V-belt Drives

Although various other types of belt drives are also used, V-belts are
the most common. However, many of the maintenance considerations
that apply to V-belts are also relevant to other types of belt drive such
as flat belts and timing belts.

Principles of Operation

V-belts are normally used to transfer power between two shafts whose
axes are parallel and some distance apart.

The belt is mounted on pulleys that are attached to the driving and
driven shafts and the drive relies on friction between the belt and the
pulleys for its operation. The belt sits in the groove of the pulley and
makes contact with the sides of the groove as shown below:
 V-belt

Pulley
Friction between
the belt and sides
of pulley groove

In order to be able to transmit power, the belt must be under tension so

that it is forced down into the groove. The belt is squeezed and friction
develops between the sides of the belt and the sides of the groove. The
depth of the groove is always greater than the thickness of the belt,
however, and the belt should never bottom in the groove. The operation
of the belt and its ability to transmit power depend on the size of the
friction force and the arc of contact of the belt. The greater the arc of
contact the more power the belt can transmit.
As well as performing its primary function of transmitting power, a V-belt can
be used to change the speed of the driver output and hence the torque
transmitted to the driven unit.

There are three basic alternatives as shown below:

Driver

Speed Ratio 1:1 Driven

Driver

Driven
Speed Increase

Driver

Speed Decrease Driven

 The speed ratio between the two pulleys of a belt drive can be
calculated from this simple formula.

driver pulley diameter (mm)

driven speed (RPM) = x driver speed (RPM)
driven pulley diameter (mm)

It is generally accepted that V-belt drives are limited to belt speeds

between 300 and 3000 metres per minute. If required to operate at
higher speeds, then dynamic balancing of the pulleys becomes
increasingly important.

Example
In an arrangement a motor runs at 450 rpm. The diameter of the driver
pulley is 300mm and the diameter of the driven pulley is 150mm.
Calculate the output speed.
Example
In the arrangement shown below calculate the output speed if the
driver is running at 500 rpm.

Driven
Ф 200 mm

Driver
Ф 600 mm
Example
In the arrangement shown below calculate the diameter of the driven
pulley if the output speed needs to be 600 rpm. The motor runs at
300 rpm.

Ф 120 mm
Driven

Driver
Types and Arrangements

Single V-belt

The most common type is the single belt arrangement whose operation
has been described in the illustrations above. In addition to being used to
transmit power between parallel shafts, the single belt can also be used
for quarter turn drives and angle drives as shown below.

Quarter Turn Drive

Angle Drive
Multiple V-belt

In order to increase the capacity of the drive an arrangement which

uses several belts mounted on multi-grooved pulleys is often used.

multiple grooves
carry several belts

Banded V-belts

In order to overcome the tendency of belts to whip, twist or jump off,

a banded V-belt, in which the V-sections are vulcanised to a common
band can be used.
common band
Belt Tension

V-belts are often tensioned by means of an idler pulley for the

following reasons:

 If the relative position of the shafts cannot be adjusted then an

idler pulley can be used to assist installation of the belt.

 If the driver is subject to varying loads then a spring loaded idler

can provide automatic adjustment of belt tension.

 The inclusion of an idler pulley can help to increase the arc of

contact and hence the power transmission capacity of the drive.

It is generally recommended that idler pulleys be mounted on the slack

side of the belt, as shown below and positioned close to the drive pulley.

Idler Pulley

Driver Drive
Maintenance Practices
The following general points should be taken into account in the
maintenance of V-belts.

 The operation of V-belts depends largely on the condition and

correct positioning of the pulleys.

 V-belt pulleys should be kept clean, free of oil and grease and
free from damage and wear.

 Pulleys should be installed parallel and in line with each other.

 Belt tension should be adjusted according to the manufacturer’s

recommendations.

 V-belts should never be forced or levered on to the pulley as

shown in the illustration below.

Lever Pulley

 Multiple V-belts should be correctly matched to ensure the load

is evenly distributed. As well as being the same size it is
preferable that all belts are supplied by the same manufacturer.

 Multiple V-belts should be changed as a set. A single new belt

will be shorted than the worn, stretched belts and will tend to
carry more than its fair share of load. It is therefore likely to fail
prematurely.

 No dressing of any kind should be applied to the V-belt.

 V-belts should be stored in a clean, dry place and should not be

exposed to heat or direct sunlight.

 Do not hang V-belts on nails or small pegs while in storage.

