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BELT TECHNOLOGIES, INC.

11 Bowles Road
Agawam, MA 01001 USA
Phone: 413-786-9922
belttechnologies.com

EUROPE AND ASIA

BELT TECHNOLOGIES EUROPE
West Suite 6, Ground Floor
Riverside House, Newburn
Newcastle-Upon-Tyne,
Tyne and Wear, U.K.
NE15 8NY
Phone: + 44-191-4153010
belttechnologies.co.uk

DESIGN GUIDE AND ENGINEERS’ REFERENCE

© 2021 BELT TECHNOLOGIES, INC.
FOR METAL BELTS
At Belt Technologies, we help our customers achieve optimal performance
from machinery for precision positioning, timing, conveying, power
transmission, packaging and automated manufacturing operations. For
more than 50 years, we have provided a comprehensive resource for the
application-specific design and manufacture of PureSteel® metal belts,
drive tapes and pulleys.

PureSteel® metal belts possess many unique properties that result in superior
precision, control, longevity and cost effectiveness. In many cases, they are
preferable to other belt types (such as rubber, plastic and elastomer) and other
power transmission or motion control components (such as linear actuators,
lead screws and chains). Frequently they are the only design option.

To put the advantages of PureSteel® metal belt systems to work, Belt

Technologies offers extensive capabilities:

• Engineering and Design Assistance

• Metallurgical Consulting
• High Energy Beam Fabrication
• Complete Tooling Design and Manufacture
• Metal Fabrication
• Coating Application

Our climate-controlled facilities are equipped to produce PureSteel® metal

belts, drive tapes and complementary pulleys in prototype and high-volume
production quantities.

This document is provided for information and reference. It is a design guide, not a design
textbook. Belt Technologies cannot accept responsibility for actual designs attempted using
this manual as a basis. Readers should feel free to contact our Engineering staff for further
information and advice on unusually perplexing applications.
 Why Consider PureSteel® Metal Belts for Your Application? 3
CONTENTS
Page 2
Introduction Engineers who specify metal belts have options available to them CLEAN
that they do not have when using other products or materials.
Page 3 Unlike HTD or flat neoprene belts, PureSteel® metal
Some important features and benefits are discussed below.
Why Consider PureSteel® Metal Belts belts do not generate particulate and are ideal for food and
pharmaceutical processing.
for your Application HIGH STRENGTH-TO-WEIGHT RATIO
Page 4 This is an advantage in practically every application where high CLEAN ROOM COMPATIBLE
PureSteel Metal Belts, Drive Tapes
® strength, light weight or both are important.
PureSteel® metal belts do not require lubricants and will not
& Applications generate dust that would introduce foreign substances into
DURABILITY clean room environments. Additionally, they may be sterilized
Pages 5–6 PureSteel® metal belts can withstand sustained exposure to in an autoclave.
PureSteel® Pulleys extremes of temperature, hostile environments and vacuum.
• Designs INTRODUCTION A variety of alloys may be used, each with its own resistance to PRECISE CONSTRUCTION
• Materials chemicals, humidity and corrosion. Engineers generally select a
Belt Technologies has produced this Design Guide to give engineers a reference The edges of PureSteel® metal belts are smooth, and the
• Tolerances belt material based on physical properties, availability and cost.
publication detailing fundamentals of metal belt design and application, with dimensions are tightly toleranced.
• Types of Pulleys
topics including:
Page 7 NO LUBRICATION
• Why consider PureSteel® metal belts for your application?
Surface Treatments Unlike the links of a chain, a PureSteel® metal belt is a single
• PureSteel® metal belts, drive tapes and applications
• Teflon® element and, therefore, does not generate any component friction
• PureSteel® pulleys
• Neoprene or Urethane that requires lubrication. This reduces system maintenance,
• Surface treatments
• Silicone improves reliability and keeps the system clean.
• Design considerations
• Hard Coat Anodize
• Belt life
• PureSteel® metal belt materials (Appendix)
NONSTRETCHABLE
Pages 8–14
The high modulus of elasticity of PureSteel® metal belts make
Design Considerations We hope this information helps you understand the many benefits of them virtually non-stretchable as compared to other belt
• System Design Guidelines PureSteel® metal belts and gives you the knowledge you need to specify types and chains. This makes them ideal in high-performance
• Loading metal belts with confidence. applications for precision positioning.
• Accuracy
• Position Accuracy Because no two customers have identical needs, Belt Technologies designs each
• Repeatability product to unique specifications. Therefore, it is important to keep in mind SMOOTH OPERATION
• Belt Tracking that this Design Guide cannot include every possible application. There may be PureSteel® metal belts are free from the pulsation of chordal action
• Timing excellent applications for metal belts, perhaps yours, that are not described. often seen in other belt types and chains. This results in smooth and
• Tensioning precise translation of the control system motion profile.
• System Frame Stiffness We invite you to contact Belt Technologies to discuss your ideas with our Sales
• Reverse Bends Engineers. Please use the design checklist on the inside back cover to help us ACCURATE AND REPEATABLE
• Cantilevered Shafts better understand your project. Our company’s long-term success is in large
PureSteel® metal timing belts can be fabricated with a pitch
• Magnetic Permeability measure due to our ability to continually advance the science of metal belts and
accuracy of ±0.0005 in (.013mm) station to station. This high
• Belt Sag develop new solutions.
degree of precision is extremely valuable in designing indexing,
• Elevated Temperatures positioning or processing equipment.
• Belt Creep
• Design-Imposed Restrictions GOOD THERMAL AND ELECTRICAL CONDUCTIVITY
• Belt Life
PureSteel® metal belts can transmit energy in the form of heat,
Page 15 cold and electricity.
Appendix: PureSteel® Metal
Belt Materials NO STATIC BUILDUP
PureSteel® metal belts discharge static electricity, a crucial
Pages 16–24 capability in the manufacturing of electronic components such
PureSteel® Pulley Design Guide
as integrated circuits and surface mount devices.
A review of general design concepts for
pulleys used with PureSteel® metal belts

Inside Rear Cover

PureSteel® Metal Belt Design Check List
4 PureSteel® Metal Belts, Drive Tapes & Applications Pulleys 5

PURESTEEL® BELTS PURESTEEL® BELTS WITH COMBINATION BELTS/TAPES

PureSteel® metal belts are created by ATTACHMENTS Often, combinations of belt options
welding together two ends of a metal PureSteel® perforated metal belts can also are required in order to satisfy system
strip to form an endless belt. High energy be fitted with precision machined, cast or objectives. Attachments or pockets
beam welding techniques, pioneered in molded attachments to provide unsurpassed may be utilized to locate components,
the space program, form a high integrity positional accuracy and repeatability, to act while a vacuum drawn through the belt’s
butt weld that is extremely strong and as a product transport device, or to control perforations is employed to secure the
smooth. Some typical plain metal belt specific stages of a manufacturing process. component in place during transport.
applications include: Applications include: Specific edge geometries may be
developed to conform to component
• Conveying • Precision Position Indexing for profiles, while attachments locate
• Heat Sealing Automated Assembly the components and satisfy timing
• Casting
• Imaging
• Lead Frame Drives
• Timed Transfer Lines
requirements. Applications include:
PURESTEEL® PULLEYS profile is machined into a round stock pulley MATERIALS
in a fashion that maintains the structural
• Packaging Systems • Timed Parts Nesting All metal belts and drive tapes travel around To address the needs of your specific
integrity of the pulley while removing
PURESTEEL® PERFORATED • Component Orientation and Conveying pulleys. Belt Technologies custom designs
substantial amounts of weight, thereby
applications, pulleys can be manufactured
BELTS PURESTEEL® DRIVE TAPES • Automated Dimensional/Electrical
Inspection
and manufactures PureSteel® pulleys
that optimize the unique characteristics of
reducing the effects of rotational inertia.
from a wide range of materials.

