SYNCHRONOUS BELT DRIVES

Synchronous Belt Drives

 Synchronous belts are constructed with ribs or teeth across the underside
of the belt
 Synchronous Belt Drives
 The teeth mate with corresponding grooves in the driving and
driven pulleys, called sprockets, providing a positive drive without
slippage.
 Therefore, there is a fixed relationship between the speed of the
driver and the speed of the driven sprocket.
 Synchronous belts are often called timing belts and when properly
designed will have an efficiency as high as 98%.

Synchronous belts can therefore be used for applications such as automatic

machinery where a definite motion sequence or indexing is necessary.
 Synchronous Belt Drives
 Synchronous action is critical to the successful operation of such systems
as printing, material handling, packaging, and assembly.
 Synchronous belt drives are increasingly being considered for applications
in which gear drives or chain drives had been used previously.

Because of the nature of synchronous belt mechanisms, they are also called
‘timing belt’ mechanisms. And they can be used in machinery where precision is
very important. At power transmission of 3D printers, robotic mechanisms,
synchronous belt drive mechanisms are generally used.
 If you look at the front of the engine under the timing cover, you’ll find a tooth belt in some cases
(although in most current vehicles, this belt is replaced by a chain).

 It’s attached to the crankshaft and camshaft via several pulleys. Also called a gilmer drive belt many
years ago.

 The timing belt has two jobs.

1. It powers the engine’s camshaft
2. It keeps it exactly in sync with the crankshaft. This ensures that the valves open and close at the right
time. That’s why it’s called a timing belt. It times the valvetrain.
• Most internal combustion engines utilize a
similar design, with a crankshaft at the
bottom, and a camshaft above it. Both shafts
spin, with the crankshaft being connected to
the pistons; rotating as the pistons move up
and down. The camshaft uses a series of
lobes to open and close the valves, which let
air in and out of your engine.

• Since it’s crucial that the valves open and

close at the correct time, the crankshaft and
camshaft are connected by a timing belt, or
timing chain.

• If this valve timing is not correct, the engine

will perform poorly – or worse, may damage
itself.

• If your car is equipped with a timing belt, it is

the single most important maintenance item
on your vehicle.
 Advantages of Synchronous Belt
Drives
 Synchronous belts provide a positive and trouble-free
transmission of power and offer these advantages:
1. High capacity
2. Highly accurate registration
3. Low vibration
4. Low noise
5. No lubrication required
6. No stretching due to wear
7. Corrosion resistance
8. Abrasion resistance
9. Clean operation
Sizes and Shapes for Synchronous
Belts
Sizes and Shapes for Synchronous
Belts
 Belt Tooth Shape

(c) better timing and indexing

(b) high load-carrying capacity and is used in high-
torque applications
(a) GT(Gates Tooth)-modified curvilinear tooth profile
Synchronous Belt Construction
Sprockets and Bushings
Belt Dimensions
 Various widths of belts are available for each given pitch to
provide a wide range of power transmission capacity.
 Belts are also available in various perimeter lengths. This
allows a two-sprocket belt drive system to have a wide
range of center distances
Belt Designation: 1760-8MGT-30
 The first set of numbers (in mm) represents the belt
perimeter, the second set represents the belt pitch with the
style of the tooth profile, and the last number represents
the belt width.
 Sprocket Designations
 Table 7–4 shows the available sprockets with a pitch of 8 mm.
 The corresponding taper-lock bushing number is given for each sprocket
and is based on the sprocket width.
Sprocket Designation: P72-8MGT-50
 The first set of numbers (in mm) represents the number of teeth, the
second set represents the belt pitch with the style of tooth profile, and the
last number is the belt width.
 Taper-Lock Bushing
• The taper-lock
bushing minimum
and maximum bore
diameters will limit
the size of the shaft
for a specific
sprocket.
• The three half holes
are aligned with the
three half holes in
the sprocket and are
used to tighten the
taper-lock bushing to
Taper-Lock Bushing
 When installing or removing a Taper Lock bush, it is imperative that no lubrication be
used between the taper.
 The presence of lubricant on the tapered surfaces is not desirable, as the taper bushing
relies on friction to operate effectively, and lubricants reduce friction.
 We use industry standard Part Numbers to identify the specifications of each Taper Lock
bush or Taper bush. For example:
Sprockets with 8mm Belt Pitch
Taper-Lock Bushing
 Sprocket Designations
 Table 7–4 shows the available sprockets with a pitch of 8 mm.
 The corresponding taper-lock bushing number is given for each
sprocket and is based on the sprocket width.
General Selection Procedure for Synchronous Belt
Drives
1. Specify the speed of the driving sprocket (typically a motor
or engine) and the desired speed of the driven sprocket.
2. Specify the rated power for the driving motor or engine.
The rated power of the motor or engine is based on the
calculated power of the driven machine.
3. Determine a service factor (SF) using Table 7–8.
4. Calculate the design power by multiplying the driver rated
power by the service factor.
General Selection Procedure for Synchronous Belt
Drives
5. Determine the required pitch of the belt using the belt pitch selection
guide Figure (7-27). The belt pitch is based on the design power and
the angular velocity of the faster (smaller) sprocket.
6. Calculate the velocity ratio VR between the driver and driven
sprockets.
7. Select the candidate combinations using Table 7–7 of the number of
teeth in the driver sprocket to that in the driven sprocket that will
produce the calculated velocity ratio, VR.
General Selection Procedure for Synchronous Belt
Drives

