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The group decided on a 'wedge belt' based 'overhung shaft' drive system.
genrated 3
genspeed 1500
turbspeed 625
genrated
powergen
geneff
powergen 4.286
genspeed
Speedratio
turbspeed
Speedratio 2.4
The driving shaft rotates slower than the driven shaft and thus the system is a speed-increasing drive.
conversion 9550
conversionpower
gen
N m
genspeed
torquegen
Note:
torquegen 27.286 J
1J=1Nm
http://www.fptgroup.com/index/index.asp
Fenner International Ltd are a leading manufacturer of belts for a variety of drive systems.
Fenner international can be found in Europe, North America, Australia and South Africa.
South Africa is particularly important. South Africa is the main trading partner of Malawi. The
group was informed at the beginning of the project to proceed under the premise that if the
materials were available in South-Africa then they are also available in Malawi.
As Malawi is a developing country it is often hard to obtain information about such matters
unless one has a contact in the country knowledgeable in the particular field.
servicefactor 1.11
This was obtained knowing the speed ratio and using Table 3 from the
Fenner Belt Drive Catalogue.
dutyfactor 1.2
designpower powergenservicefactordutyfactor
designpower 5.709
Selection of Belt SPA, SPB, SPC or SPZ, all industry standard sections.
This is dependent on the design power calculated above and the generator running speed.
Table 2 Fenner Catalogue. At 5.7 kw at 1500 rpm follow graph reading instructions in
catalogue.
The grade is SPZ. These are British standards for wedge belts. If operating conditions fall between
area encompassed by two belts use the lower one.
Minimum Pulley Diameter (mm)
Again using the design power and the generator speed the minimum pulley diameter was found from
Table 1. 80 mm. Checking this theoretical value against available stock of minimum pulley diameters
at the desired speed ratio of 2.4, table page 43 SPZ belts, nearest value was 75mm.
Minpully 75
Approximation of Large Pulley Diameter (mm)
Largepully MinpullySpeedratio
Largepully 180
If a pulley is not actually available at this size it will have an effect on the generator running speed.
Over or under speed. There are expectable levels for this given for any generator.
Calculate the new speed ratio if necessary. Multiply by turbine speed and see if the over/under speed of
generator is within range. Conclude if acceptable or not.
basicbeltpower 1.65
Speed ratio Increment (kW/belt)
The increase in belt power due to the speed ratio per belt. Obtained using generator speed against
speed ratio in the lower SPZ-belt power rating table, page 54
additionkwbelt 0.23
Corrected Power (kW)
The corrected power per belt= (basic belt power + speed ratio increment)X Correction factor
correctionfactor 0.85
designpower
numberbelts
correctedpower
numberbelts 3.572
Use four belts, the next whole number as guided by selection manual.
numberbelts1 4
Belt Tension
The following belt tension formula was obtained form page 215, Harvey.A, Micro Hydro Design Manual
A guide to small scale water power schemes.
Number of Belts
numberbelts1 4
p 16.41
Obtained from force tables tables Harvey. A, page 207 and interpolating for shown value.
Belt Tension
Td 2.1 103 N
Td 32 p numberbelts1N
Turbineshaft_power 3.722103
Turbinetorque
Turbineshaft_powerN m
2
turbspeed 60
Turbinetorque 56.868 J
Drunner 0.246m
Turbinetorque
Forcejet
0.5Drunner
Forcejet 462.341 N
Td 2.1 103 N
L1 0.125m
ltotal L4 L2
L2 0.250m
ltotal 0.44 m
L3 0.120m
L4 0.190m
Moments about B
Td 2.1 103 N
Ra
Forcejet 462.341 N
Td L1 Forcejet L2 L3
Ra 1.735 103 N
L2
Now wish to find the maximum bending moment in the X_X plane. Using the formula:
Bending Moment at any point= The sum of forces to the left of that point X distance from left to the
point
Mrunner 0
J=Nm
Ma ForcejetL3
Ma 55.481 J
Mbelt Forcejet L3 L2 L1 Ra L2 L1
Mb Td L1 Ra L2 Forcejet L2 L3
Mbelt 103.54 J
Mb 2.842 10 14 J
Almost Zero
Y_Y Plane Radial Forces
g 9.807
m
2
Weightrunner mrunnerg
mrunner 7.5kg
Weightrunner 73.55 N
The decision was taken to go with senario 2. As it is quicker and will give a conservative answer.
