1

Belts and rope drives

1.1 Introduction
Power source is always required to process the textile materials in order
to convert it into a final product. An electric power is converted to rotational
energy by means of electric motor and it is transferred to the machines to
perform various jobs. Power can be transmitted between two parts or shafts,
either by negative or positive means. In the case of negative method of
power transmission there is slippage, whereas in the positive one there is
no slippage. The belts and rope drives are negative methods of power
transmission. This chapter deals in detail about the various methods of
belt and rope drives and highlights their merits and demerits.

1.2 Various methods of drive

Generally machines are driven by the following two methods:
1. Individual drive
2. Group drive

1.2.1 Individual drive

The motor may drive the machine shaft directly through a coupling, rope,
belt, chain and gears. Hydraulic actuators, D.C. motors, A.C. motors or
Stepping motors are used for machine drives.

1.2.2 Group drive

A prime mover, either a diesel engine or electric motor drives a common
shaft running through a shed from which all the machines gets its drive by
a belt or rope.

3
4 Mechanics and calculations of textile machinery

1.3 Applications of belt and rope drives in textile

industry
(a) Drives in blow room: motor to mono-cylinder, ERM beater, mixing-
bale-opener and stripping and take-off rollers in unimixer.
(b) Drives from top coiler to base coiler plate of modern carding machine.
(c) Main drives in all spinning, texturing machines and compressors.
(d) Motor to licker-in and cylinder.
(e) Cleaner roller of stripper roller at the delivery side.
(f) Motor to flat-stripper roller.
(g) Crossed-flat-belt drive from cylinder to a pulley from where further
drive (consisting of clutch, worm/worm gear) to the driving-shaft of
flat in a modern card.
(h) Drive to drafting rollers and other rolling elements in a single delivery
draw frame. The use of flat belts instead of timing belts or gears
reduces periodic faults. The fibre, dirt accumulation on the teeth of
toothed wheels used in timing belt drive increases the periodic faults.
(i) Drives to opening rollers, friction drums, and take-off rollers of DREF
spinning machine.
(j) Drive to rotor in a rotor-spinning machine.
(k) Main drive from motor in draw-texturing machine.
(l) Drive to creel-rollers of a modern draw frame.
(m) Tape drives used in driving spindles in a group at ring spinning, ring
doubling and TFO.
(n) Flat belt drives used in driving spindles in a group at ring spinning
and TFO.
(o) Variator pulley drives at ring spinning and more.

1.4 Transmissions of power by belts and ropes

The belts and ropes transmit power through the friction between belt or
rope and rim of the pulley. The function of a belt and rope drive is to
transmit rotational motion and torque from one shaft to another, smoothly,
quietly and inexpensively. Belt and rope drives provide the best overall
combination of design flexibility, low cost, low maintenance, ease of
assembly and space savings.
Compared to other forms of power transmission, belt drives have the
following advantages:
(a) They are less expensive than gear or chain drives.
(b) They have flexible shaft centre distances, where gear drives are
restricted.
(c) They operate smoothly and with less noise at high speeds.
 Belts and rope drives 5

(d) They can be designed to slip when an overload occurs in the machine.
(e) They require no lubrication, as do chains and gears.
(f) They can be used in more than one plane.
(g) They are easy to assemble and install and have flexible tolerances.
(h) They require little maintenance.
(i) They do well in absorbing shock loading.
They do not have an indefinite life. While in use, they need regular
inspection schedule to guard against wear, aging and loss of elasticity.
There is some slip and creep in the belts, and so the angular velocity
ratio between the driver and driven is neither constant nor equal to the
ratio of the pulley diameters (exemption – timing belts). During working,
the belt tension is sag on one side of the driving pulley and tight on another
side. The belt should be arranged such that the tight side is on the bottom
side and slack side on top of the pulleys. This is shown in the Fig. 1.1.
Otherwise, the angle of contact between the belt and rim of the pulley
reduces, decreasing the power transmission of the belt.

1.5 Different methods to adjust the belt tensions

When belts are in operation, they stretch over time. Machines that utilize
a belt drive need some feature that can compensate for the belt stretch,
such as an adjustable motor base, or an idler pulley.

D rive r
L

S lack side M
D rive n

+ A B
+

R
Tigh t sid e
Q

1.1 Slack and tight side of belt.

6 Mechanics and calculations of textile machinery

An idler pulley is used to maintain constant tension on the belt. It is

usually placed on the slack side of the belt and is preloaded, usually with
springs, to keep the belt tight (Fig. 1.2).
In the case of flat belts with joints or hinges, a short length of belt is cut
periodically to remove the slackness in the belts.
For endless belts (some flat belts and V belts), the centre distance
between pulleys is slightly increased by means of an adjusting screw. In
case of drive from motor to main shaft of a machine, provision is made to
move the motor away from the driven pulley through adjusting screws on
the bed of the motor as shown in Fig. 1.3.
Other way of adjusting the belt tension is through mounting the motor
on to a bed with pivot as shown in Fig. 1.4.

1.6 Types of belts

Belts are typically made of continuous construction of materials, such as
rubberized fabric, rubberized cord, reinforced plastic, leather, and fabric
(i.e., cotton or synthetic fabric).
There are six types of belts as listed below:
1. Flat belt 4. Cog belt
2. V-belt 5. Timing belt
3. Multi-V-belt 6. Round belt or rope drive

A d ju sta ble w e ig h t

Id le r p ulle y
L oo se sid e

Tig h t sid e

1.2 Idler pulley with adjustment weight.

 Belts and rope drives 7

M otor

B a se p la te w ith slo ts

1.3 Adjusting screws on motor bed.

Ts

Tt

1.4 Motor bed with pivot.

Types of belt-drive
There are two common types of belt drives: (a) open-belt drive, and (b)
crossed-belt drive. In the open-belt drive the driver and the follower move
in the same direction. While in the crossed-belt drive, the sense of rotation
of the driven pulley must be opposite to that of the driving pulley. These
two arrangements, illustrated in Fig. 1.6, are used to connect shafts which
are parallel.
8 Mechanics and calculations of textile machinery

1.5 Types of belts.

1.6 (a) Quarter-turn drive. (b) Right angle drive.

1.6.1 Flat belt

A flat belt is shown in Fig. 1.5(a), Fig. 1.7 and Fig. 1.8. It is the simplest
type but is typically limited to low-torque applications because the driving
force is restricted to pure friction between the belt and the pulley. The
 Belts and rope drives 9

1.7 Flat pulley and belt.

1.8 Flat belt application in textile mills: Carding machine; Wool and cotton cards.

properties such as flexibility, durability, strength of the belt and high

coefficient of friction between the belt and the rim of the pulleys are to be
considered for the construction of flat belts.
Group-drive systems were in use in olden days, which drives several
machines through pulleys and flat belts. Earlier, flat leather belts were
available in two varieties, viz., oak-tanned and mineral or chrome-tanned.
They were made by using few layers of leather cemented together to get
the required thickness. Commercial leather belts were specified according
to the number of layers, such as single-, two-, three- and four-ply belts.
These belts offer moderate coefficient of friction between rim of the pulley
and the belt. Over a period of time, they become rigid and exhibit creep.
Also they have poor resistance against moisture.
10 Mechanics and calculations of textile machinery

1.9 Flat tape drive in spinning/doubling/TFO machines.

Nowadays, flat belts are made of urethane or rubber matrix, reinforced

with fabric or nylon cords or steel wire. They are strong and durable to
withstand higher speeds. Flat belts are quite, efficient at high speeds, and
can transmit large amounts of power over long distances. The coefficients
of friction of leather, polyamide and urethane flat belt are 0.4, 0.5 to 0.8
and 0.7, respectively.