8. Eliminate the sprocket combinations that will not work due to space
limitations and shaft diameter requirements. Some of the larger sprockets
may interfere with the machine or guarding and can be eliminated due to
these space limitations.
9. Using the desired range of acceptable center distances, determine a
standard belt length that will produce a suitable value. Table 7–7 shows
that the center distance is determined by the belt length and sprocket
velocity ratio.
General Selection Procedure for Synchronous Belt
Drives

10. Selection of the width of the belt: An 8-mm pitch belt is available in
four different widths: 20 mm, 30 mm, 50 mm, and 85 mm. The belt
width selection Tables 7–9 and 7–10 are shown for the 30-mm and 50-
mm wide belts.
 You will notice for a given sprocket size as the speed increases, the
power rating of the belt increases.
 A larger sprocket will decrease the belt width required and yield a
longer service life. The belt width should not exceed the sprocket
diameter.
General Selection Procedure for Synchronous Belt
Drives
 Catalog data will show factors less than 1.0 for shorter belt
lengths and greater than 1.0 for longer belt lengths.

11. Calculate the belt linear velocity. Belt speeds above 3500 fpm
increase the noise level of the synchronous belt drive.
General Selection Procedure for Synchronous Belt
Drives

12. Specify the final design details for the belt drive system. This
includes all sprockets, type and bore size of taper-lock bushings,
belt, and tensioner if required. Summarize the design, check
compatibility with other components of the system, and prepare
the purchasing documents.
 Example Problem
For the belt drive layout shown in Figure 7–28 perform
the following calculations for the kinematics of the
drive:
 Example Problem
For the belt drive layout shown in Figure 7–28 perform the
following calculations for the kinematics of the drive:
a. Specify the number of teeth and the pitch diameter of each
sheave.
b. Calculate the velocity ratio of the belt drive and the angular
velocity of the driven sheave.
c. Calculate the belt linear velocity.
d. Determine the center distance using a 1200- MGT-30 belt.
 Example Problem
Figure 7–29 shows a 20-hp electric motor driving a gear pump using a
synchronous belt drive. The normal torque motor speed is 1750 rpm and the
gear pump speed is to be 875 rpm. The drive system is on a steel mounting
plate with slots permitting an adjustment of the pump position by 0.375 in
from the nominal center distance of 22.00 in. The motor shaft diameter is
1.625 in and the gear pump shaft diameter is 1.375 in. The sprocket on the
pump shaft cannot exceed 14.00 in due to potential interference with the
base plate. The pump will operate 16–24 h/day, 5 days per week. Specify the
complete drive system.
 Example
Sprocket Designations
Problem
 Example Problem
Given:
 Motor: 20 hp; 1750 rpm; Normal torque; shaft diameter = 1.625
in.
 Gear pump: 875 rpm; shaft diameter = 1.375 in; Maximum OD =
14.00 in.
 Center distance between motor and pump shafts = 22.00 in 0.375
in; The range is 21.625 in minimum to 22.375 in maximum.
 Operating conditions: 16 to 24 h/day, 5 days per week.
 Specify the synchronous belt drive system including driving and
driven sprockets, bushings, and the belt.
Alternate Configurations for Synchronous
Belt Drives
• The tensioner may decrease the life of the belt and the belt manufacturer should be
consulted.
 Twin Power Belts