Store flat if possible.
Alignment

The correct alignment of the shafts and pulleys is vital to the operation
of a V-belt drive. Misalignment of pulleys can occur in several ways.

The first step in aligning the pulleys is to check that the shafts are
level and parallel. This should be done by using a spirit level on the
exposed shafts to check for level, and then by using a feeler bar or
gauge to check the distance between the shafts on both sides of the
pulleys.

Spirit Level
Pulley

Feeler Bar
Once the shafts are parallel then the pulleys can be brought into line
by using a straight edge across the faces as shown below.

Straight Edge

Reposition either of the pulleys until they are properly aligned. If

either shaft is subject to end float make sure that it is in the normal
running position when the alignment is checked. Rotate the shafts
and check the alignment in several positions before it is finally
accepted.

Belt Tension
The most common is to depress the belt and measure the deflection
using a ruler and a straight edge as shown below.

Straight Edge Ruler

If this method is not considered to be sufficiently accurate then a
spring balance can be used to deflect the belt against a specified pull
as shown below.

Spring Balance
Ruler

A third alternative is to measure the elongation of the belt under

tension. This is done by marking a defined length of the belt and then
re-measuring between the same two marks when the belt is under
tension as shown below.

For normal drives the elongation of the belt should be around 2%.
This may increase for high speed drives and should be checked
against manufacturer’s recommendations.
Installation of V-belt Drives

The following procedure should be adopted when installing V-belts.

1. Check the condition of the pulleys and check for wobble.

2. Align the pulleys according to the procedures outlined above.

3. Reduce the centre distance of the shafts by adjusting the

position of the motor. If an idler pulley is used release the
tension on the idler so that the belt can be fitted.

4. Fit the belt or belts taking care not to damage them in the
process.

5. Adjust the belt tension as recommended above.

6. Run the unit for a short period, say 10 minutes, to allow the
belt to seat correctly in the pulley grooves.

7. Readjust the tension.

8. Recheck the tension after 24 hours of operation.

9. Ensure that the drive is protected with a suitable guard at all

times during operation. The guard should be provided with
ventilation and secure against removal by unauthorised
personnel.
Failure Patterns
Like most machine elements, V-belts do not have an unlimited life and
will eventually wear out. Their normal life expectancy will depend on
the operating conditions, speed and loading. When belts fail
prematurely it is important to determine the precise cause of failure so
that corrective action can be taken and performance improved for future
operation. As with other machine elements an investigation of failure
patterns can be divided into an analysis of symptoms and an analysis of
causes.

Symptoms fall into two categories, those apparent during operation and
those visible on shutdown of the machine and inspection of the drive.

Operating Symptoms

The following conditions can be considered to be

evidence of malfunction.

Belt Slippage

Any tendency of a V-belt to slip will lead to rapid wear and premature
failure. The common causes of belt slippage are insufficient tension,
drive overload and the presence of oil or grease on the belt.

Belt Squeal

Squealing often accompanies belt slippage and is also caused by

overload and insufficient tension. It may also occur when the arc of
contact between the belt and pulley is insufficient..
 Belt Ticking or Slapping

When the operation of a belt drive is accompanied by a ticking or a

slapping sound this is often evidence that some form of mechanical
interference is taking place. This may be due to poorly aligned guards
or contact with other machine parts.

Belt Whipping

If a V-belt starts to whip it is likely to jump out of the pulley groove or to

roll over and become damaged. Whipping may be the result of the
drive centres being too far apart or due to wobbling pulleys. Sometimes
a pulsating load will also cause belt whip, in which case the suitability of
the drive should be reviewed.

Belts turned over

If the cords in the belt are broken during installation by levering the belt
on to the pulley then the belt will stretch excessively and loose strength.
Lack of tension may also allow a belt to roll over in the pulley groove.
The affect of impulse loads and whipping may also cause the belt to roll
over and this may be overcome by installing a spring loaded idler
pulley. Once a belt has turned over it will be damaged and should be
automatically discarded and replaced.
 Belt Breakage

If a V-belt breaks immediate action is clearly required. Breakage may

occur due to overloading in the form of shock loads or heavy starting
loads but if the belt has been properly selected this should not occur. A
belt that has been weakened by being levered on to the pulley is very
likely to break prematurely. The presence of foreign objects or material
may also damage the belt sufficiently for it to break.