PureSteel® perforated belts are plain PureSteel® metal drive tapes are made Machining holes into the web further Aluminum
• High Speed Packaging PureSteel® metal belts.
metal belts manufactured with precision of the same high-quality strip as metal reduces weight. Aluminum with hard coat anodize is a
• Cutting
perforations that can be produced
mechanically, chemically or by using
belts but, unlike belts, drive tapes are
not endless. Drive tapes are fitted
DESIGNS Capped Tube frequent choice. The combination is
strong, light weight, tough and cost
Most pulleys for PureSteel belt systems
® These pulleys employ end caps attached
non-impact methods. They are used with specialized end attachments or effective. Extremes of temperature can be
take one of three forms: round stock, to the ends of tube stock having sufficient
in applications such as: perforations. They can perform with a limiting factor; however, and outgassing
I-beam or capped tube. Any of these pulley wall thickness to ensure adequate strength.
zero or near zero backlash in applications may be an issue in vacuum environments.
• Timing types may be designed with drive lug timing The capped assembly is then machined to
including:
• Carriage Positioning pockets, relief channels, conventional meet rigid specifications for roundness and Stainless Steel
• Vacuum Conveying • Carriage Positioning timing teeth or Belt Technologies’ patented concentricity. Again, it is crucial to reduce In corrosive operating environments,
• Web Conveying • Plotters ball bearing timing teeth. weight without compromising strength. stainless steel is a good choice. Stainless
• Indexing • Robot Arms steel also offers excellent wear and strength
• Read/Write Head Positioning Round Stock Low Inertial Pulley
characteristics. There are many different
• Optical Element Drives Because of their relatively low cost, These pulleys consist of a solid thin-walled
alloys available, each with special advantages.
round stock pulleys are incorporated into stainless steel cylinder with welded stainless
most system designs. Normally, round steel end caps. This design gives the Non-Metals
stock pulleys are used in sizes up to 6” designer the lowest possible inertia without Certain plastics can offer excellent wear
outer diameter with widths up to 4”. sacrificing rigidity. and strength characteristics. In some
applications and in high volume, plastic
I-Beam can be less costly than metal pulleys.
As diameter and width increase, rotational
Figure 1 – PureSteel® inertia considerations may require a pulley
Plain Belts with an I-beam cross section. An I-beam
Figure 3 – Figure 5 – Combination Belts
PureSteel® Belts
with Attachments
TOLERANCES Table 1 – Pulley Tolerance up to 14” (0.36 m) Diameter
TIMING PULLEY FRICTION PULLEY
Table 1 shows typical tolerances for
Tape Support Diameter (O.D) ±0.001” (±0.025mm) ±0.002 (±0.051mm)
the primary design dimensions of
timing and friction drive pulleys. These Face Width ±0.005” (±0.013mm) ±0.005” (±0.013mm)
tolerances are applicable to the three +0.001”/-0.0000” +0.002”/-0.0000”
Bore Diameter
(+0.025mm/-0.0000mm) (+0.051mm/-0.0000mm)
pulley body designs: round stock, I-beam
and capped tube. Concentricity 0.001” (0.025mm) 0.001” (0.025mm)
Figure 2 –
PureSteel® Figure 4 – PureSteel® Timing Location 25 arc seconds N/A
Perforated Belts Drive Tapes
6 Pulleys Surface Treatments 7

TYPES OF PULLEYS Friction Drive Timing SURFACE TREATMENTS It is different from all other non-stick temperatures and extreme flexibility.
PureSteel friction drive pulleys are
®
PureSteel timing pulleys have either
® coatings in that the basecoat contains a Bonding silicone to metal belts can be
Even with all the variations in form, Surface treatments give engineers the
generally flat faced with no timing teeth or pockets located radially around carefully chosen and blended combination difficult but workable solutions do exist.
material and design features, pulleys opportunity to alter the natural surface
element. Crowning pulley faces is not the outside diameter of the pulley body. of resins and unusually hard materials,
generally serve one of two purposes: properties of a metal belt, drive tape or pulley.
friction driving or timing.
generally recommended. To discuss Teeth engage timing holes in the metal
Surface treatments may be applied to one or
permitting a far higher percentage of HARD COAT ANODIZE
the reasons why, please contact a Belt belt; pockets engage drive lugs on the special reinforcing elements than normal. Hard coat anodize is an electrochemical
both surfaces of a belt or drive tape, or to a
Technologies Engineer who is familiar belt’s inner circumference. It should be The midcoat, (actually a basecoat used in process used to increase the hardness
pulley. Application methods include coating,
with metal belt dynamics. noted that even in these pulleys, the other reinforced systems), also contains and wear characteristics and corrosion
plating, laminating and bonding.
driving is accomplished by frictional forces the special reinforcing element, while the resistance properties of aluminum pulleys.
When crowning is appropriate, two generated between the flat belt and pulley topcoat is rich in fluoropolymers and is
Depending on the method selected, the The process forms a layer of aluminum
geometries may be used: full radius and surfaces. Teeth or pockets are used only dedicated entirely to release properties
thickness of a surface treatment may be as oxide that becomes an integral part of
trapezoidal. A full radius crown is less for timing, not for power transmission. (non-stick characteristic).
Figure 6 – Perforated and little as 0.001” (0.025mm). The surface the metal, both penetrating and building
ball bearing tape pulleys stressful on the belt, but it is more difficult
can be uniform or, to provide pockets on up on all pulley surfaces. The coating
to machine and, therefore, more costly. Timing elements, particularly timing
the belt surface for transporting small URETHANE OR NEOPRENE thickness is uniform and mirrors the
The trapezoidal crown is more cost effective teeth, must be hard. Hardness is essential
components, punched or die cut. Vacuum Both urethane and open or closed cell precision of the pulley itself.
and works well, but it should be avoided in to ensure minimal wear from successive
holes can be combined with pockets for neoprene change the surface coefficient
applications having high belt tensile loads engagements of belt and pulley. As an
due to stress risers at the crown’s transition example, Belt Technologies’ patented
more positive orientation and retention of of friction of a metal belt and also can act OPTIONS
delicate parts during transport. as a nest for delicate parts. These materials
points between angled flats. Blending these pulley uses hardened ball bearings as teeth. The range of options for surface treatments is
points can be helpful but does not eliminate are securely bonded to a metal belt. Prior so large that it cannot be fully documented in
For primary mechanical and physical
the high stress risers. When designing a two-pulley timing to bonding, they can be die cut when a this guide. Unusual surface treatments have
characteristics of popular surface
system, the drive pulley should be timed specific pocket geometry is important. included fluorocarbon compounds, copper
treatments, see Table 2.
while the idler, or driven pulley, should be cladding, gold plating and powdered diamond
a friction drive pulley with relief channels SILICONE bonding. Appropriate specifications will be a
for lugs if necessary. When the environment is not suitable for function of application and technology.
other coatings, silicone may be a good
option. Silicone has unique properties The Belt Technologies Engineering staff will
including a high-friction surface, release be pleased to discuss issues related to your
properties, the ability to withstand elevated specific needs.
Figure 7 – Surface Treatments