Geometry of belt drive

Open and crossed-flat belt drives
The length of the belt in an open belt drive is found by the following
equation:
L = 2C + [π (D1 +DS)/2] + [(D 1 – D S)2/4C] … (1)
For crossed belt as shown in Fig. 1.12, the following equation is valid.
L = 2C + [π (D1 +DS)/2] + [(D 1 – D S)2/4C] … (2)

As ά = ά S = ά 1 = 2[180 – cos–1{(D 1 +DS)/2C}] … (3)

Power ratings
Power rating of flat belt depends upon its maximum possible tension. This
 Belts and rope drives 11

ω1 S lack side

Ds

vb - B e ll sp ee d
D1
Tigh t sid e

N o te : D 1 a nd D s are
p itch diam eters

1.10 Geometry of belt drive.

C
β

αs α1
β
Ds D1

1.11 Open belt drive.

1.12 Cross belt drive.

12 Mechanics and calculations of textile machinery

is obtained from the equation:

PT = (TA × v × F P × FV) ÷ K
where, PT = Power transmitted; TA = 2Ti = Allowable belt tension (N);
Ti = Initial belt tension (N); v = Belt speed (m/sec); FP = Pulley or belt
correction factor; FV = Velocity correction factor; K = Belt service factor.

Maximum power transmission of belt

(a) Power transmission by belts

Power in kW = (T1 – T2) y/1000

where, T1 and T 2 = Belt tensions in N, y = Belt speed in m/s.
= 2π NMt / 60,000
where, Mt = Torque in Nm and Mt = (Tl – Ts) × D/2; D = Diameter of
pulley in metres.

(b) Relation between Tl and Ts

Tl/Ts = eµθ,
Where, µ – co-efficient of friction and θ – angle of overlap over smaller
pulley in radians. [Radian = θπ/180°]

(c) Centrifugal tension in a belt

Tc = ρv2, π = mass of belt per unit length in kg/m.
Tc = ρv2A, ρ = mass of belt per unit volume in kg/m3.
A = Area of cross-section of belt in m2.
Initial tension = (Tl + T s) / 2 [When Tc is negligible]

= (Tl + T s + 2Tc) / 2 [When Tc is considered]

T max = Tl + Ts

(d) For absolute maximum power

Tc = T max/3
From the above equation, optimum belt speed for absolute maximum
power can be calculated.
 Belts and rope drives 13

(e) Rope or V-belt drive

Tl /Ts = e [µθ/sinα], where, α = semi-groove angle.

Selection of pulley diameter

The diameter of the driving pulley can be determined from the expression

D = 1.114 × 3 ( P ÷ N ) mm

where, D = diameter of the driving pulley; P = power transmitted in

kW; N = rpm of the driving pulley.
A pulley can be selected from the belt manufacturer’s catalogue. A pulley
whose size is nearest to the dimension as per the design calculation may
be selected. As a result, the belt velocity and the size of the driven pulley
would also vary.

Special purpose belt drives

Flat belts with cone drums or cone pulleys are used for variable speed
drives in blow rooms and speed frames as shown in Fig. 1.25. The belt is
moved axially for varying the output speed. For stepped pulleys, V-belt or
round belt can be used with grooved sheaves as shown in Fig. 1.26. The
stepped pulleys with V-belts are commonly used in main drives of many
textile machines.
Speed adjustment of driven pulley is possible with a variator-drive using
adjustable grooved/conical discs and V-belt without varying the speed of
the motor. A variator drive used in ring frame is shown in Fig. 1.27. By
shifting the driver and driven discs axially, the effective diameters of the
discs over which the axis of the belt passes are simultaneously varied,
thus varying the output speed. To increase the output speed or spindle
speed, the driver discs are moved closer to each other and the driven discs
moved apart and vice versa. A control device through hydraulic or
pneumatic pistons and lever mechanisms effect the movement of the discs.
The spindle speed can be varied in several steps depending on the doff-
position and the end-breakage rate of the yarn. This permits higher
throughput of yarn as optimum spindle speed is selected at any instant.

1.6.2 V-belt
A V-belt is shown in Fig. 1.5(b). It is the most widely used type of belt,
particularly in automotive and industrial machines. V-belts comprise cord
tensile members located at the pitch line, embedded in a relatively soft
14 Mechanics and calculations of textile machinery

matrix which is encased in a wear-resistant cover. V-belts are generally

made of rubber covered with rubber or polymer impregnated fabric and
reinforced with nylon or polyester, glass, aramid or steel wires/cords. The
wedging action of a V-belt in a pulley groove results in a drive which is
more compact than a flat belt drive, but short centre V-belt drives are not
conducive to shock absorption. The V shape causes the belt to wedge tightly
into the pulley, increasing friction and allowing higher operating torque.
A V-belt or rope meshing in a V-shaped groove of the pulley increases
greatly the frictional resistance to slipping, for a given maximum belt
tension, as compared to flat belt. The rope or V-belt does not rest on the
bottom of the groove but wedges itself into the groove.
The cross-section of a V-belt is trapezoidal as shown in Fig. 1.13. The
thickness b ranges from 8 to 19 mm and the width ranges from 12.5 to 38
mm. The belt section angle may be around 40°. The V-belts are available
in A, B, C, D, E sections. The width, thickness, minimum sheave diameter
increase from section A to E, in other words, belts become heavier from
section A to E.

S kin

Tensile
m em ber

m atrix
pitc h
G ap diam eter

1.13 V- belt and grooved pulley.

1.6.3 Multi-V-belt
A multi-V-belt is shown in Fig. 1.5(c) and Fig. 1.14. Its design is identical
to several V-belts placed side by side but is integrally connected. It is used
to increase the amount of power transferred. If a single V-belt is inadequate
for power transmission, then multiple belts and corresponding multi-
grooved pulleys (Fig. 1.15) are necessary; this pulley is equipped with a
tapered bush for axle clamping without the stress concentration associated
with a key.
 Belts and rope drives 15

1.14 Multi-V-belt.

1.15 Multi-grooved pulleys.

The rather extreme short-centre drive above illustrates a problem with

multiple belts – how to ensure equitable load sharing between flexible
belts whose as-manufactured dimensional tolerances are significantly
looser than those of machined components, for example.

1.6.4 Cog belt

A cog belt is shown in Fig. 1.5 and Fig. 1.16. Its design is similar to a V-belt
but has grooves formed on the inner surface known as cogging which
alleviate deleterious bending stresses as the belt is forced to conform to
pulley curvature. This feature increases belt flexibility, allowing the belt to
turn smaller radii, and hence can be used on smaller pulleys, reducing the
size of the drive. The belt illustrated also incorporates slots on the underside.

1.16 Cog belt and pulley.

16 Mechanics and calculations of textile machinery

1.6.5 Timing belt

A timing belt is shown in Fig. 1.17. Its design has teeth-like gear that
engages with mating teeth on the pulleys. It combines the flexibility of a
belt with the positive grip of a gear drive. It is widely used in applications
where relative positioning of the respective shafts is desired.

1.17 Timing belt.

These are positive drives using flat-type belts. The belts have flat outer
surface and evenly spaced teeth on the inner surface and operate on toothed
pulleys. The toothed pulley looks like a spur gear as shown in Fig. 1.18.
Timing belts offer very good accuracy in transmitting motion compared to
flat belts and are comparable to gears. In addition they offer greater
flexibility in the location of driver and driven.

