Basics of belt drives

Power transmission belting has been used for more than 200 years. The first belts were
flat and ran on flat pulleys. Later, cotton or hemp rope was used with V-groove pulleys to
reduce belt tension. This led to the development of the vulcanized rubber V-belt in 1917.
The need to eliminate speed variations led to the development of synchronous or toothed
belts about 1950 and the later development of fabric-reinforced elastomer materials.

Today, flat, V, and synchronous belting is still being used in power transmission. When
compared to other forms of power transmission, belts provide a good combination of
flexibility, low cost, simple installation and maintenance, and minimal space
requirements.

Belt-driven equipment uses readily available components. Replacement parts can be

easily obtained from local distributors. This availability reduces downtime and inventory.
Sheaves and pulleys are usually less expensive than chain drive sprockets and have little
wear over long periods of operation.

Belt types
All power transmission belts are either friction drive or positive drive. Friction drive belts
rely on the friction between the belt and pulley to transmit power. They require tension to
maintain the right amount of friction. Flat belts are the purest form of friction drive while
V-belts have a friction multiplying effect because of wedging action on the pulley.

Positive drive or synchronous belts rely on the engagement of teeth on the belt with
grooves on the pulley. There is no slip with this belt except for ratcheting or tooth
jumping.

Flat belts

Modern flat belts are made with reinforced, rubberized fabric that provides strength and
high friction levels with the pulley (Fig. 1). This eliminates the need for high tension,
lowering shaft and bearing loads. Flat belts can transmit up to 150 hp/in. at speeds
exceeding 20,000 fpm.
Fig. 1. Flat belts have thin cross-sections and wrap around pulleys easily

A significant advantage of flat belts is efficiency of nearly 99%, about 2.5-3% better than
V-belts. Good efficiency is due to lower bending losses from a thin cross-section, low
creep because of friction covers and high modulus of elasticity traction layers, and no
wedging action into pulleys.

Pulley alignment is important to flat belts. Belt tracking is improved by crowning at least
one pulley, usually the larger one. Flat belts are forgiving of misalignment; however,
proper alignment improves belt life.

Different flat belt surface patterns serve various transmission requirements. In high-
horsepower applications and outdoor installations, longitudinal grooves in the belt
surface reduce the air cushion flat belts generate. The air cushion reduces friction
between the pulley and belt. The grooves nearly eliminate the effects of dirt, dust, oil, and
grease and help reduce the noise level.

Flat belts operate most efficiently on drives with speeds above 3000 fpm. Continuous,
smooth-running applications are preferred. Speed ratios usually should not exceed 6:1. At
higher ratios, longer center distances or idlers placed on the slack side of the belt create
more wrap around the smaller pulley to transmit the required load.

V-belts
Fig. 2. V-belts come in a wide variety of sizes and shapes

V-belts are commonly used in industrial applications because of their relative low cost,
ease of installation, and wide range of sizes (Fig. 2). The V-shape makes it easier to keep
fast-moving belts in sheave grooves than it is to keep a flat belt on a pulley. The biggest
operational advantage of a V-belt is the wedging action into the sheave groove. This
geometry multiplies the low tensioning force to increase friction force on the pulley
sidewalls (Fig. 3).

Fig. 3.

Classical V-belts are frequently used individually, particularly in A and B sizes. The
larger C, D, and E sizes generally are not used in single-belt drives because of cost
penalties and inefficiencies. Multiple A or B belts are economical alternatives to using
single-belt C, D, or E sections.

Narrow V-belts, for a given width, offer higher power ratings than conventional V-belts.
They have a greater depth-to-width ratio, placing more of the sheave under the
reinforcing cord. These belts are suited for severe duty applications, including shock and
high starting loads.
Banded V-belts solve problems conventional multiple V-belt drives have with pulsating
loads. The intermittent forces can induce a whipping action in multiple-belt systems,
sometimes causing belts to turn over. The joined configuration avoids the need to order
multiple belts as matched sets.

Banded V-belts should not be mounted on deep-groove sheaves, which are used to avoid
turnover in standard V-belts. Such sheaves have the potential for cutting the band of
joined belts. Extremely worn sheaves produce the same result.

V-ribbed belts combine some of the best features of flat belts and V-belts. The thin belt
operates efficiently and can run at high speeds. Tensioning requirements are about 20%
higher than V-belts. The ribs ensure the belt tracks properly, making alignment less
critical than it is for flat belts.

Synchronous belts

Synchronous belts have a toothed profile that mates with corresponding grooves in the
pulleys, providing the same positive engagement as gears or chains. They are used in
applications where indexing, positioning, or a constant speed ratio is required.

The first tooth profile used on synchronous belts was the trapezoidal shape (Fig. 4). It is
still recognized as standard. Recent modifications to tooth profiles have improved on the
original shape. The full-rounded profile distributes tooth loads better to the belt tension
members. It also provides greater tooth shear strength for improved load capacity.