Table 2 – Coating Properties

TEFLON® COATING CHIEF OPERATING
THICKNESS COLOR
Teflon® became a household word as MATERIAL CHARACTERISTICS TEMPERATURE
a non-stick coating for cookware. TEFLON® TFE Anti-Stick
up to 500º F 0.001” Black
Teflon is actually available in a variety up to 260º C (0.025mm) Green
up to 428º F
of formulations, each having distinct Corrosion 0.001” to 0.030”
up to 220º C
operating properties regarding release TEFLON® FEP Resistance Low
down to -328º F
(0.025mm to Metallic Gray
characteristic, lubricity, resistance to Temperature 0.75mm)
down to -200º
abrasion, temperature range and color. Hard Teflon® 0.001” to 0.0015”
up to 446º F
TEFLON® 550 for Abrasion (0.025mm to Black
up to 230º C
GATORCOAT® Resistance 0.038mm)
0.001” to 0.006”
FDA-approved Gatorcoat® coatings are Food Contact up to 500º F
GATORCOAT® (0.025mm to Metallic Gray
Approved up to 260º C
high-release and extremely wear-resistant 0.15mm)
NOTE: coatings. Their unique three-coat, high-cure, SILICONE Excellent Release up to 392º F
0.004” (0.10mm) Various
Both friction and timing pulleys can be designed as internally-reinforced, non-stick surface RUBBER High Friction up to 200º C
narrow-bodied rolls. Essentially, the narrow-bodied 0.008” to 0.125”
offers abrasion resistance over 10 times that POLYURATHANE up to 158º F
roll is a pulley whose width is narrower than the High Friction (0.203mm to Various
of Teflon®. It is household chemical resistant MOLDABLE up to 70º C
belt that is running on it. They can make belt 3.175mm)
and features high non-stick properties, 0.016” to 0.250”
tracking easier and reduce total pulley weight as NEOPRENE Compressibility up to 158º F
well as cost. The pulley face is typically not less
stain resistance and performance at high (0.40mm to Black
RUBBER Die Cut Pockets up to 70º C
temperatures. 6.4mm)
than half the width of the belt.
8 Design Considerations Design Considerations 9

F1
NOTE TO THE DESIGNER Driving Pulley Figure 8 – Loading Stress 3. DETERMINE BENDING 4. DETERMINE THE TOTAL
With information from previous sections, F2 STRESS (Sb) ON BELT. STRESS (St) ON THE BELT. TYPICAL SIZES AND
you may have begun thinking about
Driven Pulley A significant bending stress is induced in a The total stress on the belt is the sum of the SPECIFICATIONS
the design for your metal belt. This metal belt as it is repeatedly flexed over a working stress (SW) and the bending stress
section builds on the previous sections pulley. This stress must be calculated and (Sb). Metal belts typically range in
by incorporating elements that will help added to the working stress SW (see Step 4) thickness from 0.002” (0.051mm)
you optimize system performance. Since
every design is unique, it is not possible
1. DETERMINE THE WORKING 2. DETERMINE THE HIGHEST to determine the total stress St on the belt. St = Sw + Sb to 0.031+” (0.8mm) resulting in
to discuss every design consideration. LOAD (FW) ON THE BELT. LOAD (F1) ON THE BELT. The formula for the bending stress is: Fw
pulley sizes of 2” (50mm) to 20”
(504mm) in diameter. A typical
You are invited to review your design The working load can be determined from Since FW = F1 - F2 as shown in the two Et Sw =
bxt metal belt with a thickness of 0.005”
ideas, numbers and methods with a the driving motor torque rating, the load to pulley example in Step 1, F1 is the greatest Sb = (0.127mm) with a 1,000,000 cycle
Belt Technologies Engineer. be moved or accelerated, or by an analysis force on the belt. To design for the stress (1- u )D
2
life would require pulleys with a 3.125”
of the system requirements. For a simple condition resulting from this force, we Where:
(79.4mm) diameter. Size ranges vary
SYSTEM DESIGN GUIDELINES two-pulley system as shown in Figure need to calculate its value. For a friction Where: b = belt width
by application and load considerations,
8, the working load on the belt (Fw) is drive system to operate without slippage, E = modulus of elasticity in psi (N/mm2) t = belt thickness
Any system with metal belts is generally so please talk to a Belt Technologies
enhanced by following these guidelines: FW = F1 – F2, where: the two forces, F1 and F2 are related by t = belt thickness in inches (mm) Applications Sales Engineer for help
the formula: Belt Technologies recommends that St
D1 and D2 = pulley diameters D = smallest pulley diameter in inches (mm) with your design ideas.
• Use as few pulleys as possible. not exceed one third the belt material yield
• Use large pulley diameters. F1 - FC u = Poisson’s Ratio strength. For further information, please
and 2= torque action on μθ contact a Belt Technologies Engineer.
• Use pulley systems that avoid reverse 1
respective pulleys =e Table 3 – Belt Life
F2 - FC This calculation requires an assumption of
bending.
belt thickness and pulley diameter. Pulley At this point it is necessary to select PULLEY DIAMETER TO BELT LIFE
• Use large length-to-width ratios. F1 and F2 = force on belt at each pulley BELT THICKNESS RATIO EXPECTANCY
diameter may be the easiest to determine various parameters and work back through
in lbs force (newtons) Where: because of space limitation or other design the calculations to find a combination
LOADING e = 2.71828 requirements. If this is so, pick the maximum that will satisfy design requirements. 625:1
1,000,000
cycles or greater
FW is related to the torque by the equation:
Proper system design includes an μ = coefficient of friction between possible pulley diameter, then calculate the Obviously, using a wider belt reduces 400:1 500,000
examination of the various loads belt and pulley appropriate belt thickness based on Table 3. working stress without changing bending
transmitted to the belt in use. In addition
1 2
stress. Larger pulley diameters reduce 333:1 165,000
FW= θ = angle of wrap in radians of belt
to steady-state operating conditions, 1/2 D1 = 1/2 D2 bending stress or allow use of a thicker 200:1 85,000
on pulley
consideration must be given to any unusual belt, which in turn reduces working stress. Relationships are based on a two-pulley
or intermittent conditions such as potential FC = centrifugal force acting on belt friction drive system.
And to acceleration by:
jam-up, high startup loads or indexing.
For a metal belt with a standard finish
In general, the belt should be designed to L
FW=ma= (such as 0.4 micro-meter) operating on
ensure that high loading, should it occur,
gxa a machined metal pulley, experience has
will not exceed the belt’s ultimate strength.
shown the value of μ ranges between
Where: 0.25 and 0.45.
To determine the stress factor on any
L = load on belt in lbs force (newtons)
given belt, add together the results from
g= 32.2 ft/sec2 (9.8 m/sec2) One advantage of a thin metal belt is
the following four columns.
that Fc is usually negligibly small and can
a = acceleration of load in ft/sec2 (m/sec2) be disregarded. Thus, in most cases, the
formula can be simplified to:

F1
= eμθ
F2

Substituting for F2 and solving for F1, this

becomes:

FWeμθ
F1=
eμθ -1
10 Design Considerations Design Considerations 11

BELT LENGTH ACCURACY BELT STRETCH ZERO BACKLASH POSITIONING ACCURACY

One of the most important advantages Metal belts are unique as they will Zero and near-zero backlash positioning Positioning accuracy is directly related to
Figure 9 – Positioning Accuracy
of a metal belt is its overall accuracy. not stretch in normal operation after systems can be achieved through the the belt pitch tolerance, typically +/-0.001”
Perforated belts or belts with attachments achieving a normal preload tension. To use of metal belts. Run in pairs or with (0.025mm) for a metal timing belt. With
can be fabricated with pitch accuracies of calculate preload stretch for a plain belt, use inventive design ideas, these drives can special tooling, the pitch can be made to
+/-0.0005” (0.0127mm). Plain belts and the following equation. For perforated belts, be used anywhere that tolerances exist accumulate positively, shown as Pl in Figure
drive tapes can also be fabricated to a high please contact a Belt Technologies Sales for back-and-forth placement accuracy. 9, or negatively, shown as Ps in the same
degree of accuracy. Engineer. The illustrations below offer two typical graphic. These adjustments can also be
zero-backlash drive suggestions. interspersed within the same tool to virtually
BELT LENGTH ΔL = PL/AE eliminate the accumulated pitch error.
To calculate a length for a metal belt, use Where:
the formula below. It is important to know ΔL = stretch, in inches (mm) REPEATABILITY
the ideal design envelope of your system P = tension load in lbs force (newtons) Repeatability is the ability of a single
Up to 340° Pulley Rotation
before calculating belt length. Larger pulley pitch, on successive rotations of the belt,
diameters usually provide optimum belt L = initial belt length in inches (mm) Master to return to a home position within a
life, and pulley diameters can be used to A = belt cross section area in inches (mm) specified tolerance.
estimate belt thickness. See Table 3 for E = Young’s Modulus
life expectancy. Once a maximum pulley Because metal belts do not stretch, Figure 10 – Repeatability
repeatability is typically in the range of belt to track away from the tight edge of
diameter is known, divide it by the ‘pulley tension towards the loose edge when the
diameter to belt thickness ratio’ from Table Slave 0.002” (0.051mm) to 0.005” (0.127 mm).
belt is rotated.
3 for optimum belt life in your application. Idler For plain or perforated belts, belts with
Typical belt thickness ranges from 0.002” Output attachments or drive tapes, precise motion The primary objective of any tracking
[0.05mm] to 0.031” [0.813mm], and can be calculated with a high degree of technique is to counteract the influence
typical pulley diameters range from 2” accuracy. Contact a Belt Technologies Sales of accumulative negative tracking stresses
to 20”. Engineer for assistance in determining the and forces (previously defined as system
specifications for your system. squareness, uncontrolled shaft deflection,
L = 2 x C + ((D + t) x ) differential loading and belt camber) with
controlled stresses and forces, thus tuning
Where: BELT TRACKING the belt to run on the system.
L = belt length Approximately 360° of Pulley Rotation Given that a metal belt will not significantly
Figure 11 – Camber
C = center distance between two pulleys stretch under tension, tracking a metal belt Three basic techniques are used to track
D = pulley diameter can be more difficult than tracking other belts on systems using friction pulleys,
belt types. A metal belt will not stretch to timing pulleys or both:
t = belt thickness compensate for:
= 3.14159 • Pulley axis adjustment
• Lack of system squareness or alignment • Crowning friction drive pulley systems, the ISP can be fitted with
This defines the appropriate length for metal • Uncontrolled pulley shaft deflection • Forced tracking sensors and a servo motor package
belt systems incorporating two pulleys of • Differential loading to deliver hands-free automated
identical diameter. For systems with multiple • Belt camber ADJUSTABLE PULLEY tracking of metal belts. Contact your
pulleys or pulleys of different diameters, Belt Technologies has patented an Belt Technologies Sales Engineer for a
please contact a Belt Technologies Sales Among these, the Design Engineer is
probably least familiar with belt camber. Independently Steerable Pulley (ISP) supplemental engineering paper on the
Engineer. Contact information is listed to aid in the tracking of all flat belts, Independently Steerable Pulley and
inside the back cover. Camber, or edge bow, is the deviation
of a belt edge from a straight line. Every including metal belts. In automated how it might benefit your application.
belt has some camber. Metal belt camber
is typically less than 0.050” (1.27mm) in
8’ (2.44 m). When placed in a squared
two-pulley system and tensioned, one
edge of the belt will be tensioned more
than the other because it has a shorter
edge circumference. This will cause the Figure 12 – Forced Tracking
12 Design Considerations Design Considerations 13