P itch

P itch

P u lley P itch
P itch Line

O utsid e
D ia m ete r

P itch
C ircle

1.18 Timing-belt drive.

They are commonly used in high-speed machines, when the distance

between driver and driven is of considerable length. In these situations
they offer greater advantage over gear drives in terms of lower power
consumption and noise. Usage of gear drive system under these
 Belts and rope drives 17

circumstances involves placement of several carrier wheels/gears (gear

trains), which leads to high power consumption due to their own weights
and also leads to noise. In addition, the gear drive system becomes so
complicated that changing of certain gears (change wheels) to effect a
change in the process parameters or for maintenance purpose is difficult.
Examples of use of timing belts in textile machinery are texturing
machines and rolling elements at the delivery side of modem carding
machine, such as doffer, stripper, calendar and coiler rollers. Drive between
top coiler plates of a combing machine is through timing belts. Required
belt tensions in timing belts are low and, consequently, bearing loads are
reduced. Timing belts find application in drives for changing the direction
of yarn twist in ring frame.

1.19 Timing belt drive in an air-jet texturing machine.

A timing belt drive used in an air-jet texturing machine is shown in

Fig. 1.19. The belt is guided over driving and driven wheels by two discs
(guards) placed on each side of these wheels. This is to avoid the belt
slipping out of the wheels due to misalignment of the wheels. The belt is
kept under tension by means of a tension wheel, which does not have side
discs.
Timing belts find application in drives for changing the direction of
yarn twist in ring frame. Timing belt is made of rubberized fabric reinforced
with steel wires to take on the tension. The steel wire is located at the
pitch line and the pitch length is the same regardless of the
18 Mechanics and calculations of textile machinery

B e lt
v
1 - d riveR ω1
2 - d riveN ω2
r2 +
r 1+

velocity ω2 r 2 < V < ω1 r 1 (cree p)

^
F
fre e
r2 +
b od ie s T2
^ r1 +
F T1
^
^
to rq ue T 2 /r2 = (F – F) = T 1 /r 1

P o w er - fo r b elt: P 2 = ω2 T 2 < ω1 T 1 = P 1 ; η = P 2 /P 1 < 1

1.20 Kinematics and kinetics of a belt drive.

The kinematics and kinetics of a belt drive

Figure 1.20 shows the kinematics and kinetics of a belt wrapped around
two pulleys. The transfer of power in a belt drive relies critically on friction.
The tensions Fmin and Fmax in the two strands (the nominally straight parts
of the belt not in contact with the pulleys) cause a normal pressure over
the belt–pulley contact, and it is the corresponding distributed friction
whose moment about the pulley centre equilibrates the shaft torque T –
provided gross slip of the belt on the pulley surface does not occur due to
friction breakaway. The speed reduction ratio and the torque amplification
ratio are each equal to the radius ratio, so that the output power equals the
input power and the efficiency is 100%.
The torque ratio equals the ideal ratio (as may be seen from the free
bodies), but creep results in the speed ratio being less than ideal. Creep –
not to be confused with gross slip – is due to belt elements changing length
as they travel between Fmin and Fmax, and since the pulley is rigid then there
must be relative motion between belt element and pulley. Since power
equals the product of torque and (angular) speed, the consequence of the
foregoing is that efficiencies of real belts are less than 100%.

1.6.6 Rope drive belt

These belts are circular in cross-section, without any joints. They can be
used for transmission over a long distance. The pulley on which it runs
should have V-shaped groove (Fig. 1.21). For variable speed drives using
stepped pulleys, this belt can also be used. When all pulleys (driving, driven
 Belts and rope drives 19

1.21 Rope drive belt.

and guide pulleys) are at considerable distances, and at different planes,

these belts can be used.
A rope meshing in a V-shaped groove of the pulley increases greatly
the frictional resistance to slipping, for a given maximum belt tension, as
compared to flat belt. The rope does not rest on the bottom of the groove
but wedges itself into the groove (Fig. 1.22).

1.7 Rope drive

This type of drive is used in blow room for driving evener roller and stripper
roller and in carding for driving the flat cleaning brush rollers, burnishing
rollers, metallic clothing grinding equipment, etc.

1.22 Wedging of rope inside pulley groove.

20 Mechanics and calculations of textile machinery

1.23 Rope drive.

Steel or wire ropes are used for transmission of power in cases where
the parts to be connected are at a large distance apart, and where extra
strength is needed (Fig. 1.23). They are used in lifts, colliery winding and
hauling arrangements, mill drives, etc. The ropes run on grooved pulleys;
but contrary to the practice adapted with cotton ropes, they rest on the
bottom of the grooves and are not wedged between the sides of the grooves.

1.7.1 Advantages of rope drive

Following are the advantages of a rope drive over belt drive:
1. The rope drive is particularly suitable, when the distance between
the shafts is large.
2. The frictional grip in case of rope drive is more than that in the belt
drive.
3. The net driving tension (i.e., difference between the two tensions) in
the case of rope drive is more than the belt drive (because the ratio
of tensions in the case of rope drive is cosec ά times more than that
in the belt drives.)

1.7.2 Ratio of tensions in rope drive

Consider a rope running in a groove as shown in Fig. 1.24.
Let R1 = Normal reactions between rope and sides of the groove R =
Total reaction in the plane of the groove 2ά = Angle of the groove µ =
Coefficient of friction between rope and sides of the groove
Resolving the reactions vertically to the groove, R = R1 sin ά + R1 sin
ά = 2 R1 sin ά or R1 = (R/2 sin ά)
We know that the frictional force = 2µ.R1 = 2µ × (R/sin ά) = µ.R/ sin
ά = µ.R cosec ά
 Belts and rope drives 21

R1
R1
2d

1.24 Rope running in a groove.

Now consider a small portion of the belt subtending an angle δθ at the

centre. The tension on one side will be T and on the other side T + δT.
Now we get the frictional resistance equal to µ.R cosec ά against the
relation between T1 and T2 for the rove drive will be 2.3 log (T1/T2) = µ.θ
cosec ά.

1.8 HP transmitted by ropes

HP transmitted by ropes = (P v N) ÷ 4500

= [(T1 – T2) v N] ÷ 4500
where P = driving force in kgf, v = the velocity in m per minute, and N
= the number of ropes in the pulley.
The relation between two tensions T1 and T2 is given by
[µθ / Sinα]
T1 ÷ T2 = e … (a)
where ‘e’ is the base of the napierian log = 2.718, µ = coefficient of
friction for the rope on the pulley, θ = angle of lap in radians and 2 α =
angle of the groove.
Taking log on both sides, the equation (a) becomes log T1 ÷ T2 = 0.4343
× [µθ / sin α] in circular measure = 0.007578 ×[µθ / sinα] if θ is in degrees
(b)

1.9 Comparison of flat and V-belts

The advantages of flat belts in comparison to V-belts are listed below:
(1) They are simple in design and are relatively inexpensive.
(2) They can be easily maintained in terms of periodic adjustment of
belt tension and their replacement when worn out.
(3) Precise alignment of pulleys and shafts is not so critical.
(4) They give better protection to the machinery against impact or
22 Mechanics and calculations of textile machinery

overloads. As they are flexible and long, they have the ability to
absorb shock and vibrations due to slipping action.
(5) Clutching action with flat belt is possible by moving it from fast to
loose pulley and vice versa. This type of arrangement is commonly
found in old blow rooms, cards, draw frames and speed frames.
(6) Using cone pulleys, different velocity can be obtained for the driven
element by moving the flat belt axially.
(7) They can be used for long distances, even up to 15 m, where other
types of drives cannot be used.