Fig. 4. Synchronous belts have several tooth shapes

A modified curvilinear tooth design has a different pressure angle, tooth depth, and
materials for improved load/li fe capacity and nonratcheting resistance.
Synchronous belts can wear rapidly if pulleys are not aligned properly, especially in long-
center-distance drives, where belts tend to rub against pulley flanges. To prevent the belt
from riding off the pulleys, one of them is usually flanged. A recent development has
produced a belt and pulley that use a V-shaped, instead of straight, tooth shape. It runs
quieter than the other shapes and doesn't require pulley flanges.

Undertensioning causes performance problems. The drive may be noisy because belt
teeth do not mate properly with pulley grooves or the belt may prematurely wear from
ratcheting. High forces generated during belt ratcheting are transmitted directly to shafts
and bearings and can cause damage.

Link belts

Link-type V-belts consist of removable links that are joined to adjacent links by shaped
ends twisted through the next link (Fig. 5). With this design, belts can be made up of any
length, reducing inventory. The belts are available in 3L, A/4L, B, C, and D widths in
lengths from 5 to 100 ft.

Fig. 5. Link-type belts are used to make instant V-belt replacements

These belts can transmit the same horsepower as classic V-belts. The links are made of
plies of polyester fabric and polyurethane that resist heat, oil, water, and many chemicals.

Advantages of link belts include quickly making up matched sets, fast installation
because machinery doesn't have to be disassembled, and vibration dampening.

Disadvantages include cost and the possible generation of static charges. The belt should
be grounded when used in high-dust applications.

Alignment
Misalignment is one of the most common causes of premature belt failure (Fig. 6). The
problem gradually reduces belt performance by increasing wear and fatigue. Depending
on severity, misalignment can destroy a belt in a matter of hours. Sheave misalignment
on V-belt drives should not exceed 1/2 deg. or 1/10 -in. of center distance. For
synchronous belts it should not exceed 1/4 deg. or 1/16-in. of center distance.

Fig. 6. Improper drive maintenance is the biggest source of belt drive problems

Angular misalignment (Fig. 7) results in accelerated belt/sheave wear and potential

stability problems with individual V-belts. A related problem, uneven belt and cord
loading, results in unequal load sharing with multiple belt drives and leads to premature
failure.

Angular misalignment has a severe effect on synchronous belt drives. Symptoms such as
high belt tracking forces, uneven tooth/land wear, edge wear, high noise levels, and
potential failure due to uneven cord loading are possible. Wide belts are more sensitive to
angular misalignment than narrow belts.

Fig. 7. Misalignment causes belt wear, noise and excessive temperatures

Parallel misalignment also results in accelerated belt/sheave wear and potential stability
problems with individual belts. Uneven belt and cord loading is not as significant a
concern as with angular misalignment.

Parallel misalignment is typically more of a concern with V-belts. They run in fixed
grooves and cannot free float between flanges to a limited degree as synchronous belts
can. Parallel misalignment is generally not a critical concern with synchronous belts as
long as the belt is not trapped or pinched between opposite sprocket flanges and tracks
completely on both sprockets.

Tension
Total tension required in a belt drive depends on the type of belt, the design horsepower,
and the drive rpm. Since running tensions cannot be measured, it is necessary to tension a
drive statically.

The force/deflection method is most often used. Once a calculated force is applied to the
center of a belt span to obtain a known deflection, the recommended static tension is
established. Most design catalogs provide force and deflection formulas.

With too little tension in a V-belt drive, slippage can occur and lead to spin burns, cover
wear, overheating of the belt, and possibly overheating of bearings. Not enough tension
in a synchronous belt causes premature tooth wear or possible ratcheting that will destroy
the belt and could break a shaft.

When installing a new belt, installation tension should be set higher. Generally 1.4-1.5
times the normal static tension. This is necessary because drive tension drops rapidly
during the seating-in process. This extra initial tension does not affect bearings because it
decays rapidly.

Plant Engineering magazine extends its appreciation to The Goodyear Tire & Rubber
Co. for its cooperation in making the cover photo possible.

Belt application matrix

V-
Application Synchronous belt V-belt ribbed
belt
Double- Heavy- Light-
PolyurethaneRubber Polyurethane
sided duty duty
Speed/Load
High speed 2 2 1 1
Low speed 1 1 2 3
High load 1 2 4 3 3
Low load 1 2 3 4 4
Shock/impulse load 3 4 1 2
 V-
Application Synchronous belt V-belt ribbed
belt
Serpentine drive 1
Serpentine drive w/
2
shock load
Twisted drive 1 2 3
Clutching drive 1 2
Index drive w/high
1
load
Index drive w/low
1 2
load
Drive
characteristics
Reversing direction 1 1 3 4 2
Frequent start/stop 1 1 3 4 2
Start under load 1 2 3
Smooth running 3 2 1 1
Variable speed 1
Oil, chemical
1 3 4 2
environment
High temperature 1 2 4 4 3
Low temperature 1 2 3 4
1=First choice, 4=Last choice Chart courtesy The Gates Rubber Co.