Symptoms Found on Inspection

When the drive is shut down and examined the condition of the belts
and pulleys will provide evidence from which the cause of failure may
be determined. As for all machine elements, every failure is different in
some way. However, the following conditions are commonly-found
symptoms of V-belt malfunction.

Wear
A properly aligned and tensioned belt will wear along the sides and will
eventually need to be replaced. If wear is rapid and leads to premature
failure this may be due to misalignment or the presence of dust or other
abrasives.
Uneven wear, as shown below, may be the result of either misalignment
or damage to the pulley grooves.

Cracking
When hardening and cracking appear on the underside of the belt this
is usually caused by excessive heat build-up. This may be caused by
poor ventilation or by slippage.
Fraying
Any tendency for the belt to fray along the edges or for the surface to
tear and rupture as shown below is usually evidence that some
mechanical interference is taking place or that the pulleys are worn or
damaged in some way.

Stretching
If the belt stretches beyond the adjustment range of the tightener then
the chances are that the internal cords are broken and the belt should
be replaced.

Swelling

If the belt material becomes swollen or spongy it is likely that it has

been exposed to oil, grease or other chemicals.
Burns
If the belt shows evidence of burning in one particular area this may
indicate either that the belt has slipped during start-up or that the driven
unit has jammed or stalled causing the belt to burn when the drive has
run on.

Worn Sheaves
In addition to belt damage the pulley grooves may show evidence of
wear. This may appear on the sides of the groove, or as a shiny
surface on the bottom of the groove which indicates that the belt has
been bottoming. A pulley which shows excessive wear of this type
should be replaced and new belts installed.

Wear on sides of groove

 Wear on bottom of groove
Dishing of the sides of the groove.

Evidence that the belt has been bottoming.

Causes of Failure

The common causes of the types of V-belt failure listed above

can be summarised as follows:

Misalignment

As with most mechanisms good alignment is critical. Misalignment of

pulleys will cause rapid wear and damage to the belt surface, although
alignment tolerances for V-belts are not as stringent as for other
drives. The manufacturer’s instructions should be consulted to
establish the appropriate limits for a particular machine.
Incorrect Tension

Insufficient tension will cause the belt to slip and may also lead to belt
breakage due to the grab-slip effect. Over-tensioning will increase the
wear rate and shorten belt life and may also cause overloading of the
shaft bearings.

Interference

Any contact between the belt and other part of the machine or the belt
guard will cause rapid belt damage in the form of fraying or excessive
wear of the belt surface.

Foreign Material

Belts and pulley grooves should be kept clean and free from dirt, grit
and other contaminants which may cause accelerated wear or even
belt breakage. Oil or other chemicals will attack the belt and cause
deterioration of the material. A well-constructed belt guard should help
to exclude foreign material.

Damaged Pulleys

Pulley grooves should be free from nicks, burrs, chips and other
damage that may affect belts.
Overloading

The life of a belt drive will be reduced if it is subjected to loads or

speeds beyond its designed capacity. Excessive wear and belt
breakage is likely to occur if the loads and speeds are too high.

Overheating

Excessive heat is an enemy of V-belts and can lead to their rapid

deterioration. Guards should be made of mesh to allow adequate
ventilation, and belt slippage should be corrected as quickly as
possible before the heat build-up affects the belt material.

Summary of the common symptoms and

causes of V-belt failure

Symptoms Causes
Operating Inspection
Slipping Wear Misalignment
Squealing Cracking Incorrect tension
Ticking Fraying Interference
Whipping Stretching Foreign material
Turn-over Swelling Overloading
Breakage Burns Overloading
Worn sheaves Damaged sheaves
Driving Members

Methods of Securing

Drive wheels need to be located so that the driving

power can be transmitted.

Tapered keys can be use to

clamp a driving wheel in position
along the shaft. They are
normally used on larger shafts.

When plain keys are used, the

driving wheel is normally held
in position along the shaft by
clamping against a shoulder.
These are normally used for
smaller shafts.

Tapered locking bushes are

used to clamp a driving wheel in
position along the shaft. They
are sometimes keyed onto the
shaft.
Types of Driving Wheel

Flat belt pulleys are normally

held in position by a tapered
key.

V-belt pulleys can be held in

position by a key or tapered
locking bush.

Chain wheels are normally held

in position by plain or tapered
key, but tapered locking bushes
are sometimes used.

Gear wheels are normally held

in position by plain or tapered
keys.
Installing and Tensioning Belts

Installing Belts

Before installing any belt:

 Check that the safety precautions have been followed.