The major advantages of V-belt are as follows:

(1) V belts are used for short distance, which results in compact
construction.
(2) Due to wedge action between the belt and the pulley, the slip is less.
(3) Wedging action permits a smaller arc of contact, increases the pulling
capacity of the belt and consequently results in an increase in the
power transmission capacity.
(4) They can be used for high-speed reduction up to 7:1.
(5) They can be operated even when the belt is vertical.
(6) They are made available in endless form, which results in smooth
and quite operation, even at high speeds.

The major disadvantages of V-belts are as follows:

(1) The construction of V-grooved pulleys is complicated and costlier

compared to the pulleys for flat belt drives.
(2) The creep in V-belts is higher compared to flat belts.
(3) The ratio of thickness of V-belts to pulley diameter is high, which
increases the bending stress in the belt cross-section and adversely
affects its durability.

1.10 Variable speed drives

For variable speed drives in blow rooms and speed frames flat belts with
cone drums or cone-pulleys are used as shown in Fig. 1.25. For varying
the output speed, the belt is moved axially. For stepped pulleys, V-belt or
round belt can be used with grooved sheaves as shown in Fig. 1.26. The
stepped pulleys with V-belts are commonly used in main drives of many
textile machines.
Speed adjustment of driven pulley is possible with a variator drive using
adjustable grooved / conical discs and V-belt without varying the speed of
the motor. A variator drive used in ring frame is shown in Fig. 1.27. By
shifting the driver and driven discs axially, the effective diameters of the
 Belts and rope drives 23

Step pe d P ulle ys
C o ne P u lle ys

Fo rk

1.25 Cone pulley. 1.26 Step pulley.

Variator

Variable
Sp ee d
D rive

Fig. 1.27 Variator drive.

discs over which the axis of the belt passes are simultaneously varied,
thus varying the output speed. To increase the output speed/spindle speed,
the driver discs are moved closer to each other and the driven discs moved
apart and vice versa. A control device through hydraulic or pneumatic
pistons and lever mechanisms effect the movement of the discs. The spindle
speed can be varied in several steps depending on the doff-position and
the end-breakage rate of the yarn. This permits higher throughput of yarn
as optimum spindle speed is selected at any instant.
24 Mechanics and calculations of textile machinery

Reeves variable speed transmission in which the operator is able to

control the speed while running without any interruption of the work in
hand, and the change is continuous instead of being abrupt. This consists
of a pair of pulleys connected by a V-shaped belt in the manner indicated
in Fig. 1.25. Each pulley consists of a pair of driving disks with cone-
shaped faces, the disks revolving with the shafts, but at the same time
capable of sliding longitudinally along it to a certain extent. To adjust the
diameters of the pulleys, the two conical disks on one shafts forming a
pair are caused to approach each other, virtually increasing the diameter
or recede from each other when the diameter is reduced. It follows that
when the disks of one pair are approaching each other, those of the opposite
pair must automatically be made to recede to the same extent. In this manner
the ratio of driving diameter to driven diameter is readily and quickly
changed, thus securing any desired speed without the necessity of stopping
the machine.
Variable speed transmission in the case of a chain drive may be secured
by a device similar to that described above using PIV (positive, infinitely
variable) gear which has radial teeth in the conical disk.

1.11 Centrifugal tension

We have already discussed that the belt continuously runs over both the
pulleys. It carries some centrifugal force in the belt, at both the pulleys,
whose effect is to increase the tension on both, tight as well as the slack
sides. The tension caused by the centrifugal force is called centrifugal
tension. At lower speeds, the centrifugal tension is very small and may be
neglected. But at higher speeds, its effect is considerable, and thus should
be taken into account.
Consider a small portion AB of the belt as shown in Fig. 1.28,
Let m = mass of the belt per unit length
v = linear velocity of the belt
r = radius of the pulley over which the belt runs
Tc = centrifugal tension acting tangentially at P and Q
dθ = angle subtended by the belt AB at the centre of the pulley
Therefore, length of the belt AB = r.dθ and mass M = m.r.dθ
We know that centrifugal force of the belt AB,
Pc = Mv2 / r = (m.r.dθ) v2 / r = m.dθ.v2
Now resolving the forces (i.e., centrifugal force and centrifugal tension)
horizontally and equating the same,
2Tc sin (d.θ/2) = m.dθ.v2
 Belts and rope drives 25

TC

PC dθ 0

TC

1.28 Rope or round belt.

Since dθ is very small, therefore substituting sin (d.θ/2) = d.θ/2 the

above equation,
2Tc (d.θ/2) = m.dθ.v2 or Tc = m.v2

Notes
1. When the centrifugal tension is taken into account, the total tension,
on the tight side = T1 + Tc and total tension on the slack side is T2 + T c.
2. The centrifugal tension on the belt has no effect on the power
transmitted by it. The reason for the same is that while calculating
the power transmitted, we have to use the values = total tension on
tight side – total tension on the slack side
(T 1 + T c) – (T2 + Tc) = (T1 – T2)

1.11.1 Maximum tension in the belt

Consider a belt transmitting power from the driver to the follower. Let f =
maximum safe stress in the belt in N/mm2, b = width of the belt in mm,
and t = thickness of the belt in mm.
We know that maximum tension in the belt,
T = maximum stress × cross-sectional area of belt
When centrifugal tension is neglected, then maximum tension
T = T1
and when centrifugal tension is considered, then maximum tension
T = T1 + Tc
26 Mechanics and calculations of textile machinery

1.11.2 Condition for transmission of maximum power

The power transmitted by a belt,

P = (T1 – T2) × v W … (a)

where T1 = tension on the tight side in N, T2 = tension on the slack side
in N, and v = velocity of the belt in m/s
The ratio of tensions, T1 ÷ T2 = eµθ or T2 = T1 ÷ eµθ
Substiting the value of T2 in equation (a),
P = (T1 – T1 / eµθ) × v = T1 (1 – 1 / eµθ) × v = T1 × v × C (b)
where C = (1 – 1 / eµθ)
We know that tension on the tight side is T 1 = T – Tc
where T = maximum tension in the belt in Newton, and
Tc = centrifugal tension in Newton.
Substituting the value of T1 in equation (b),
P = (T – Tc) v C = (T – mv 2) v C = (Tv – mv2) C
We know that for maximum power, differentiating the above equation
and equating the same to zero,
T – 3 mv2 = 0 (c)

T – 3Tc = 0 (substituting m.v2 = T) or T = 3Tc

It shows that when the power transmitted is maximum, 1/3rd of the
maximum tension is absorbed as centrifugal tension.

1.11.3 Belt speed for maximum power

For maximum power transmission,
T – 3mv2 = 0 or 3mv 2 = T
∴ v = (T/ 3m)½
Where,
v = speed of the belt for maximum transmission of power,
T = *maximum tension in the belt,
m = mass of the belt for unit length.
Note: The power transmitted when 1/3 of the maximum tension is
absorbed as centrifugal tension (condition of last article) at belt speed for

* Maximum tension in the belt is equal to the sum of tensions on the tight side (T1)
and centrifugal tension (Tc).
 Belts and rope drives 27

maximum power (condition of the above article) is known as absolute

maximum power or in other words, maximum power which can be
transmitted under any conditions.

