In achieving the correct tension of a V-Belt Typical Construction of a Standard Duty V-Belt 1. Wear and Oil Resistant External Fabric 2. Compression Section 3. High Strength Tension Members - 2 - Here are a few examples of different belt designs that can be applied to varying applications: - 3 - Take a closer look at what goes on. Pulley wear is very important If the pulley is worn youre fighting a loosing battle. The belts V shape produces more contact surface than a flat belt can for a given pulley width. The wedge shape helps the pulley get a grip on the belt. The bottom of the V swells under the compression of the belt being bent around the radius of the pulley. If the grooves of the pulley are worn, the contact area is largely reduced. When a new belt is run on a worn pulley, the areas of contact between the pulley and the belt are at very high pressures. The belt material cannot withstand the excessive compression so the belt material will quickly be worn away. As the accelerated wear occurs, your belt drive will begin slipping in short order. You will be called back to increase the belt tension again to stop the slipping. - 4 - The Deflection Method is the best way to QUANTIFY belt tension. A popular Rule of Thumb is to deflect the belt 1/64 per inch of center distance. That is to say, if the center distance between two shafts is 100 inches, the belts should be deflected 100/64 or 1 9/16. A decimal equivalent chart is a big help in converting the measurements. You will always have a chart if you keep your copy of the Electrical Engineering Pocket Handbook nearby. The question then becomes, How much pressure should it take to deflect the belt that much? This is where the fly gets into the ointment. The following table can be used as a starting point. Recommended Tension for V-Belt Drives Small Sheave Deflection Force in Lbs. V-Belt Section Speed Range Diameter Speed Ratio 1.0 Speed Ratio 1.5 Speed Ratio 2.0 Speed Ratio 4.0 + 1800-3600 3.0 2.0 2.3 2.4 2.6 1800-3600 4.0 2.6 2.8 3.0 3.3 1800-3600 5.0 3.0 3.3 3.4 3.7 A 1800-3600 7.0 3.5 3.7 3.8 4.3 1200-1800 4.6 3.7 4.3 4.5 5.0 1200-1800 5.0 4.1 4.6 4.8 5.6 1200-1800 6.0 4.8 5.3 5.5 6.3 B 1200-1800 8.0 5.7 6.2 6.4 7.2 900-1800 7.0 6.5 7.0 8.0 9.0 900-1800 9.0 8.0 9.0 10.0 11.0 900-1800 12.0 10.0 11.0 12.0 13.0 C 700-1500 16.0 12.0 13.0 13.0 14.0 900-1500 12.0 13.0 15.0 16.0 17.0 900-1500 15.0 16.0 18.0 19.0 21.0 700-1200 18.0 19.0 21.0 22.0 24.0 D 700-1200 22.0 22.0 23.0 24.0 26.0 - 5 - Of course you can remember all of those numbers. Right? Well, dont worry, cause nobody else does either. In practice, I think you will find if you apply the criteria from the table above, your belts will be fiddle string tight. When belts are run that tight, there is no question that they will perform to their rated capacity. The belt people want you to be satisfied that their belts will pull the load, and they want you to get them so tight that they cant slip. The problem is though, in higher horsepower, multiple belt applications, these deflection specifications can add up to disaster. Remember, there are other mechanical concerns that the belt manufacturer cant begin to take into account. Concerns like will the shafts break? Can the bearings stand up under that much load? Will the heat generated in such heavily loaded bearings cause the grease to melt and run out. The bearings surely wont last if that happens. This motor shaft was broken due to excessive loading. Machines can be built to withstand excessive belt loads, but in most cases they are not. So the onus is on you to do it right. Dont take the belt manufacturers tensioning tables and use them as Gospel, because they are only addressing belt performance. They are NOT accounting for the limitations of your machinery. Use the Deflection Method to achieve uniformity in your V-belt applications. It will take good organization to establish what the correct amount of deflection is. Every application needs to be treated separately, because every application is different. You will need to establish records of successful belt drive installations and use those records in ensuing repair and maintenance operations. - 6 - In the final analysis, the correct belt tension is just enough tension to keep the belt from slipping under normal load conditions. Please Notice the word normal now, because well want to talk more about that later. The determination of the correct tension is a matter of knowing the dynamics of the application, making some careful observations, and drawing the right conclusions. The first step in a successful v-belt installation is having some idea of the capacity of the belt and pulley combination. If you know what the horsepower-per-belt rating is, you will be able to get a feeling for how much you are demanding from the belts. This information is available from the application data established by the belt manufacturer. In most cases, V- belt application engineering has been done by the equipment manufacturer or your belt and pulley vendor. Its a good thing to ask who specified the components, because anybody can make a mistake, even an equipment manufacturer. You need to know who was involved, because you need to have confidence in the finished installation. There are different approaches to V-belt application engineering, and too often, COST becomes a deciding factor in how conservatively, or aggressively V-belts and pulleys are utilized. Be advised that it costs more money to keep the applied horsepower per belt low, so if your horsepower-per-belt ratio is at the higher end of the manufacturers established limits, you will know that the belts will have to be awfully tight to transmit the load back to the motor. If the belt drive is at the high end of the horsepower per belt ratio, or works out to only have a 1.0 Service Factor, I recommend that you ask whoever specified the components to go back to the drawing board, and get you some heavier duty stuff before you waste your time putting it all together. - 7 - The next step is to take control, and take responsibility for the tensioning operation. Make a careful installation so you will be able to eliminate misalignment of the belt drive. This is very important to the belts, and it is important to the bearings in your machine and to the motor. Misalignment can damage the cords in the belts, cause excessive wear and excess heat, as well as waste energy. Multiple belt installations require careful alignment so that the belts can be tightened evenly. Accurate alignment is the part of the job your supervisor doesnt want to deal with either. So make him proud, dont ask questions, just go ahead and do it right. Now is the time, to take the time, to give the belts and your machine an even chance for success. Misalignment will significantly reduce the capacity of the drive and demand higher belt tensions in order to pull the load. Use a Straight edge or a piece of string that you can draw across the face of the pulleys to gauge the misalignment. - 8 - Taper Lock Bushings will cause you a headache too, because the engagement of the taper and the offset of the edges of the bushing and pulley will vary from one pulley to the next.