 Slacken off the tension adjustment completely.
 Clean the driving surfaces of the pulley.

Driving Surfaces

 Check the alignment of the pulleys.

When installing a metal laced flat belt:

 Place the belt around the shafts beside the pulleys with
the rough side against the pulleys.

Rough Side

 Mesh the loops of the metal lacings together.

 Fit the joining pin through the loops. A pin of the
correct material must be used.
 Run the belt onto the pulleys.

Fit To Small Pulley First

When installing a scarf joined flat belt, the rough side of the
belt and the trailing edge of the join must both be inside.

Trailing Edge
When installing a V-belt:

 Check that the belt is of the correct length and angle of taper.
 Fit the belt into the grooves of the pulley.

When installing a set of V-belts:

 Check that the belts are a matched set.

 Install the belts starting from the inside pulley and working
outwards.
NOTE

Mountings must be slackened to avoid straining belts.

Tensioning Belts

Belts must be tensioned correctly to transfer the drive, and prevent

unnecessary wear. As they stretch in use, their tension must be
regularly checked and adjusted.

To measure deflection in a slack belt:

 Check the specified deflection in the manufacturer’s

instructions.
 Find the middle of the longest span of belt between pulleys.
 Push this midpoint inwards, then pull it out and note the total
deflection, which should indicate the tension.
 Adjust the tension as necessary.
To measure tension in a taut belt as follows:

 Check the manufacturer’s instructions for the deflection

used and the force needed to reach it.
 Find the middle of the longest span of belt between the
pulleys.
 Attach a spring balance to this point.
 Pull the belt out to the required deflection and note the
reading.
 Adjust tension as necessary.
 To adjust belt tension:

 Loosen the locknuts

 Slacken off the clamping bolts.
 Move the pulley with the adjusting screws to alter the tension.
The adjusting screws must be turned equally to keep the
pulleys correctly aligned.

Clamping Bolts

Adjusting Screws
 Check the tension
 Readjust until correct
 Tighten the clamping bolts
 Tighten the locknuts
 Flat belt Joints
Cutting a belt to length.

When measuring the belt length for a complete loop:

 Check that the belting is the correct size and type for the pulleys.
 Cut one end of the belt square.

 Slacken off the drive tension completely.

Adjusting Screws
  Place the belt over the pulleys with the rough side
against the pulleys.
 Overlap the ends with the square end outside.
 Hold the belt taut and mark the position of the square
end on the back of the inner length.

When cutting a belt to the required length:

 Measure the belt length required for a complete loop.

 Check the gap or overlap required by the joint.
 Subtract the gap length from, or add the overlap length
to, the length of the belt required for a complete loop.
 Cut the belt to length.
Steel Lacings
Steel lacings are used on belts which need to be removed. The
lacing set must be the correct size for the thickness of belt.

When fitting a lacing to a belt:

 Press the lacing centrally into the jaws of the lacing

machining.
 Fit the pin into the side of the jaws to hold the lacing in
the machine.

 Place the belt centrally between the jaws of the lacing

machine and hard against the pin or lacing.
 Operate the machine to press the lacing into the belt
until it is flush with the belt.

 Trim the edges of the lacing to the width of the belt.

Scarf Joints

A scarf joint is used when a smooth drive is required or part of

the belt is to be replaced.

When tapering the belt ends:

 Check the length of taper required.

 Mark the beginning of the taper on the belt.

 Cut away the excess material.

 Cut the mating taper on the other end of the belt.
  Place the ends together and check that they fit together
properly. If necessary remove more material.

Plain Belt

Laminated Belt

Making a Scarf Joint

When using adhesives:

 Coat both tapered surfaces with the appropriate

adhesive.
 Allow the adhesive to become tacky.
 Place the tapered faces together and push the edge of
the belt against a straight edge so that the belt is
straight.
  Clamp the joint between wooden blocks and allow the
adhesive to dry.

When vulcanising:

 Check the manufacturer’s instructions for the vulcanising

equipment.
 Coat both tapered surfaces with the vulcanising
material.
 Place the tapered faces together and push the edge of
the belt against a straight edge so that the belt is
straight.
  Clamp the joint in the vulcanising press and heat the
joint for the required time.

When sewing:

 Make the joint with adhesive.

 Sew through the joint with the correct strength of cord
using a heavy duty sewing machine.