1.12 Selection of flat belt

Given data: (1) Power and speed in rpm of the driver unit. (2) Speed in
rpm of the driven unit. (3) Space limitations and operating conditions.

Procedure for selection

Step 1 Calculate the speed ratio
Step 2 Assume the belt speed, V, within the range given.
Step 3 Determine the diameters of the pulleys using the belt speed
and rpm of the respective pulleys
Step 4 Round off the pulley diameters to the recommended values
given, satisfying the following conditions:
(a) Allowable variation in the speed of driven pulley = ±10%
(b) The actual belt speed, calculated using the speed and
diameter of the driving pulley, must be within the range
Step 5: Find out correction factor for arc of contact
Step 6: Find out load correction factor
Step 7: Calculate corrected load (or) Design power, using the
following equations:
Corrected load (or) Design power = Power to be transmitted
× Load correction factor × Arc of contact factor
Step 8: Select the type of belt
Step 9: Write down the load rating of the selected belt, at the belt
speed of 10 m/s
Step 10: Calculate the load rating of the belt at the actual belt speed, V.
Step 11 : Determine the required mm plies of the belt
Step 12: Assume minimum no. of plies (= 3) and determine the required
width of the belt
Step 13: For the type of belt selected and the no. of plies assumed,
select the required width of belt. If the required width is not
standard, choose a wider belt.
If a belt to suit the requirements cannot be selected for the
no. of plies assumed, assume a higher number of plies and
repeat steps 12 and 13
Step 14: Calculate the belt length
Step 15: Determine the length by which the belt must be shortened to
provide correct initial tension
28 Mechanics and calculations of textile machinery

Problem 1.1: Select a flat belt from the manufacturer’s catalogue to

transmit 11 kW at 1200 rpm from an engine to a line shaft at 450 rpm. The
maximum centre distance between the shafts is 2 m.
1. Speed ratio = 1200 ÷ 450 = 2.66
2. Belt speed = 20 m/s (assumed)
3. To find the diameter of pulleys,
20 = (π Dn) ÷ 60;
D = (60 v) ÷ nπ
D1 = (60 × 20) ÷ 450 = 0.849 = 849 mm.
D2 = (60 × 20) ÷ 1200π = 0.318 = 318 mm
4. Standard diameters are 800 and 315 mm
(a) Speed of driven pulley N2 = 1200 × (315 ÷ 800) = 472.50 rpm
% variation in the speed of the driven pulley
472.50 – 450 × 100
= =5
450
(b) Actual belt speed (calculated using the speed and the diameter
of the driving pulley)
ðD1 N1 ð × 0.315 × 1200
V= = (belt speed is within the range)
60 60
V = 19.79 m/s
5. Arc of contact
D–d
= 180 − × 60
C
800 – 315
= 180 − × 60
2000
= 180 – 14.55
= 165.45°
Arc of contact factor = 1.0582
6. Load correction factor: 1.5 (Shock loads assumed)
7. Design power =11 × 1.5 × 1.0582 = 17.46 kW
8. Type of belt selected = FORT
9. Load rating at 1 cm/s = 0.0289 kW/mm/ply
19.79
10. Load rating at 19.79 m/s = 0.0289 × = 0.0572 kW/mm/ply
10
17.46
11. Plies of belt (in mm) = = 305.24
0.0572
 Belts and rope drives 29

305.24
12. Belt width (in mm) = = 101.75 3
3
This width is not available in FORT for three ply. Therefore 4 ply is
tried.
305.24
Belt width = = 76.06 mm
4
In 4 ply, 90 mm width belt is available in FORT.
13. So, 4 ply 90 mm belt width is selected.
14. Belt length (assuming open drive),

ð (D + d ) (D − d )
2

L = 2C + +
2 4C

ð (800 + 315 )2

= 2 × 2000 + (800 + 315) +

2 4 × 2000
= 4000 + 1751.44 + 29.4
= 5780.84 mm
15. For initial belt tension, 1% of the belt length should be reduced.
Therefore length of the belt = 5780.84 – 5780.84 × 1 / 100 = 5723.03 mm
FORT 4 ply, 90 mm belt width of 5723 mm length is selected.

1.13 Selection of V-belt

Selection procedure
Given data – Power to be transmitted, speed of the driver unit, speed of
the driven unit, space limitations, operating conditions.

(A) Determination of pulley diameters, center distance and belt length

Step 1: Select standard V-belt section based on the kW rating.
Step 2: Determine the “Optimum belt speed range” within which the belt
gives maximum power rating.
Step 3: Assume suitable belt speed less than 25 m/s within the “optimum
belt speed range”.
Step 4: Determine the diameters of the pulleys using the belt speed and
rpm of the pulleys.
Step 5: Round off the pulley diameters to R20 series satisfying the
following conditions.
a) The diameter of the smaller pulley must be greater than the
minimum value recommended.
b) The % change in the rpm of the driven pulley must be within ±5.
30 Mechanics and calculations of textile machinery

c) The actual belt speed, if calculated using the diameter and

rpm of the driving pulley, must be less than 25 m/s.
Step 6: Determine the C/D ratio corresponding to the actual speed ratio
and calculate the center distance.
Step 7: Calculate minimum center distance (C min) and maximum center
distance (C max.). Also check whether the center distance
calculated in step 6 lies between minimum and maximum. If not,
adjust the center distance suitably.
Step 8: Calculate belt pitch length. Standardize the belt pitch length.
Step 9: Calculate the center distance for the standard pitch length of the
belt. Check whether it lies between C and if not, select new
standard pitch length for the belt and repeat Step 9 till C lies
between C min and C max.

(B) Determination of number of belts

Step 10: Select correction factor for industrial service, Fa.
Step 11: Find out small diameter factor, Fb.
Step 12: Find out belt length correction factor Fc. Corresponding to ‘L’
(Assuming value).
Step 13: Find out correction factor for arc of contact, Fd.
Step 14: Determine equivalent pitch diameter.
Step 15: Find out the power rating for the selected cross-section of the
belt, at the actual belt speed, against ‘de’.
Step 16: Determine the number of belts required to transmit the power.
Round off the value to the next higher integer.
Step 17: Write down the specification of the belt selected.
Step 18: Determine the number of consecutive grading numbers any of
which may be used to make a matched set.

Problem 1.2: Select V-belts to transmit 11 kW from an AC Motor, single

phase, running at 1440 rpm to a piston compressor running at 900 rpm for
more than 10 h per day. Space available for the drive is 2 m × 2 m.

Solution:
Step 1: To transmit 11 kW, either B or C cross-section belt can be
selected. C Cross-section belt is selected.
Step 2: Optimum belt speed range within which the belt gives maximum
power rating, for C cross-section belt is 17 m/s to 28 m/s.
Step 3: The belt speed must be below 25 m/s. Otherwise, the pulley must
be of special construction and further it will require dynamic
balancing. So belt speed of 20 m/s is assumed.
 Belts and rope drives 31

Step 4: To determine diameter of pulleys.

