has high reliability and warning to failure.

Requires minimum maintenance.

Belt drives are adaptable to variety of applications

32

Belt Material

33

Gates 5V-Belt

34

Selection of transmission chain

& sprocket
Roller Chains

D = pitch diameter of the

sprocket
= pitch angle

N = number of teeth on the

sprocket
p = chain pitch

35

Chordal Action

Roller Chains

For N=20, speed variation is 1.23%

36

ANSI Standards
for Roller
Chains

37

38

39

InvertedTooth Chains
(Silent Chains)

40

Product Details

Part Number
Unit
Pitch
Material
Available Length
Assembly
Method
Approx. Links /
Foot
No. Of Strand
Avg. Tensile
Load
Weight / Foot

A 6Q 7-25
Inch
0.2500"
Hardened
Steel
Priced / Foot"
Connecting
Link
48
1
925 lbs
0.090 lbs

41

Description
0.250" Pitch hardened steel roller
chain

42

Wire Ropes &

Pulleys
Wire ropes are used for hoisting, haulage, and conveyor
Lang
laysmall
wires
in strands
applications.
Several
wires
(6, 19, 37, 42) are twisted to form a
twisted
same
direction
strand,in
then
several
strands (3, 6, 8) are twisted about a
as
strands
twisted
form
core
to form
a wiretorope
rope.
MoreLay
likely
to untwist
Regular
wires
in
but
better
wear and
fatigue
strands
twisted
in opposite
properties.
for twisted
direction toUsed
strands
moving
to formapplications
the rope. Used for
stationary applications.

43

Wire Ropes

44

Wire Rope Core

Fiber core

Fiber cores are generally made of cotton twine for

cables less than inch and hard fiber ropes (manila
or sisal) for the larger sizes.
Fiber cores extend the life by cushioning the strands
and reducing internal abrasion, good for light
crushing loads. Hard cores are impregnated with
lubricant to deter rust and lubricate.
Wire core

Wire cores offer less stretch, have better

resistance to heavy crushing loads and are not
effected by heat.

45

Standard Wire Ropes

6 x 19 fiber core

The standard hoisting

cable. Excellent strength,
flexibility, and resistance to
abrasion and fatigue.
6 x 37 fiber or wire core

More flexible than 6 x 19,

good for applications where
pulleys are limited in size.
6 x 42 fiber centers and core

The most flexible of all

standard cables, used for
moderate loads.

46

Standard Wire Ropes

1 x 19 wire core

Primarily used for

stationary (non-flexible)
applications.
19 x 7 wire core

Designed to resist the

natural tendency of a cable
to rotate when freely
suspended under load.

7 x 7 wire core

The standard flexible

aircraft cable. High strength
and rugged construction,
used for towing and power
transmission.

47

Wire Rope Stresses

Direct tensile stress in the wires of the rope.

Bending stress in the wires caused by the rope passing

around sheaves or drums.

Compressive stress (bearing pressure) between

the rope and the sheave or drum.

Direct tensile stress

T = resultant tensile force, includes load to be lifted, weight

of the rope and inertial effects due to accelerating the load.
Ar = approximate cross-sectional area of the rope, a
function of rope diameter, dr.

48

Wire Rope Stresses bending stress

Bending stress
Stress in one of the wires passing
around a sheave
an
d

Wire diameter

Sheave
diamet
Modulus of theer
rope

49

Wire Rope Stresses bearing

pressure
Compressive stress (bearing pressure)

50

Wire Rope Stresses

Fatigue strength
parameter

51

Allowable Bearing Pressure

52

53

Key Equations

Belt speed (no

slipping) =

Speed
ratio =

D11 D22
b R11 R22

2
2
Pitch dias of
1 D2
sheaves

Pitch
2 D1
dia in

rpm

inches

Belt speed
ft/min

D1n1
b
12

54

Belts
Belt drive is specially suited for applications where the center
distance between rotating shafts are large.
Advantages

Eliminates the need for a more complicated

arrangement of gears, bearings, and shafts.

Runs relatively quiet.

Reduce the transmission of shock and vibration between sha

Simple to install.

It has high reliability and warning to failure.

Requires minimum maintenance.

Belt drives are adaptable to variety of applications

55

Two Major Belt

Categories
V-Belt - works on the
principle of the wedge and
relies on tension to create
friction on the sidewall of the
sheave to transmit power

Synchronous or timing
belt - relies on accurate and
smooth meshing of the teeth
on the belt with the grooves
of the sprocket
56

Timing (toothed) Belts

Transmits torque by virtue of

positive engagement, provides a
constant angular velocity ratio (no
slip or creep).
Can transmit high torque and
power.
Can be operated at high speed, up to
16,000 ft/min.
Requires minimal initial tension, just enough
to prevent tooth skipping when starting or
braking.
Refer to manufacturers catalog for belt selection
procedures.

57

V-Belts and V-Belt Drives

The function of a belt is to
simply transfer rotation from
the powered pulley to one
or more driven pulleys. The
belt must be designed and
manufactured to transfer
this torque efficiently and
reliably.

58

Description
0.250" Pitch hardened steel roller
chain

59

Wire Rope Stresses bending stress

Bending stress
Stress in one of the wires passing
around a sheave
an
d

Wire diameter

Sheave
diamet
Modulus of theer
rope

60

Flat Belts
Fy = 0, and for small
angle

d/
2

Fx = 0, and for small

angle

Low speed
application
For relatively high speed application, the centrifugal
force acting on the belt creates the tension Pc
Where m is mass per unit length of belt V is
Torque that can be transmitted by a
Initial belt
the
belt
linear
velocity,

the angular speed,

flat belt
tension
and r the pulley radius.
61

62

Wire Rope Safety Factor

63

64

Flexible Shafts
Flexible shafts are used to
transmit motion or power along a
curved path between two shafts
that are not collinear.
Flexible shafts are built up
solid by tightly winding one
layer of wire over another
about a single mandrel wire
in the center.
The shafts are encased in a
metal or rubber covered flexible
sheath, it protects the shaft
from damage and retains the
lubricant.
65

Flexible Shafts

66

Allowabl
e Torque
Bend
radius

67

Chain Drives
Types of Chains

68

Chain Drives
Roller Chain Construction (Most common Type)

69

Chain Design Process

1.)

# of sprocket teeth, N1 (smaller sprocket) > 17 (unless

low speed < 100 rpm.)

2.)
3.)

Speed ratio = n1/n2

30 x Pitch Length < Center Distance < 50 x Pitch

Length

4.) Angle of contact of chain on smaller sprocket > 120

5.) # sprocket teeth, N (longer sprocket) < 120
2

70

Design of pulley

71

72

73

74

75