From the pages of Plant Engineering Magazine

BASICS OF BELT DRIVES

Joseph L. Foszcz, Senior Editor, Plant Engineering Magazine -- 9/1/2001

Key concepts
For long life, select the
belt type best suited for
the application.
There are three basic
types of power
transmission belting: flat,
V, and synchronous.
Misalignment is a
common cause of
premature belt failure.
Sections:
Belt types
Alignment
Tension
Sidebars:
Belt drive advantages
Belt drive disadvantages
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 Vbelts 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 Vbelts. 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 highhorsepower 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 fastmoving 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 longcenter-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 Vbelt 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

Synchronous belt

V-belt

V-

Polyurethane Rubber Double- Heavy- Light- Polyurethane

Speed/Load
High speed

Low speed

High load

Low load

Shock/impulse

1
1

Serpentine

2
1

1
3

Serpentine
Twisted drive

4
2

Twisted drive

Clutching drive

Index drive
w/high load

Index drive
w/low load

Drive
characteristics
Reversing
direction

Frequent
start/stop

Start under
load

Smooth running

Variable speed

Oil, chemical
environment

High
temperature

Low
temperature

3
2

3
3

1=First choice, 4=Last choice Chart courtesy The Gates Rubber Co.
Troubleshooting V-belt drives
Problem
Cause

Remedy

Belt stretch beyond take-up

Belts stretch unequally

Misaligned drive
overloading some belts.
Belt tensile member
broken from improper
installation

Realign and retension drive. Replace

with a new, matched set, properly
installed

All belts stretched

equally

Insufficient take-up
allowance

Check take-up and follow

recommended allowance

Greatly overloaded or
under-tensioned drive

Redesign drive

Tensile members
damaged from improper
i t ll ti

Replace with new, matched set,

properly installed

Short belt life

Rapid belt failure

installation
Worn sheave grooves

Replace sheaves

Under-designed drive

Redesign drive

Belt sidewalls soft and

sticky. Low adhesion
between cover, plies.
Cross section swollen

Oil or grease
contamination of
belt/sheave

Remove source of oil or grease.

Clean belts and sheave grooves
cloth moistened with nonflammable,
non-toxic degreasing agent or
commercial detergent and water

Belt sidewalls dry and

hard.

High-temperature
environment

Remove source of heat

Low adhesion between

cover and plies

Ventilate drive

Deterioration of belt's
rubber compounds

Belt dressing

Never use dressing on rubber Vbelts. Clean belts and sheave

grooves cloth moistened with
nonflammable, non- toxic degreasing
agent or commercial detergent and
water. Tension drive properly to
prevent slip

Extreme cover wear

Belts rubbing against belt

guard or other obstruction

Remove obstruction or align belts to

provide proper clearance

Spin burns on belt

Belts slip on starting or

load stalls

Retension drive

Bottom of belt cracked

Sheaves too small

Redesign drive for larger sheaves

Broken belts

Object falling into or hitting Replace with new, matched set of

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

from improper installation

Replace belts with new, matched set,

properly installed

Incorrectly placed idler

pulley

Carefully align idler pulley on slack

side of drive, as close as possible to
driver sheave

Belt slip

Retension drive

Belt noise

Improper driven speed

Incorrect driver/driven
ratio

Design error

Change sheaves

Hot bearings
Drive overtensioned

Worn sheave grooves.

Belts bottom out and can't Replace sheaves. Tension drive
properly
transmit power unless
overtensioned
Improper tension

Retension drive

Sheaves too small

Motor/belt manufacturer's
recommendations not
followed

Redesign drive

Bearing wear

Underdesigned bearings
or poor bearing
maintenance

Observe recommended design and

maintenance

Drive undertensioned

Belts slip and cause heat

buildup

Retension drive

Power
transmission
belting
manufacturers
The following
companies provided
input for this article by
responding to a written Company
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.

Belt type

Speed Max.
Horsepower
range, length,
range
fpm
in.

1/166

275
600

none

0.010.1

98
196

none

Circle
221

Fenner Drives

fennerindustrial.com Flat

222

Link

varies by application

Emerson Power

1.3925

1000
450
6500

emerson-ept.com

Synchronous 3.8318

1000
270
6500

223

224

226

225

Link

1.316

1000
450
5000

The Gates Rubber

Co.

0.11000

1
663
20,000

gates.com

Synchronous 0.11200

1
270
15,000

Flat

0.150

1
126
25,000

Link

0.150

1
7000

Goodyear Tire &

Rubber Co.

01000

0
900
10,000

goodyearptp.com

Synchronous 01100

0
280
20,000

Flat

0500

0
1620
10,000

416

1000
open
5000

Flat

120

1000
open
8000

Stock Drive
Products/Sterling
Instr.

0.14.5

500
12,000 32.5
rpm

sdp-si.com

Synchronous 0.0118

8000
25,000 149.6
rpm

Flat

2000
20,000 19.7
rpm

Shingle Belting Co.

0.040.2

none

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

Copyright 2001 Reed Business Information