V = ðdn1 ; 20 = ðd × 1440 ; d = 265 mm

60 60
d × n1 × ç  
D= = 265 × 1440 × 0.98 = 439 mm
n2 900
Step 5: Standard pulley diameters: d = 280 mm and D = 450 mm (OR)
d = 250 mm and D = 400 mm can be selected. For this problem,
d = 280 mm and D = 450 mm is selected.
a) The diameter of the smaller pulley is greater than the minimum
value (200 mm) recommended.
b) The percentage change in the rpm of the driven pulley
n1
n2 = d ç
D
280
= × 1440 × 0.98 = 878.08 rpm
450

% change in rpm of the driven pulley = 900 – 878.08 × 100

= 2.44 < ± 5
ðdn1
c) The actual belt speed V =
60 × 1000

= ð × 280 × 1440
= 21.11m/s .
60 × 1000
Note: The actual belt speed is calculated using the diameter
and rpm of the driving pulley.
The actual belt speed is <25 m/s. The standard pulley
diameters satisfy all the three conditions.
Step 6: (A) To determine C/D ratio:

D
—
S m a ll P ulle y L arg e P ulle y 2
d
—
2

D istan ce be tw ee n C en tre

Actual speed ratio standard = diameter ratio

32 Mechanics and calculations of textile machinery

D = 450
= 1.607
d 280
Therefore, corresponding C/D ratio by interpolation

= 1.5 − 0.3 × 0.607 = 1.5 – 0.1821 = 1.3179

1
C = 1.3179 × D = 1.3179 × 450 = 593.05 mm.
Step 7: C min = 0.55 (D + d) + T
= 0.55 (450+280) +14 = 415.5 mm
C max = 2 (D + d) = 2 (450 + 280) 1460 mm
The centre distance calculated in Step 6 lies between C min and
C max. The two pulleys must be accommodated within the 2 m
space available.
The space occupied by the two pulleys = C + (D + d)/2 =
593.05 + 450 + 280 = 948.05 mm < 2000 mm
Step 8: Belt pitch length (assuming open belt drive)
L = 2C + π/2 (D + d) + (D – d)2/4C
= 2 × 593+ π/2 (450 + 280) + (450 – 280)2/(4 × 593)
= 2344.86 mm
Nearest standard belt pitch length per C section belt = 2342 mm.
Step 9: Centre distance for a given belt length and diameter of pulleys
C = A+ √ A 2 – B
2342 ð450 + 280
A = ( L / A ) − π ( D + d ) / 8 =
−
4 8
= 585.5 – 286.67 = 298.83 mm
B = (D – d)2/8 = (450 – 280)2/8 = 3612.5 mm
C = 298.83 +v (298.83)2 – 3612.5 = 591.55 mm

(B) Determination of no. of belts

Step 10: For piston compressors, driven by an AC single phase motor,
running for more than 10 h/day. Industrial service factor, Fa = 1.5
Step 11: Small diameter factor, Fb = 1.12, corresponding to D/d ratio of 1.607.
Step 12: Belt length correction factor, F c = 0.90
Step 13: Arc of contact =180 – 60 [D – d]/C = 180 – 60 (450 – 280)/
591.55 = 162.76°; Fd = 0.9592 (by interpolation)
Step 14: Equivalent pitch diameter, dc = dp × Fb = 280 × 1.12 = 313.6 mm,
where dp is pitch diameter of smaller pulley.
Step 15: Power rating of C cross-section belt at actual belt speed of 21.11
m/s and equivalent pitch diameter of 313.6 mm = 11.33 kW.
 Belts and rope drives 33

Step 16: No. of belts required to transmit power

= P × Fa = 11 × 1.5 = 1.6 ~ 2.
kW × Fe × Fd 11.33 × 0.91 × 0.9592
So, two belts are required. [Where, Fa = Correction factor; Fe =
Correction factor length; Fd = Correction factor Arc of Contact]
Step 17: Designation of the V-belt selected C 2286/90 IS:2494
Step 18: No. of consecutive grading numbers any of which may be used
to make a matched set = 4.

Problem 1.3: A 10 kW motor running at 1750 rpm has a pulley of 160 mm

diameter fitted to it. It drives a line-shaft at a speed of 800 rpm. Three
machines are driving by the line-shaft, their speed being 300, 500 and 200
rpm. The driving pulleys of the machines are respectively 240, 320 and
400 mm in diameter. Find the size of the pulleys to be fitted on to the line-
shaft.
Here D1 = 160, n1 = 1750, n 2 = 800, D2 = ?
D 2 = D 1 × n1 / n2 = (160 × 1750) ÷ 800 = 350 mm.
D 2 is the diameter of the pulley on the line-shaft through which power
from the motor is transmitted.
Let d1, d 2, and d 3 be the diameters of the pulleys fitted on the line shaft
for driving machines.
d1 × 800 = 300 × 240 = 90 mm
d2 × 800 = 500 × 320 = 200 mm
d3 × 800 = 200 × 400 = 100 mm

Problem 1.4: An motor shaft running at 120 rpm is required to drive a

machine shaft by means of belt. The pulley on the motor shaft is of 2 m
diameter and that of the machine shaft is of 1 m diameter. If the belt
thickness is 5 mm, find the speed of the machine shaft when (i) there is no
slip, and (ii) there is a slip of 3%.
Solution: Given, N1= 120 rpm; d1= 2 m; d 2 = 1 m; t = 5 mm = 0.005 m;
s = 3%.
(i) Speed of the machine shaft when there is no slip. We know that speed
of the machine shaft,
d1 + t
N2 = N 1 × = 120 × 2 + 0.005 = 239.4 rpm
d2 + t 1 + 0.005
(ii) Speed of the machine when there is a slip of 3%. We know that speed
of the machine shaft,
34 Mechanics and calculations of textile machinery

d1 + t (1 – 3)
N 2 = N 1× × = 120× 2 + 0.005 × (1 – 3) = 232 rpm
d2 + t 100 1 + 0.005 100

Problem 1.5: The width of a belt is 150 mm and the maximum tension per
mm of width is not to exceed 1.6 kg. The ratio of tension on the two sides
is 2¼, the diameter of the driver 1 m, and it makes 220 rpm. Find the horse
power that can be transmitted.
Solution: In this case, T1 = 1 .6 × 150 = 240 kg and T1/T2 = 2.25 or
T2 = 240 ÷ 2.25 = 106.7 kg.
Therefore, P = T1 – T2 = (240 – 106.7) = 133.3 kg.
We know that V = π d n = 3.142 × 1 × 220 m/min.
133.3 × 3.142 × 220
Therefore, hp = = 20.5
4500
Ratio of driving tensions in a belt: The ratio of driving tensions in a
belt just on the point of slipping is given by

T1
µθ
T2 = e

where e is the base of the log = 2.718, µ = coefficient of friction for the
belt on the pulley, and θ = angle of lap or arc of circumference embraced
by the belt in radians.
Taking log on both sides, the equation becomes
log T1/T2 = µ θ log e
= 0.434 π θ in circular measure
= 0.007578 µ θ if θ is in degrees 1.6

Problem 1.5: Find the length of belt necessary to drive a pulley of 500
mm diameter running parallel at a distance of 12 m from the driving pulley
of diameter 1600 mm.
Solution: Given, d 2 = 500 mm = 0.5 m or r2 = 0.25 m; 1 = 12 m;
d1 = 1600 mm = 1.6 m or r1 = 0.8 m.
In this example, no mention has been made whether the belt is open or
crossed. Therefore we shall find out the value of length of the belt in both
the cases.
 Belts and rope drives 35

Length of the belt if it is open

We know the length of the belt if it is open,
L = π (r1 + r2) + 2l + (r1 – r2) 2/ l = π (0.8 + 0.25) + 2 × 12 +
(0.8 – 0.25)2 / 12 = 27.32 m