PULLEY AXIS ADJUSTMENT Figure 13 – Pulley Axis Adjustment TENSIONING SYSTEM FRAME STIFFNESS MAGNETIC PERMEABILITY
Adjusting the pulley axis in a metal belt Friction drive systems can operate with A stiff system frame is necessary to allow Magnetic permeability is commonly
system as shown in Figure 13 is the tensions as loose as a bicycle chain and fine adjustments for timing and belt tracking. defined as a measure of the ability of a
most effective way of tracking a metal as tight as a guitar string. Belt tension is If there is uncontrolled flex in the system substance to carry magnetism as compared
belt. Belt edge tensions are changed in extremely important in timing systems frame, the system will bow when the belt to air, which has a permeability of 1.
a controlled manner, thus steering the and should be kept as low as possible. In is tensioned. Offsetting one force (system
belt. The technique is equally applicable general, low belt tension improves belt flex) with another force (axis adjustment) Three hundred series stainless steels are
to both flat-faced and crowned pulleys. life and reduces wear on other system does not provide a controlled system and considered to be nonmagnetic, but the
FORCED TRACKING TIMING components. can result in tracking problems. To make sure cold working used to produce their spring
Ideally, both the drive and idler pulleys In cases where simple axis adjustment Timing pulleys for metal belts are either that any axis adjustments are controllable, it temper and high-tensile strength results
would have adjustable axes. In reality, cannot completely eliminate improper toothed or pocketed, each engaging Belt tension should not be increased to is important to design sufficient stiffness into in an increase in magnetic permeability.
however, only the idler is adjusted. The tracking, forced tracking methods respective belt perforations or drive lugs. reduce sag between pulleys. Over-tensioned the system. Therefore, 301 full hard has a greater
drive pulley is usually difficult to adjust such as cam followers or flanges made belts may develop a crossbow, much like magnetic permeability than 301 half hard.
Care should always be taken in the
due to its interface with motors or other
power transmission devices.
preferably from glass filled Teflon® may
design of timing pulleys to ensure that
that on a tape measure. In addition to a
cross bow, over tensioning will cause uneven
REVERSE BENDS Generally, 316 stainless has the lowest
magnetic permeability.
be necessary and acceptable. System
all timing elements have spherical or motion, reduce repeatability and reduce The best system design utilizes two pulleys.
design relationships may need to change,
CROWNING FRICTION DRIVE such as using a thicker belt than might involute radii. This ensures smooth belt life. Adding reverse bends to the system adds
bending stress, compromising belt life.
Refer to the Appendix for rated magnetic
permeability properties of common metal
engagement and disengagement of the
PULLEYS be otherwise recommended, since forced
belt and pulley. To avoid problems due to Belt tension should be determined by Because each pulley can have a steering belt alloys
tracking techniques can contribute to a
When crowned friction drive pulleys must accumulated tolerances, the clearance of the operating system and selecting the influence, tracking problems can result.
decrease in expected belt life.
be used, it is in conjunction with—not in the belt/pulley timing features typically lowest possible workable tension. This BELT SAG
place of—axis adjustment. This is because An alternative forced tracking technique should be at least ±0.005” (0.127mm) to can be maintained through the use of air CANTILEVERED SHAFTS When the span between pulleys is long,
crowned pulleys will not self-center a for wider belts employs a V belt bonded ±0.007” (0.178mm). Zero or near zero cylinders, springs or jack screws. It is preferable for pulley shafts to have the belt can sag. Even on the tight side
metal belt. Crowned pulleys work best on to the inner circumference of the metal backlash applications are a special case. solid termination points at each end. of tension there is some sag. To ensure
thin belts as the belt web must conform belt. This two-element belt, which Belt Cantilevered shafts can create a pivot. proper tension and prevent sagging, drag
to the crowned face of the pulley. While Technologies calls Metrak©, distributes When manufacturing a toothed pulley,
When tension is introduced, the shaft may the working surface of the belt across
increased tension can be used to achieve tracking stresses on the V belt rather than each timing tooth is inserted into a hole
Figure 15 – Timing Pulleys deflect and can cause tracking problems. a stationary support surface such as
belt to pulley face conformity, tension on the metal belt, thus maximizing belt life machined in the pulley body. Great care
If cantilevered shafts are necessary, their ultra-high molecular weight materials
cannot be so high as to cause permanent in a forced tracking system (Figure 14). must be given to the radial location of each
stiffness must be ensured through the (UHMW). Avoid rotating surfaces,
belt deformation. The best face geometry tooth to ensure overall pitch accuracy.
frame design and shaft rigidity. which can introduce axial shift and cause
for a crowned pulley is a full radius with Timing teeth, discussed in the next section,
While designing a timing pulley, it is tracking problems. Sliding or dragging
the crowning being no more than the are for timing only and should not be used
critical that the pitch diameter be at the the belt across a stationery surface has a
belt thickness. for tracking.
neutral axis of the belt (one half the belt negligible effect on tracking or belt life.
thickness for a thin flat belt), not at the
base. Since metal belts are generally thin,
there is a temptation to neglect their
thickness in calculating the pulley tape
support diameter. Failure to include the
belt thickness in these calculations results
in mismatching of timing elements.

The tape support diameter can be

determined by the formula:

NP
D= –t

Where:
N = number of pitch lengths or teeth
on a pulley
Figure 14 – Forced Tracking
P = perforation pitch
t = belt thickness
14 Design Considerations Design Considerations 15

ELEVATED TEMPERATURES Table 4 – Elevated Temperature Characteristics of Principal Alloys

APPENDIX: METAL BELT DESIGN IMPOSED RESTRICTIONS of 10,000 revolutions may be excellent for
one application, whereas another belt may
If a metal belt will be exposed to elevated ALLOY
TEMPERATURE
MEAN COEFFICIENT OF
THERMAL EXPANSION
MEAN YIELD STRENGTH OF
TEMPERATURE RANGE IN
MATERIALS Application restrictions such as space
make 10,000 revolutions each hour.
temperatures, it is crucial that the RANGE ºF (°C) limitations or unusual chemical, thermal,
10-6IN/IN/ºF (CM/CM/ºCX10-6) 1000 PSI (N/MM2) Particularly demanding applications—such as
material selected for the belt, as well as 301/302 68 to 400 160 to 135 those involving high temperatures, extremely electrical or system requirements, may So how long can you expect your metal belt
any attachments or surface treatments, 9.4 (16.9) demand design tradeoffs. Consider
Full Hard (20 to 204) (1,100 to 930) corrosive environments, or unusual electrical to last? While not trying to avoid what is a
be able to withstand the temperature. 400 to 800 220 to 170 or magnetic requirements—may preclude these examples: fair question, the best answer is: it depends.
Consideration also must be given to the 17-7 CH-900 6.1 (10.9)
(204 to 426) (1520 to 1170) the use of certain alloys for metal belts and
expansion and contraction of the materials • Metal belts do operate on pulleys with It depends on factors such as system
Inconel® 718 drive tapes. The following Materials Table diameters as small as 1/4” (6.35mm),
as temperature fluctuates. Changes due to Solution 800 to 1,000 157 to 155 design, material strength, environment,
6.6 (11.9) summarizes important selection criteria. but belt life is reduced.
temperature will impact timing, tracking, Annealed and (426 to 537) (1082 to 1068) stress, tension, surface treatments,
tension, flatness and other factors. Heat Treated • Belts operate in ovens up to 1,000°F attachments, etc. The same factors that
(537°C), but because much of the have an effect on the design of your system
Table 4 lists the principal alloys used BELT CREEP Within the effective arc, the belt and belt’s strength comes from cold working and your metal belts also affect belt life.
in specific temperature ranges as well pulley surfaces are in sliding contact and or specific heat treatments, such high
Belt creep is a phenomenon associated With the preceding in mind, it is indeed
as corresponding thermal expansion the surface speed of the pulley is greater temperatures reduce belt strength.
with power transmission between a drive reasonable to say that metal belts have the
coefficients and yield strengths. Table than that of the belt. This phenomenon Refer to Table 6.
pulley and the tensile member of the belt. potential to significantly outlive other belt
5 illustrates how physical properties is caused by dimensional changes in the • Doctor blades can induce a cupping
Due to creep in a friction drive system, types and chain. They also have the potential
of 17-7 CH-900 change as a function belt due to the differential forces acting effect across the belt width. Properly
the pulley actually moves slightly faster to be more accurate and repeatable, lighter,
of temperature. on it as it passes around the pulley. As designed doctor blades, such as those
than the belt. faster and more cost effective.
sliding contact occurs, frictional forces made of UHMW, can minimize the
Consider Figure 16. The 180° of wrap are developed to match changes in belt negative effects.
Table 5 – Physical Properties vs. Temperature A discussion with a member of our
between drive pulley and belt is divided tension and power is transmitted.
Changes (17-7 CH-900) Engineering staff can help you estimate
into two arcs:
Because the tensile member of a metal
BELT LIFE the belt life you can expect in your
Ultimate Tensile Strength, ksi

belt is the metal belt with its associated Belt life means different things to different specific application.
• The idle arc (where no power
high modulus of elasticity, creep in a people and different processes. A belt life
is transmitted)
• The effective arc, also called the metal belt is much less than that in belts
made of most other materials. Table 6 – Some of the most popular metal belt alloys and their room temperature engineering properties
angle of creep (where power
THERMAL
transmission occurs) YIELD THERMAL
If not controlled, however, creep in a STRENGTH TENSILE TENSILE CONDUCTIVITY
EXPANSION
ELONGA- MODULUS OF (32° TO 212° F)
friction drive metal belt results in a loss of
0.2% Yield Strength, ksi