After you have resolved the initial angular misalignments, you will probably have to move one of the pulleys to correct any remaining parallel misalignment. Do yourself a favor by taking some measurements while the pulleys are mounted. Your straight edge will indicate how much the pulley has to move. This measurement is indicated by the RED lines in the drawing to the left. In this particular instance, I would decide to move the top pulley back further onto the shaft. This will get the pulleys closer to the machine and help to reduce bearing loads. The BLUE lines are the measurement from the bushing to the end of the shaft. I would add the earlier pulley offset to the bushing measurement and then position the top bushing accordingly, further onto the shaft. After the bushing is retightened, the parallel alignment of the pulleys should be correct. amount. - 9 - When mounting the belts, dont force them onto the pulleys. Move the shafts close enough together so there is plenty of slack to allow the belts to slide easily over the pulleys. Never STRETCH the belts when putting them on. If you get too rough putting the belts on the pulleys, you could damage or even break the internal tension members in the belts. Damage to the tension members might cause the belts to flip over or even break when they go into operation and encounter heavy loads. Go ahead and tighten the belts to something approaching what the manufacturer calls for in their table. Be sure to roll the pulleys as you get closer to the final tension setting. Let the belts feel their way into the pulley grooves as you increase the tension. Verify the accuracy of your alignment as you go. Continue to take up the slack while maintaining even tension on all of the belts. If the belts arent equally tensioned, find out why and make the necessary adjustments. Now youre ready to start the machine. Follow all of your normal safety precautions and then alert those working within the vicinity of the machine about your intentions to attempt a start-up. Remove the lockouts and start the machine. Listen and observe carefully. If you are NOT using some soft start method for starting the motor, dont be alarmed if the belts Squawk during the acceleration of a high inertia or fan load. Normal, Design B, squirrel Cage motors develop 200% (or more) of their rated torque during acceleration. Keep in mind that your belt drive needs to be rated for the motor and the load. It doesnt need to be rated for twice your motors horsepower. In the case of across the line starting, its OK, and you can expect, the belts to slip a little at some point while the load is accelerating. Dont think you need to totally eliminate belt squawk when a motor starts. - 10 - In the case of an existing installation, it is natural, due to belt stretch, to have to re- tension a belt drive, but consider the possibility that something may have changed to increase the load. Electric motors are capable of developing more power than their continuous rating implies, so if your belts are slipping, you should measure the motor currents before you decide on what action to take. Re-tensioning the belt drive might not be the right thing to do. If the belts squeal or slip when the machine is at full speed and running at a full normal load, shut it down and re-tighten the belts. Use the Deflection Method, and employ the data that was learned during the initial start-up on the machine. If you are working on a new installation, be sure and consider whether the machine was running normally, or if it is encountering some unusual transient load. Be aware that new start-ups may present overload situations that can be accounted for and eliminated once the process variables have all been examined and properly adjusted. Make sure that the motor is not being overloaded before you tighten the belts. In any event, monitor bearing temperatures before and after making adjustments to belt drives. Elevated bearing temperatures may be your best indicator of potential problems. Ball bearings will run hot if they are under-greased, over-greased, or if they are overloaded. Most ball bearings get warm when running, and a good rule of thumb is that normal conditions should not generate bearing temperatures higher than about 150 degrees F at the housing. If you see bearing housing temperatures over 170 degrees F, something is probably wrong, or you are dealing with a very unusual application. Know what the normal operating temperatures of the bearings are before making adjustments to the belt drive. It is a good idea to ask if someone has just added grease to the bearings before you begin your work. If recent (excessive) relubrication is a possibility, check your maintenance records to determine that the bearings are operating at their normal temperature before re-tensioning the belt drive. If the bearing temperatures are elevated, you may have to purge excess grease before making adjustments. If you have determined the appropriate course of action is to re-tension the drive, go ahead and tighten the belts. Just be sure to use the Deflection Method so the belts are tightened to established standards, or document your work so that YOU can establish those standards. Always remember: the correct belt tension is just enough tension to keep the belt from slipping under normal load conditions.