Serpentine Belt drive

configurations
Do all cars have serpentine belts?
 Most modern vehicles do have serpentine
belts, but older models can have v-belts. The
serpentine belt is a single, continuous belt
that operates multiple devices in an engine
including the alternator, air conditioner,
water pump, and power steering pump. In
engines that have v-belts.
 Individual belts operate these components
and the automobile can have up to four
different belts.
 The advantage of a serpentine belt is its
efficiency.
 Having a single belt increases fuel economy
and available power.
 The disadvantage of a serpentine belt is if it
breaks several critical functions of the engine
are lost and the engine will conk out leaving
you stranded.
CHAIN DRIVES
 Chain Drives
 When transmitting power between rotating shafts, the chain engages
mating-toothed wheels, called sprockets.
 The most common type of chain is the roller chain, in which the roller on
each pin provides exceptionally low friction between the chain and the
sprockets.
 Roller Chain
 Roller chain is classified by its pitch, the distance between
corresponding parts of adjacent links.
 U.S. Standard roller chain carries a size designation from 40
to 240.
 For example, the no. 100 chain has a pitch of 10/8 or 1-1/4
in.
 The average tensile strengths of the various chain sizes are
also listed in Table 7–12.
 ISO standards define several different chain types, data for
three of which are listed in Table 7–13.
Roller Chain
Chain
Drives
A chain is a power
transmission element
made as a series of
pin-connected links.
The design provides
for flexibility while
enabling the chain to
transmit large tensile
forces.
Roller
Chains
Synchronous Belt Drives
Metric Chain sizes for Heavy Power
Transmission
Metric Chain sizes for Agricultural uses
Roller Chain Shapes
 Double Pitch Roller Chain has the
same basic construction as Standard
Roller Chain, but double pitch means
the chain pitch is twice as long, has
flat-shaped link plates, and longer
attachments.
 Design of Chain Drives
 The rating of chain for its power transmission capacity considers
three modes of failure:
1. fatigue of the link plates due to the repeated application of the
tension in the tight side of the chain.
2. impact of the rollers as they engage the sprocket teeth.
3. galling between the pins of each link and the bushings on the
pins

The ratings are based on empirical data with a smooth driver and a
smooth load (service factor = 1.0) and with a rated life of
approximately 15 000 h
Design of Chain Drives
 FATIGUE
1. As the chain passes around the sprocket wheel, it is subjected to a tensile force,
which varies from a max on the tight side to a min on the loose side.
2. The chain link is subjected to one complete cycle of fluctuating stresses during
every revolution of the sprocket wheel which results in fatigue failure.
 IMPACT
1. The engagement of the rollers with the teeth of the sprocket results in impact which
leads to breakage of roller or bushing.
2. By increasing the number of teeth on the sprocket or reducing chain tension and
speed we can reduce the magnitude of the impact force.
 GALLING
1. Galling is a stick-slip phenomenon between the pin and the bushing
2. When the chain tension is high, welds are formed at the high spots of the contacting
area.
3. Such microscopic weld immediately broke down due to the relative motion of the
contacting surface, eventually leading to excessive wear even in the presence of the
lubricant.
Chain Wear
 Sometimes, the wear between the pin and bushing causes the chain to elongate
(grow longer but not stretch) until the chain will not fit the sprockets correctly or
will not maintain correct spacing or timing.
 Chain wear elongation usually progresses through three stages as shown in
Figure. First, there is a short period of rapid initial or run-in wear. In this first
stage, high spots are worn off the pins and bushings, and minor misalignments
are quickly worn away.
 Second, there is a period of constant slow, or lubricated wear. In this second
stage, the pins are seated properly in the bushings and the bearing areas are
normally well-lubricated.
 And finally, there is another period of rapid, or terminal wear. In this final stage,
lubrication may have become ineffective or failed completely, or the hard case
on pins and bushings may have worn through, or chain elongation on the
sprocket may have caused loads on individual joints to increase dramatically.
Chain Wear