Length of the belt if it is crossed

We know that length of the belt if it is crossed,
L = π (r 1 + r2) + 2l + (r1 + r2) 2/ l = π (0.8 + 0.25) + 2 × 12 +
(0.8 + 0.25)2 / 12 = 27.39 m

Problem 1.6: Find the length of the belt required for driving two pulleys
in a cross belt drive of 600 mm and 300 mm diameter when 3.5 m apart.
Take thickness of the belt as 5 mm.
Solution: Given: d1 = 600 + 5 = 605 mm = 0.605 m or r1 = 0.3025 m;
d2 = 300 + 5 = 305 mm = 0.305 m or r2 = 0.1525 m; l = 3.5 m
We know that length of the cross belt drive
L = π (r1 + r2) + 2l + (r1 + r2)2/ l
= π (0.3025 + 0.1525) + 2 × 3.5 + (0.3025 + 0.1525) 2 / 3.5
= 8.488 m

Problem 1.7: The tensions in the two sides of the belt are 1000 and 800
N, respectively. If the speed of the belt is 75 m/s, find the power transmitted
by the belt.
Solution: Given, T 1 =1000 N; T2 = 800 N; v = 75 m/s
We know that power transmitted by the belt,
P = (T1 – T2) × v
= (1000 – 800) × 75
= 15,000 N–m/s = 15000 W = 15 kW

Problem 1.8: Find the necessary difference in tensions in kgf in the two
sides of a belt drive, when transmitting 20 hp at 30 m/s.
Solution: Given, P = 20 hp; v = 30 m/s
36 Mechanics and calculations of textile machinery

Let (T1 – T2) = Necessary difference in tensions in the two sides of the
belt.

Problem 1.9 A laminated belt 8 mm thick and 150 mm wide drives a pulley
of 12 m diameter at 180 rpm. The angle of lap is 190° and mass of the belt
material is 1000 kg/m2. If the stress in the belt is not to exceed 1.5 N/mm2
and the coefficient of friction between the belt and the pulley is 0.3,
determine the power transmitted when the centrifugal tension is (i)
considered, and (ii) neglected.
Solution: Given, t = 8 mm = 0.008 m; b = 150 mm = 0.15 m; d = 1.2 m;
N = 180 rpm; θ = 190° = 190 π/180 = 3.316 rad; π = 1000 kg/m3; f = 1.5
N/mm2; µ = 0.3

(i) Power transmitted when the centrifugal tension is considered

Let T1 = Tension in the tight side of the belt, and
T2 = Tension in the slack side of the belt.
We know that speed of the belt,
v = π × 1.2 × 180/60 = 11.31 m/s
Maximum tension in the belt,
T = fbt = 1.5 × 150 × 8 = 1800 N and
mass of the belt per metre length,
m = area × length × density
(0.008 × 0.15) × (1) × (1000) = 1.2 kg/m
Therefore, centrifugal tension,
Tc = m.v2 = 1.2 (11.31) 2 = 153.5 N
and tension in the tight side
T1 = T – Tc = 1800 – 153.5 = 1646.5 N
We also know that
2.3 log (T1 / T2) = µ.θ = 0.3 × 3.316
= 0.9948; log (T1 / T2)
= 0.9948 ÷ 2.3 = 0.4325
Therefore, 1646.5 / T2 = 2.707 (Taking antilog of 0•4325) or T2 = 1646.5/
2.707 = 608.2 N and power transmitted,
P = (T1 – T 2 ) × v (1646.5 – 608.2) × 11.31 N–m/s
= 11,740 W = 11.74 kW
 Belts and rope drives 37

(ii) Power transmitted when the centrifugal tension is neglected

We know that tension in the tight side (without centrifugal tension),
T1 = 1800 N
Therefore, T2 = 1800/2.707 = 665 N and power transmitted,
P = (T 2 – T1) v = (1800 – 665) 11.31. N–m/s
= 12,840 W = 12.84 kW

Problem 1.10 A flat belt is required to transmit 3.5 kW from a pulley of

1.5 m effective diameter running at 300 rpm. The angle of contact is spread
over 11/24 of the circumference and the coefficient of friction between
the belt and pulley surface is 0.3. Taking centrifugal tension into account,
determine the width of the belt. Take belt thickness as 9.5 mm, density as
1.1 Mg/m 3 and permissible stress as 2.5 N/mm2.
Solution: Given, P = 3.5 kW; d = 1.5 m; N = 300 rpm; θ = 2π × 11/24
= 288 rad; µ = 0.3; t = 9.5 mm = 0.0095 m; ρ = 1.1 Mg/m3 = 1100 kg/m3;
f = 2.5 N/mm2.
Let b = Width of the belt in mm,
T 1 = Tension on the tight side of the belt, and
T 2 = Tension on the slack aide of the belt.
We know that velocity of the belt,
v = π × 1.5 × 300/60 = 23.56 m/s and
power transmitted (P),
35 = (T1 – T2) v = (T1 – T2) × 23.56
Therefore,
(T 1 – T2) = 35/23.56 = 1.486 kN = 1486 N … (a)
We also know that
2.3 log (T1/T2) = µ.θ = 0.3 × 2.88
= 0.864 log (T1/T2) = 0.864/2.3 = 0.3757
Therefore, (T1/T2) = 2.375 (Taking antilog of 0.3757) or
T1 = 2.375 T 2
Substituting the value of T1 in equation (a),
2.375 T2 – T 2 = 1486
Therefore, T2 = 1486/1.375 = 1081 kN and T1 = 2.375 × 1081 = 2567 kN
We know that maximum tension in the belt,
T = fbt = 2.5 × b × 9.5 = 23.75b N and
38 Mechanics and calculations of textile machinery

mass of the belt per metre length,

m = Area × Length × Density
(0.00b × 0.0095) × (1) × (1100) = 0.010 45 b kg
Therefore, centrifugal tension,
Tc = m.v 2 = 0.010 45b (23.56)2 = 5.8b N and
tension on the tight side of the belt (T1)
2567 = T – Tc = 2.375b – 58b = 17.95b
Therefore, b 2567/17.95 = 143 mm, say 150 mm

Problem 1.11: A belt 100 mm wide and 10 mm thick is transmitting power

at 1200 m/min. The net driving tension is 18 times the tension on the slack
side. If the safe permissible stress on belt section is 1.8 N/mm2, calculate
the power that can be transmitted at this speed. Assume mass density of
the leather as 1 t/m3.
Also calculate the absolute maximum power that can be transmitted by
this belt and the speed at which this can be transmitted.
Solution: Given, b =100 mm; t = –10 mm; v =1200 mm/min = 20 m/
s; (T1 – T2) = 1.8 T2; f = 1.8 N/mm2; ρ = 1 t/m3

Power transmitted by the belt

We know that maximum tension in the belt,
T = fbt = 1.8 × 100 × 10 = 1800 N and
mass of the belt per metre length,
m = Area × Length × Density
(0.1 × 0.001) × (1) × (1000) 1 kg/m
Therefore, centrifugal tension,
Tc = mv2 = 1(20) 2 = 400 N
and tension in the tight side,
T1 = T – Tc =1800 – 400 = 1400 N
Now 1400 – T2 = 1.8 T2 (Given T1 – T2 = 1.8 T2) T2 = T1/2.8 = 1400/
2.8 = 500 N and power transmitted by the belt,
P = (T1 – T2) v = (1400 – 500) 20 N–m/s
18,000 W = 1.8 kW
 Belts and rope drives 39