(0.2% STRENGTH POISSON’S DENSITY COEFFICIENT MAGNETIC CORROSION

Within the idle arc, the belt and pulley ALLOY TION IN HARDNESS ELAS-TICITY IN BTU/FT2/HR/
OFFSET) 1000PSI RATIO #/IN3 (32° TO 212° F) IN/ PERMEABILITY RESISTANCE
surfaces are in static contact and no repeatability. Fortunately, creep in metal 51MM % 106 PSI ºF/IN
1000PSI (N/MM2) IN/º F (0° TO 100°C)
belts is easily controlled. (IN 105 N/MM2) (0° TO 100°C)
power is transmitted. The belt runs onto (N/MM2)
CM/CM/°CX10-6
CM/CM/°CX10
the pulley with tight-side tension T1 and 180
Timing teeth or lugs are the most common 301 FULL HARD 160 (1100)
(1240)
5-15 RC40-45 28 (1.93) .285 0.29 (7.9) 113 (0.039) 9.4 (16.9) L-M M
speed V1, which matches the surface
way to combat creep. The number of 260 280
speed V1 of the drive pulley. Both speed 301 HIGH YIELD 1 N/A 26 (1.79) .285 0.29 (7.9) 113 (0.039) 9.4 (16.9) L-M M
Elongation in 2” ,%

timing locations should be the smallest (1790) (1930)

and tension remain constant as contact 180
number possible to prevent creep from 302 FULL HARD 160 (1100)
(1240)
1-5 RC40-45 26 (1.79) .285 0.29 (7.9) 113 (0.039) 9.6 (17.3) L-M M-H
continues through the idle arc.
occurring. In many systems, it is possible to 180
304 FULL HARD 160 (1100) 1-5 RC40-45 26 (1.79) .285 0.29 (7.9) 113 (0.039) 9.6 (17.3) L-M M-H
have as few as six to eight timing locations (1240)
316 FULL HARD 175 (1200) 190 (1310) 1-2 RC35-45 28 (1.93) .285 0.28 (7.8) 97 (0.036) 8.9 (16.0) L H
in the circumference of the pulley. 210 260
716 FULL HARD 5-10 RC52 32 (2.20) .285 0.28 (7.8) 170 (0.059) 5.9 (10.6) H L-M
(1450) (1790)
17-7
Figure 16 – Creep Theory 185 (1275) 215 (1480) 5 RC43 28 (1.93) .305 0.28 (7.8) 114 (0.037) 8.5 (15.3) M-H M-H
CONDITION C
AB is the idle arc. BC is the effective arc. 240 250
17-7 CH-900 2 RC49 29 (2.00) .305 0.28 (7.8) 114 (0.037) 6.1 (10.9) M-H M-H
(1655) (1720)
210
INCONEL® 718 175 (1200) 17 RC41 29 (2.00) .284 0.29 (7.9) 86 (0.030) 6.6 (11.9) L H
(1450)
CARBON
240 260
STEEL 7-10 RC50-55 30 (2.07) .287 0.29 (7.9) 360 (0.124) 5.8 (10.5) H L
(1650) (1790)
SAE 1095
TITANIUM
150
15V-3CR- 165 (1140) 11 RC35 15 (1.03) .300 0.17 (4.7) 56 (0.019) 5.5 (9.7) L M
(1030)
3AI-3SN
INVAR 36 50 (340) 75 (520) 30 RB80 20 (1.38) .317 0.30 (7.9) 120 2.1 (1.2) L M-H
16 Pulleys Used With Metal Belts Pulley Body Materials 17

A REVIEW OF GENERAL DESIGN PULLEY BODY MATERIALS: Stainless steel is used selectively as a pulley Following are formulas to approximate the
body material in metal belt applications. Type weight in pounds of solid round stock pulleys
CONCEPTS FOR PULLEYS USED Once the pulley diameter has been
304 is selected for its corrosion resistance, made of the materials described:
WITH METAL BELTS: determined, the Design Engineer needs
and while less corrosion resistant, Type
to evaluate the best material for the pulley Stainless Steel (0.223 x D2) x Width
• The use of crowned and/or flanged pulleys 440-C is used in those applications requiring
body, considering pulley weight, corrosion
is not universally recommended for metal a through hardness in the order of RC50. Aluminum (0.077 x D2) x Width
resistance, wear resistance, coefficient of
belt applications. These designs are used These choices come at the expense of greatly
friction, and cost. Most pulleys specified
selectively and should be utilized only after increased weight and cost. In the case of Type Plastic (0.040 x D2) x Width
and manufactured by Belt Technologies are
contacting a Belt Technologies Engineer 304, tight tolerances are more difficult to
made of 6061-T6 aluminum with hard coat Sizing the belt to the pulley is important.
who is familiar with both metal belt hold as a result of temperature build up and
anodize. Aluminum is light weight, easy to The Application Sales Engineer and Design
dynamics and application idiosyncrasies. resulting thermal expansion when the pulley
machine, and stable under load. When hard Engineer can make recommendations for
• The manufacture of either friction drive or is being machined.
coat anodized, these pulleys have wear- the proper pulley width to belt width ratio
timing pulleys for precision systems using resistant surfaces with a proper coefficient Plastics and composites are also used as pulley depending on the application, tracking
metal belts is not a matter of simply turning of friction to drive the metal belt. For timing body materials. They offer the lowest weight, requirement, weight and what type of
round stock. The precision and repeatability pulleys, hardened timing elements can be but not necessarily the lowest cost. As with pulley configuration is chosen.
of the metal belt will only be as good as the press fit into the aluminum pulley body. aluminum, hardened timing elements can be
precision of its complementary pulleys. Toothed pulleys are based on a patented press fit into the pulley body. Bores, keyways,
Belt Technologies’ design which uses bearing and taps can be added via QD® bushings.
balls (Fig. 18 and Fig. 19) as timing teeth. An With the proper choice of materials, wear
alternate timing design makes use of modified resistance is excellent, no particulate is
drill bushings (Fig. 17) which are pressed into generated, and the coefficient of friction
Fig. 17 – Drill Bushing Timing Pulley the TSD surface of the pulley. These bushings complements the metal belt system.
act as timing pockets which engage timing
lugs on the belt.