Chain elongation
process
Lubrication effects on chain life
 The majority of chain drives and conveyors will perform better and
last longer when timely and adequate lubrication is provided. One
rule-of-thumb is that proper lubrication can extend chain life by as
much as 100 times

 Rapid joint wear can cause early

loss of timing in a conveyor. Lack of
lubrication can increase friction and
power consumption and cause a
harmful temperature rise.
 Design of Chain Drives
 Tables 7–14 to 7–16 list the rated power for three sizes of
standard chain: no. 40 (1/2 in), no. 60 (3/4 in), and no. 80
(1.00 in).
 These are typical of the types of data available for all chain
sizes in manufacturers’ catalogs and can be used for
problems in this book.
 Design of Chain Drives
 The ratings are based on the speed of the smaller sprocket
and an expected life of approximately 15 000 h.
 For a given speed, the power capacity increases with the
number of teeth on the sprocket.
 For a given sprocket size (a given number of teeth), the
power capacity increases with increasing speed up to a
point; then it decreases.
 Fatigue due to the tension in the chain governs at the low
to moderate speeds; impact on the sprockets governs at
the higher speeds.
 Design of Chain Drives
 The ratings are for a single strand of chain. Although
multiple strands do increase the power capacity, they do not
provide a direct multiple of the single-strand capacity.
 Multiply the capacity in the tables by the following factors.
 Two strands: Factor = 1.7
 Three strands: Factor = 2.5
 Four strands: Factor = 3.3
 The chain manufacturer’s ratings are for a service factor of
1.0. Specify a service factor for a given application as shown
in Table 7–16.
 DESIGN GUIDELINES FOR CHAIN
DRIVES
1. The minimum number of teeth in a sprocket should be 17
unless the drive is operating at a very low speed, under
100 rpm.
2. The maximum speed ratio should be 7.0, although higher
ratios are feasible. Two or more stages of reduction can be
used to achieve higher ratios.
3. The center distance between the sprocket axes should be
approximately 30 to 50 pitches (30–50 times the pitch of
the chain).
 DESIGN GUIDELINES FOR CHAIN
DRIVES
4. The larger sprocket should normally have no more than 120 teeth.
5. The preferred arrangement for a chain drive is with the centerline
of the sprockets horizontal and with the tight side on top.
6. The chain length must be an integral multiple of the pitch, and an
even number of pitches is recommended. The center distance
should be made adjustable to accommodate the chain length and
to take up for tolerances and wear.
 DESIGN GUIDELINES FOR CHAIN
DRIVES
➭ Chain Length in Pitches

Center Distance in Pitches

The computed center distance assumes no sag

in either the tight or the slack side of the chain,
and thus it is a maximum.
 DESIGN GUIDELINES FOR CHAIN
DRIVES
7. The pitch diameter of a sprocket with N teeth for a chain with a
pitch of p is:
➭ Pitch Diameter of Sprocket

8. The minimum sprocket diameter and therefore the minimum

number of teeth in a sprocket are often limited by the size of the
shaft on which it is mounted. Check the sprocket catalog.
 DESIGN GUIDELINES FOR CHAIN
DRIVES
9. The arc of contact,, often called the angle of wrap, of the chain on
the smaller sprocket should be greater than 120°.
➭ Angle of Wrap Smaller Sprocket