Moments about B
Rav
Weightrunner L2 L3
Rav 108.854 N
L2
Assuming the belt tension is completely horizontal as assumed in the micro-hydro design
manual.
Now wish to find the maximum bending moment in Y_Y plane. Using the formula:
Bending Moment at any point= The sum of forces to the left of that point X distance from left to the
point
Mrunnerv 0
Mav WeightrunnerL3
Mav 8.826 J
Now calculate the necessary shaft diameter. Several formula are available ofr this purpose.
We will use a historical approach based on a code established by the ASME (American
Society of Mechanical Engineers) in 1927. This method is based on the maximum shear
stress theory and will tend to give a conservative result.
Structural Steel A36 , Hibbler, Mechanics of Materials, gives values for yield and ultimate tensile
strength of respectively.
Sy 250
Yield Strength
mm
Sut 400
N
2
mm
tpa 0.30Sy
tpb 0.18Sut
Need to take the lower value, a permissible shear stress of tpb= 72MPa.
Need to change tpb into N/mm2 to be consistent with the units of yield and ultimate tensile
strength and give a shaft diameter in mm. 1Mpa= 1 N/mm2.
tpbnew 72
N
2
mm
Note this unit change is done manually mathcad has not been set up to do this. So if i change
the material properties of the steel i will have to go back and manually adjust the permissible
stress value into the corect units.
For belt drives, the shaft rotating and the load is considered steady. Thus,
shock factor, Cm=1.5 and fatigue factor Ct=1
Cm 1.5
tbelt Mbelt
Ct 1
Where M.belt = t.belt
1
0.5
5.1
2
2
d
t
m a t belt
tpb
d 0.021 m
Might not be able to get a shaft exactly 21 mm. So dactual_shaft is set up to be able to change
shaft diameter for deflection calculations and allow input of stock size shaft that will actually be
used. Allows mathcad sheet to adjusted to increase shaft diameter if deflection critria below is
not satisfied.
dactualshaft 0.026m
Deflection of Shafts
Weightrunner 73.55 N
Td 2.1 103 N
E 200109 Pa
dactualshaft
X_X Plane
64
Forcejet 462.341 N
I 2.243 10 8 m
Formulae for calculating the deflections pg 233 Harvey.A, Micro-Hydro design manual.
Forcejet 462.341 N
Td 2.1 103 N
Deflection at d
C due
due to
to belt
belt only
only
dcbelt
Td L2
ddbelt
48EI
2
Td L3 L2
16EI
Deflection at C
d due
due to
to force
force jet
jet
dcforcejet
ForcejetL3 L2
16EI
ForcejetL3 L2 L3
ddforcejet
3 E I
2
dallowable 0.00050.25m
dallowable 1.25 10 4 m
0.125mm
ddforcejet 1.83 10 4 m
d caused by T only
ddbelt 2.195 10 4 m
Deflection form both Force_jet and belt tension at point d
dtotald 3.644 10 5 m
Ok
dcforcejet 4.831 10 5 m
c caused by T only
dcbelt 1.524 10 4 m
Deflection form both Force_jet and belt tension at point c
dtotalc 1.041 10 4 m
Ok
Deflection at C is more than D this makes sense because the force of jet is less than that of belt
tension.
Can recduce deflection by increasing the shaft diameter
Both deflections are under the maximum allowable value.
Therefore the final values for shaft diameter and lenght are 26 mm dia shaft or above of length
44 mm.
dactualshaft 0.026 m
ltotal 0.44 m