Fig. 18 - Conveyor featuring Ball Bearing Timing Pulley

Fig. 19 - Ball Bearing Timing Pulley

18 Primary Design Considerations - Pulleys Pulley Body Geometries 19

DIAMETER: PULLEY BODY GEOMETRIES: A belt’s tracking characteristic is a function which works with metal belts as thin as
of uncontrolled stresses and forces acting 0.005 inch. Teflon® flanges are attached
When designing a pulley for a metal High throughput, precision position
on the belt. Belt Technologies recommends to the pulley body via a bolt hole circle in
belt application, a critical design factor indexing for automated assembly and
controlling these stresses and forces to the both the flanges and the pulley body.
is the pulley’s diameter. There are two inspection systems require low weight
Design Engineer’s advantage. The belt and
considerations when determining diameter; and low rotational inertia pulleys. When The balance of this Design Guide will detail
pulleys are tuned relative to one another
the diameter which is best for any design the system index profile is integrated to pulley design standards for the major
using pulley axis adjustment. The belt is
constraints of the system, and the diameter the belt/pulley system it may be found pulley types and body styles. Included
steered to a stable tracking state, with the
which best manages bending stress in the that solid round stock pulleys are not will be: Friction Drive, Type I and Type II
center of the belt width at the center of
metal belt to assure optimum performance the proper design. Alternate pulley body Timing, I-Beam, Capped Tube, and Belt
the pulley width.
and longevity. designs are the I-Beam and the Capped Technologies’ patented Independently
Tube. The I-Beam design is used for Traditionally, axis adjustment has been Steerable Pulley.
The proper pulley diameter in a given pulleys up to 8” of face width, after which
Table 7. Expected Belt Life in Friction Drive Systems for Different Pulley Diameter to Belt Thickness Ratios introduced by adjusting pulley shaft
application is defined in terms of a pulley the Capped Tube becomes the preferred terminating pillow blocks left/right and up/
diameter to belt thickness ratio. Ideally, this DIAMETER/BELT THICKNESS RATIO BELT LIFE
design. Both options are relatively down, with belt tracking accomplished by an
ratio will be 625:1 or more. This relationship 625:1 Minimum of 1,000,000 Cycles expensive as I-Beam requires a great deal iterative process of such adjustments. Using
typically results in total stresses which are 400:1 500,000 Cycles of machining, and Capped Tube requires Belt Technologies’ petented Independently
one-third the yield strength of the metal 333:1 165,000 Cycles increased fabrication. Steerable Pulley is substantially easier. This
belt (with total stresses defined as the sum 200:1 85,000 Cycles design is based on the use of a steering collar
of bending, working, and loading stresses). (With a lifecycle defined as one complete belt revolution around a two pulley system) TRACKING: and bearing assembly which press fits into
As the diameter to thickness ratio When considering pulley design, the the body of an idler pulley. Rotating the
decreases, belt bending stress increases, Design Engineer needs to consider how the pulley shaft rotates the steering collar,
For all steel belt systems, the neutral axis t = Belt thickness which changes the pulley’s face angle
and belt life is reduced. Based on bending metal belt is going to be tracked. Traditional
has been determined to be one-half the relative to the shaft. This controlled use of
stress life testing conducted by Belt The timing pulley TSD is approximated by elastomeric belt tracking designs such as
belt thickness. The formula to determine stresses and forces tracks the belt quickly
Technologies, the following table details the preferred 625:1 pulley diameter to belt crowning the face of the pulley or using
the TSD of the pulley which results in the and dynamically.
expected belt life in a friction drive system thickness ratio, then adjusted to achieve flanges are only used selectively to assist in
belt being driven at its neutral axis is:
for select pulley diameter to belt thickness a balance between the number of timing tracking metal belts. Crowned pulleys help
Regarding the use of flanges, Belt
ratios, without consideration for other NxP elements, timing pitch, and belt thickness to stabilize any off-tracking characteristic
Technologies will recommend steel flanges
stresses which may impact belt life. TSD = -t to obtain the appropriate TSD. of a metal belt but will not self-center the
for belt thicknesses greater than 0.010”.
metal belt. Flanges, with the exception of
A timing pulley used with a metal belt For belt thicknesses under 0.010”, we have
Teflon® flanges as detailed later, are used at
must be designed with an O.D. (or with a where: perfected a design using glass filled Teflon®
the expense of belt life.
metal belt what is known as a Tape Support TSD = Tape Support Diameter
Diameter, or TSD) such that the metal
N = Number of timing elements
timing belt will be driven at its neutral
axis. This assures smooth engagement and P = Timing pitch
disengagement of the belt to the pulley.
Isp / I-Beam Pulley Capped Tube Pulley Teflon® Flanged Pulley
20 Friction Pulley Design Timing Pulley Designs 21

FRICTION PULLEY DESIGN: Type I Type II

To maximize belt life, whenever possible metal
belts should be used with friction pulleys. When an
application requires timing or repeatability, a timing
pulley is used at the driving end of the system and a
friction guide pulley at the driven end of the system.

The drawing and the table below detail typical

dimensions and corresponding tolerances of
a friction pulley design. To minimize tracking
complications, Belt Technologies manufactures
these pulleys to a 0.002” (0.051mm) concentricity.

Belt Technologies custom manufactures pulleys

for each application. The TSD sizes indicated
are for illustrative purposes only and are
intended to delineate the range of sizes and the
Type I Type II
interrelationships of other design criteria.

Table 8. Typical dimensions and corresponding tolerances of a friction pulley design Table 9. Typical dimensions and corresponding tolerances of a timing pulley design
A A B C D F
B C D E F E
TSE TSE BORE KEYWAY WIDTH KEYWAY HEIGHT MINIMUM WIDTH
BORE KEYWAY WIDTH KEYWAY HEIGHT UNF TAP MINIMUM WIDTH UNF TAP
+ 0.0015 (+.050MM) - + 0.0015 (+0.0381MM) +0.0015 (+0.0381MM) +0.002 (+0.050MM) +0.010 (+0.254MM) +0.010 (+0.254MM)
+ 0.0015 (+.0381MM) - + 0.002 (+.050MM) - + 0.010 (+.254MM) - N/A + 0.010 (+.254MM) - N/A
0.0000 (-.050MM) - 0.0015 (-0.0381MM) -0.0000 -0.000 -0.000 -0.010
0.0000 (MM) 0.000 (MM) 0.000 (MM) N/A 0.010 (MM) N/A
(MM) (MM) (MM) (MM) (MM) (MM)
1/4 – 28 5/16- 28
2.000 (50.80) 0.7500 (19.05) 0.188 (4.775) 0.837 (21.259) 0.250 (6.35) 2.860 (72.644) 1.0000 (25.40) 0.250 (6.35) 1.114 (28.295) 0.500 (12.700)
(M6 X 1.0) (M8 x 1.25)
5/16 – 24 5/16- 28
3.000 (72.20) 1.0000 (25.40) 0.250 (6.350) 1.114 (28.295) 0.375 (9.52) 3.815 (96.901) 1.0000 (25.40) 0.250 (6.35) 1.114 (28.295) 0.500 (12.700)
(M8 X 1.25) (M8 x 1.25)
5/16 – 24 3/8- 24
4.000 (101.60) 1.0000 (25.40) 0.250 (6.350) 1.114 (28.295) 0.500 (12.70) 5.725 (145.415) 1.2500 (31.75) 0.313 (7.95) 1.178 (29.921) 0.500 (12.700)
(M8 X 1.25) (M10 x 1.50)
3/8 – 24 3/8- 24
6.000 (154.40) 1.2500 (31.75) 0.313 (7.950) 1.178 (29.921) 0.500 (12.70) 7.634 (193.904) 1.2500 (31.75) 0.313 (7.95) 1.178 (29.921) 0.500 (12.700)
(M10 X 1.50) (M10 x 1.50)
3/8 – 24 3/8- 24
8.000 (203.20) 1.2500 (31.75) 0.313 (7.950) 1.178 (29.921) 0.500 (12.70) 9.544 (242.419) 1.2500 (31.75) 0.313 (7.95) 1.178 (29.921) 0.500 (12.700)
(M10 X 1.50) (M10 x 1.50)
3/8 – 24 3/8- 24
10.000 (254.60) 1.2500 (31.75) 0.313 (7.950) 1.178 (29.921) 0.500 (12.70) 10.000 (323.266) 1.2500 (31.75) 0.313 (7.95) 1.178 (29.921) 0.500 (12.700)
(M10 X 1.50) (M10 x 1.50)
3/8 – 24
14.000 (355.60) 1.2500 (31.75) 0.313 (7.950) 1.178 (29.921) 0.500 (12.70)
(M10 X 1.50)
TIMING PULLEY DESIGNS its neutral axis, the Illustrative TSD’s
shown in the table are based on a 1.000”
Belt Technologies’ PureSteel® timing
(25.4mm) timing pitch and a 0.005”
pulley design incorporates a pulley body of
(0.127mm) thick belt.
hard coat anodized aluminum, into which
hardened timing components are press fit. As with the PureSteel® friction drive
design, a Belt Technologies’ PureSteel®
In the Type 1 timing pulley shown above,
timing pulley is manufactured to a 0.002”
a hardened tooth press fit into the pulley
concentricity. Other critical tolerances
body engages a perforation in the belt. In a
in a timing pulley are the radial location
Type II timing pulley a modified drill bushing
tolerance (G) of +/- 10 seconds for both
engages a timing lug on the metal belt.
pulley types, and a tooth height tolerance
As a timing pulley diameter must be of within 0.003” (0.076mm) true position.
designed so the belt will be driven at
22 I-Beam And Capped Tune Designs Patent# 5,427,581 - Independently Steerable Pulley 23