10. For reference, the arc of contact, u2, on the larger sprocket is:
➭ Angle of Wrap Large Sprocket
 Synchronous Belt Drives
 Synchronous belts are constructed with ribs or teeth across the
underside of the belt
 Lubrication
 It is essential that adequate lubrication be provided for chain
drives.
 There are numerous moving parts within the chain, along
with the interaction between the chain and the sprocket
teeth.
 The designer must define the lubricant properties and the
method of lubrication.
 Lubrication
 Lubricant Properties. Petroleum-based lubricating oil similar
to engine oil is recommended.
 Its viscosity must enable the oil to flow readily between chain
surfaces that move relative to each other while providing
adequate lubrication action.
 Table 7–18 gives the recommended lubricants for different
ambient temperatures.
Lubrication
 Design of Chain Drives
 The ratings are for a single strand of chain. Although
multiple strands do increase the power capacity,
they do not provide a direct multiple of the single-
strand capacity.
 Lubrication
 Method of Lubrication. The American Chain Association
recommends three different types of lubrication depending on the
speed of operation and the power being transmitted.
 See Tables 7–14 to 7–16 or manufacturers’ catalogs for
recommendations.
 Lubrication
Method of Lubrication.
 Type A. Manual or drip lubrication: For manual
lubrication, oil is applied copiously with a brush or
a spout can, at least once every 8 hours of
operation
Drip Lubrication: Usually 4-20 drops of oil per
minute. Excess oil should be caught in a drip pan.

 Type B. Bath or disc lubrication: The chain cover

provides a sump of oil into which the chain dips
continuously. Alternatively, a disc or a slinger can
be attached to one of the shafts to lift oil to a
trough above the lower strand of chain.

 Type C. Oil stream lubrication: An oil pump

delivers a continuous stream of oil on the lower
part of the chain.
The oil is pumped under pressure to nozzles that
deliver a stream or spray onto the lower span of the
chain from the inside of the loop. The oil spray should
be distributed uniformly across the entire width of the
chain.
 Lubrication
Method of Lubrication
1) Type A
 Manual or drip lubrication: For manual
lubrication, oil is applied copiously with a brush, or a
spout can, at least once every 8 hours of operation.
 The amount of oil and the frequency of its application
must be adequate to prevent the formation of a
reddish-brown discoloration in the chain joints.
 In drip lubrication, oil is dripped between the link
plate or sidebar edges at a rate from four to 20 drops
per minute, depending on speed.
 The amount of oil and the frequency of its application
must be adequate to prevent the formation of a
reddish-brown discoloration in the chain joints.
Lubrication
2) Type B
 Bath or disc lubrication: The chain cover provides a
sump of oil into which the chain dips continuously.
 Alternatively, a disc or a slinger can be attached to one of
the shafts to lift oil to a trough above the lower strand of
chain.
 The chain should always run above the oil level in the
casing.
Lubrication

3) Type C
 Oil stream lubrication: An oil pump delivers a continuous
stream of oil on the lower part of the chain.
 the oil is pumped under pressure to nozzles that deliver a
stream or spray onto the lower span of the chain from the
inside of the loop
 The oil spray should be distributed uniformly across the entire
width of the chain.
 The excess oil is collected in the bottom of the sump and
returned to the pump via a reservoir.
 Anoil cooler may be used to keep oil temperature below the
maximum limit.
Lubrication
Lubrication
 Example Problem
Figure 7–37 shows a drive for a
heavily loaded conveyor for use in
the fields of a large commercial
produce farm to take heavy
containers of potatoes from the
field onto trucks that will transport
them to the processing plant. The
conveyor is to be driven by a
gasoline engine delivering 15.0 hp
at a speed of 900 rpm. The
conveyor pulley speed is to be 230
to 240 rpm. Design the chain drive.
 Example Problem

Step 1: Specify a service factor and compute the design power. From
Table 7–17.
Step 2. Compute the desired ratio.
Step 3. Refer to the tables for power capacity (Tables 7–14 to 7–16),
and select the chain pitch.
Step 4. Compute the required number of teeth on the large sprocket.
Step 5. Compute the actual expected output speed
Step 6. Compute the pitch diameters of the sprockets.
 Example Problem

Step 7. Specify the nominal center distance.

Step 8. Compute the required chain length in pitches.
Step 9. Specify an integral number of pitches for the chain length and
compute the actual theoretical center distance.
Step 10. Compute the angle of wrap of the chain for each sprocket.
Summarize the design
 Example

Create an alternate design for the conditions of Example Problem 7–5 to produce a
smaller drive
References
 Chapter 7, ‘Belt Drives, Chain Drives,
and Wire Rope’
 Machine Elements in Mechanical Design
 By Robert L. Mott, Edward M. Vavrek, Jyhwen
Wang, 6th edition