Troubleshooting V-belt drives

Problem Cause Remedy

Belt stretch beyond take-up
Misaligned drive
overloading some belts. Realign and retension drive. Replace
Belts stretch unequally Belt tensile member with a new, matched set, properly
broken from improper installed
installation
All belts stretched Insufficient take-up Check take-up and follow
equally allowance recommended allowance
Greatly overloaded or
Redesign drive
under-tensioned drive
Short belt life
Tensile members damaged Replace with new, matched set,
Rapid belt failure
from improper installation properly installed
Worn sheave grooves Replace sheaves
Under-designed drive Redesign drive
Belt sidewalls soft and Oil or grease Remove source of oil or grease. Clean
sticky. Low adhesion contamination of belts and sheave grooves cloth
Problem Cause Remedy
between cover, plies. belt/sheave moistened with nonflammable, non-
Cross section swollen toxic degreasing agent or commercial
detergent and water
Belt sidewalls dry and High-temperature
Remove source of heat
hard. environment
Low adhesion between
Ventilate drive
cover and plies
Never use dressing on rubber V-belts.
Clean belts and sheave grooves cloth
Deterioration of belt's moistened with nonflammable, non-
Belt dressing
rubber compounds toxic degreasing agent or commercial
detergent and water. Tension drive
properly to prevent slip
Belts rubbing against belt Remove obstruction or align belts to
Extreme cover wear
guard or other obstruction provide proper clearance
Belts slip on starting or
Spin burns on belt Retension drive
load stalls
Bottom of belt cracked Sheaves too small Redesign drive for larger sheaves
Object falling into or Replace with new, matched set of
Broken belts
hitting drive belts
Belt turnover
Excess lateral belt whip Use banded belt
Foreign material in sheave
Remove material. Shield drive
grooves
Misaligned drive Realign drive
Worn sheave grooves Replace sheaves
Tensile member broken Replace belts with new, matched set,
from improper installation properly installed
Carefully align idler pulley on slack
Incorrectly placed idler
side of drive, as close as possible to
pulley
driver sheave
Belt noise
Belt slip Retension drive
Improper driven speed
Incorrect driver/driven
Design error Change sheaves
ratio
Hot bearings
Worn sheave grooves.
Belts bottom out and can't Replace sheaves. Tension drive
Drive overtensioned
transmit power unless properly
overtensioned
Improper tension Retension drive
Motor/belt manufacturer's
Sheaves too small recommendations not Redesign drive
followed
Problem Cause Remedy
Underdesigned bearings or Observe recommended design and
Bearing wear
poor bearing maintenance maintenance
Belts slip and cause heat
Drive undertensioned Retension drive
buildup

Power transmission belting manufacturers

The following companies provided input for this article by responding to a written
request from Plant Engineering magazine. For more information on their product lines,
circle the number on the Reader Service Card or visit their web site.

Horsepower Speed range, Max.

CircleCompany Belt type
range fpm length, in.
221 Fenner Drives V 1/16—6 275—600 none
fennerindustrial.com Flat 0.01—0.1 98—196 none
Link varies by application
222 Emerson Power V 1.3—925 1000—6500 450
emerson-ept.com Synchronous3.8—318 1000—6500 270
Link 1.3—16 1000—5000 450
223 The Gates Rubber Co. V 0.1—1000 1—20,000 663
gates.com Synchronous0.1—1200 1—15,000 270
Flat 0.1—50 1—25,000 126
Link 0.1—50 1—7000 none
Goodyear Tire & Rubber
224 V 0—1000 0—10,000 900
Co.
goodyearptp.com Synchronous0—1100 0—20,000 280
Flat 0—500 0—10,000 1620
226 Shingle Belting Co. V 4—16 1000—5000 open
Flat 1—20 1000—8000 open
Stock Drive 500—12,000
225 V 0.1—4.5 32.5
Products/Sterling Instr. rpm
8000—
sdp-si.com Synchronous0.01—18 149.6
25,000 rpm
2000—
Flat 0.04—0.2 19.7
20,000 rpm

Belt drive advantages

• Cleanliness
• Lubrication-free
• Absorbs shock loads
• Wide selection of speed ratios
• Can provide variable speeds
• Quiet operation
 • Efficiency over 95%
• Transmits power between widely spaced shafts
• Visual warning of failure

Belt drive disadvantages

• Need to retension periodically
• Deterioration from exposure to lubricants or chemicals
• Cannot be repaired, must be replaced