Speed at which absolute maximum power can be transmitted

We know that speed of the belt, at which maximum can be transmitted,

v= T / 3m = 1800 / 3 × 1 = 24.5 m/s

Absolute maximum power that can be transmitted by the belt

We know that for maximum power, the centrifugal tension, Tc = T/3 =
1800/3 = 600 N Therefore, tension on the tight side, of the belt, T1 = T – Tc
= 1800 – 600 = 1200 N and tension on the slack side of the belt, T2 = T1/2.8
= 1200/2.8 = 428.6 N

Problem 1.12: Two parallel shafts whose centre lines are 4.8 m apart are
connected by an open belt drive. The diameter of the larger pulley is 1.5 m
and that of the smaller pulley is 1 m. The initial tension in the belt, when
stationary, is 30 kN. The mass of the material is 1.5 kg/m length and the
coefficient of friction between the belt and the pulley is 0.3. Calculate the
power transmitted, when the smaller pulley rotates at 400 rpm.
E
F

M α
J θ
K

H
G

0.75 m 0.5 m

Solution:Given, l = 4.8 m; d1= 1.5 m r1= 0.75 m; d2 = 1 m; or r2 = 0.5

m; T0 = 3 kN; m = 1.5 kg/m; µ = 0.3; N2 = 400 rpm. Let T1 = Tension in
the tight side of the belt, and T2 = Tension in the slack side of the belt.
We know that velocity of the belt,
v = π d 2 N ÷ 60 = (π × 1 × 400) ÷ 60 = 20.94 m/s
and initial tension in the belt when stationary (T0)
3 = (T 1 + T2) ÷ 2 or T 1 + T2 = 6 kN … (a)
Now for an open belt drive,
Sin ά = (r1 – r 2) ÷ l = (0.75 – 0.5) ÷ 4.8 = 0.0521 or ά = 3o
Therefore, Angle of lap for the smaller pulley,
40 Mechanics and calculations of textile machinery

θ = 180o – 2ά = 180o – (2 × 3) = 174o = π × 174/180 = 3.04

rad.
We also know that
2.3 log (T1/T2) = µθ = 0.3 × 3.04 = 0.912
Therefore,
log (T1/T2) = 0.912 / 2.3

= 0.3965 or T1/T2 = 2.49 or T1 = 2.49 T2

(Taking antilog of 0.3965)
Substituting the value of T1 in equation (a)
2.49 T2 + T2 = 6
Therefore, T2 = 6/3.49 = 1.72 kN and T1 = 2.49 T2 = 2.49 × 1.72 = 4.28 kN
Therefore, Power transmitted by the belt,
P = (T1 – T2) v = (4.28 – 1.72) 20.94 kN–m/s = 53.6 kW

Problem 1.13: Find the power transmitted by a rope drive, from the
following data:
Angle of contact 180o; Pulley groove angle 60°; Coefficient of friction
= –0.2; Mass of rope 0.4 kg/m length; Permissible tension 1.5 kN; Velocity
of rope 1.5 m/s.
Solution: Given, θ = 180° = 3.142 rad; 2α = 60° or α = 30°; µ = 0.2;
m = 0.4 kg/m; T = 1.5 kN; v = 15 m/s.
We know that the centrifugal tension,
Tc = m.v2 = 0.4(15)2 = 90N
Therefore, T1 = T – T c = 1500 – 90 =1410 N and
2.3 log (T1/T2) = µ.θ cosec α
= 0.2 × 3.142 cosec 30°
= 0.2 × 3.142 × 2.0 = 1.257
Therefore, log (T1/T2) = 1.257 × 2.3 = 0.5465 or
1410 ÷ T2 = 3.52 (Taking antilog of 0.5465)
Therefore, T2 = 1410/3.52 = 400 N
We know that power transmitted by the rope drive,
P = (T1 – T2)v = (1410 – 400) × 1.5 N–m/s,
15,150 W = 15.15 kW
 Belts and rope drives 41

Problem 1.14: A rope pulley with 5 ropes and surface speed of 1000 m/min
transmits 100 hp. Find the tensions on the tight side and slack side, if the
angle of lap is 130°, and the angle between the sides of the groove is 45°.
Assume µ = 0.3.
Power transmitted per rope,
hp = 100 ÷ 5 = 20 hp
In case of rope pulleys,
log T1 ÷ T2 = 0.4343 × [µθ/Sinα] α = 45° ÷ 2
= 22.5° [2α = 45°]
θ = [π ÷ 180] × 130 = 2.27 radian
Therefore,
log (T1 ÷ T 2)= 0.4343 × (0.3 × 2.27) ÷ sin 22.5 = 0.77,
(T1 ÷ T2) = 5.888
hp = [(T1 – T2) × v] ÷ 4500 or
20 = [(T1 – T2) × 1000] ÷ 4500 (T 1 – T2)
= (20 × 4500) ÷ 1000
= 90 kgf = 5.888 T2 – T2 or
T2 = 18.4 kgf or T1 = 5.888
T2 = 5.888 × 18.4 = 108.3 kgf

Problem 1.15: A rope drive is required to transmit 1 MW from a pulley of

1 m diameter running at 450 rpm. The safe pull in each rope is 224 kN and
the rope has mass of 1 kg/m. The angle of lap and the groove angle are
150 o and 45°, respectively. Find the number of ropes required for the drive,
if the coefficient friction between the rope and the pulley is 0.3.
Solution: Given, P = 1 MW = 1000 kW; d = 1 m; N = 450 rpm; T = 22.5
kN = 2250 N; m = 1 kg/m; θ = 150° = 150 π/180 = 2.62 rad; 2α = 45° or
α = 22.5°; µ = 0.3.
We know that velocity of the ropes,
v = π × l × 450/60 = 23.56 m/s
Centrifugal tension,
Tc = m.v 2 = 1(23.56)2 = 555 N
T1 = T – Tc = 2250 – 555 = 1695 N and
2.3 1og (T1/T2) = µθ cosec α = 0.3 × 2.62 cosec 22.5°
= 0.3 × 2.62 × 2.613 = 2.054
log (T1/T2) = 2.054/2.3 = 0.8930
42 Mechanics and calculations of textile machinery

1695 ÷ T2 = 7.816 (taking anti-log of 0.8930)

Therefore,
T2 = 1695/7.816 = 217 N and
Power transmitted by one rope
= (T1 – T2) v = (1695 – 217) 23.56 N–m/s
= 34820 kW = 34.82 kW
Therefore, no. of ropes

= Total power to be transmitted = 1000

Power transmitted by one rope 34.82
= 28.7, say 29

Normal belt life requirements kh

Industrial – 12–26
l Equipment with long operating hours or continuous operations like fans, 7.5–20
pumps, conveyors
l Hand tools, office equipment 6–12
l Equipment with intermittent or occasional operation  

Agricultural –
l Stationary equipment with long operating hours or continuous operations 6–12
like fans, pumps, conveyors
l Stationary equipment with intermittent or occasional operation 2–6
l Mobile equipment like harvesters, sowing machines, manure spreaders, 0.5–1
hay balers  

Automotive –
l Passenger cars, vans 1–3
l Lorries, buses, tractors, road construction machines 5–10
Home Appliances –
l Heating, ventilation, air conditioning 5–10
l Washing machines, tumbler dryers, dish washers 1.5–2
l Sewing machines, lawn mowers, hand tools  0.2–1