I-BEAM AND CAPPED TUBE: INDEPENDENTLY STEERABLE PULLEY:

When designing a pulley, the most Pulley Adjusts Instead A steering collar-bearing assembly is press fit into
fundamental consideration is establishing of Shaft the body of a friction drive idler pulley constructed
whether it will be used as a friction as a solid body or I-Beam. The steering collar serves
or timing pulley. Once determined, I-Beam with Steering Collar a dual role in that it is the method by which the
Minimum pulley diameter 4.00 (10.16cm)
the Design Engineer then begins to pulley is affixed to a dead shaft, as well as the means
Minimum face width 3.00 (7.62cm)
incorporate additional design features best by which a belt can be dynamically tracked. For
Maximum face width 8.00 (20.32cm)
suited to the specific application. If a solid additional details, please refer to Belt Technologies
round stock pulley design is incompatible Independently Steerable Pulley New Product Data
with overall system objectives (primarily Sheet.
the requirement for low rotational inertia
due to an aggressive precision position To assist the Design Engineer in sizing the pulley
indexing motion profile) the pulley body assembly to the system, the drawing and part
can be changed to an I-Beam or Capped tabulation below details overall design dimensions of
Tube type construction. the steering collar element of the assembly.

Both types of pulleys are affixed to a shaft Capped Tube pulleys use a variation of this design
via various locking assemblies such as QD® concept. Please contact a Belt Technologies
Bushings, Tran-Torque® Collars, Ringfeder® Engineer for details.
Revolutionary Design is
Locking Assemblies, or by the steering in the Pulley Collar
collar of Belt Technologies’ Independently
Steerable Pulley design. These designs
are, by nature, more complex than those
of a solid body pulley, and specific design
guidelines are beyond the scope of this
document. The drawings shown above will
serve as design concepts against which a
Belt Technologies Engineer can assist you Steering
Collar
with the specifics of your application.
Sealed Bearing

Capped Tube
Minimum pulley diameter 4.00 (10.16cm)
Minimum face width 6.00 (15.24cm)

IN CONCLUSION: Table 10. Typical ISP Bushing Variations

B
As with any precision technology, idiosyncrasies A +0.001 (+0.025MM) C
in both the design and manufacture of friction -0.000
and timing pulleys for metal belts requires design -1 1.20 (30.48) 0.500 (12.70) 1.956 (49.682)
experience and manufacturing expertise. Belt -2 1.50 (38.10) 0.750 (19.05) 2.331 (59.207)
Technologies invites you to use this document for
-3 2.50 (63.50) 1.000 (25.40) 2.393 (60.782)
PureSteel® Metal Belt and Pulley designs, then
-4 2.50 (63.50) 1.250 (31.75) 2.893 (73.482)
contact one of our Sales Engineers to assure a
successful plan is in place for your project. -5 3.00 (76.20) 1.500 (38.10) 3.456 (87.782)
24 Complete the design checklist on-line. 25

STEEL BELT DESIGN CHECKLIST

Use additional sheets for further information, if appropriate

North and South America Europe and Asia

Belt Technologies, Inc. Belt Technologies Europe
11 Bowles Road West Suite 6, Ground Floor
Agawam, MA 01001 USA Riverside House, Newburn
Phone: 413-786-9922 Newcastle-Upon-Tyne,
Fax: 413-789-2786 Tyne and Wear, NE15 8NY
belttechnologies.com United Kingdom
Phone: + 44-191-4153010
Fax: + 44-191-4150333
belttechnologies.co.uk

From: ______________________________________________________________________________________________________________________________________________________________ (Name)

_________________________________________________________________________________________________________________________________________________________ (Company)

____________________________________________________________________________________________________________________________________________________________ (Address)

__________________________________________________________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________________________________________ (Tel / Fax)

1. USE:  Convey  Index  Time  Position  Power Transmission

We hope this introduction to metal
belt technology provided you with an 2. SIZE CONSIDERATIONS:
understanding of important design
considerations and helped you qualify Belt Width________________________________________________________________ Pulley Diameter_____________________________________________________________________
your application. Our unique metal belt
technology has resulted in a wide range Number of Pulleys_____________________________________________________ Pulley Centers_______________________________________________________________________
of solutions for a long and growing list of
satisfied customers. We will provide a list 3. LOADING:
of these companies at your request.
Belt Speed________________________________________________________________ Max Drive Torque___________________________________________________________________
Should you require further assistance
and design review, please contact a Acceleration_____________________________________________________________ Static Load____________________________________________________________________________
Belt Technologies Sales Engineer by
telephone, fax or email. 4. DESIRED BELT CHARACTERISTICS:
Please fax or email the design checklist  Strength  Precision  Cleannes  Corrosion Resistance  Thermal Conductance
from the facing page with your
application information. High Temperature _____________________________________________________  oC  oF

Thank you for your interest in

5. QUANTITIES: Number of belts to be quoted __________________________________ Number of pulleys to be quoted________________________________
Belt Technologies.

6. PLEASE INCLUDE A DIAGRAM OF YOUR SYSTEM.