PART K. A90 Series Correspondence Lessons. Power Transmission II

Transcription

1 A90 Series Correspondence Lessons PART K Power Transmission II Lesson A9025 V-Belts Lesson A9025A Timing and Other Belts Lesson A9026 Pulleys Lesson A9027 Shaft Couplings Lesson A9027A Gear Boxes

2 PART A Roller Chain & Sprockets Series 90 Training

3 Correspondence Course LESSON A9025 Introduction to V-Belts Part K POWER TRANSMISSION II Lessons A9025 to A9027A Table of Contents Advantages of V-Belt Drives 3 Agricultural V-Belts 9 Auto V Belts 23 Automotive Belts 10 Automotive Poly Vee Belts 10 Classic Blue Label 12 Double Angle 15 Gold Label Cog Belt 13 Gold Label Cog Band 18 How do V-Belts work? 3 Industrial Belts 6 Introduction 3 Power Wedge - Raw Edge 16 Power Wedge- Wrap 17 Super Blue Ribbon 13 Super V-Band 19 Tension Cord Materials 25 Types of V-Belts 6 Variable Speed Cog 19 V-Belt Construction 4 Wedge Band Aramax 17 What is a V-Belt? 3 XDV Xtra Duty Belts 22 Structured Training Plan This lesson is the twenty fifth of a series of Correspondence lessons in the BSC Structured Training Plan. Objectives The objective of this lesson is to introduce you to the basics of V-belt design and usage, their limitations and numbering systems. The various series will be designed together with the more popular types. Pre-requisites Completion of Lessons A A9024. Methods Achievement of the objectives is by presentation of lessons in an 'On-Line' or Correspondence Course format. The lessons in a Correspondence Course style are conducted for internal students in a lecture situation. Assessment A formal test is provided with this lesson. LESSON A9025 Series 90 Training

4 LESSON A9025 Introduction to V-Belts Series 90 Training page 2

5 Introduction Energy Efficiency of all drive systems is at the mercy of its weakest link. The maintenance industry has taken great strides to improve energy efficiency and productivity of motors and driven equipment. Belt drives can be a major source of energy waste. A simple change to a more efficient belt construction can average between 4% - 12% reduction in energy. These savings offer end users the potential to reduce energy costs immediately far outweighing the costs of changing the belts. WHAT IS A V BELT? V Belts are flexible machine elements used for the transmission of power over comparatively long distances. These belts provide a compact, resilient transmission and are used extensively in automotive and industrial drives for fans, generators, pumps etc. They are specified by the belt type and section identification, and also by the circumferential length of the belt. On page 2, there is a diagram of the two types of V Belt construction. HOW DO V BELTS WORK? Only the angular sides of a V Belt come in contact with the sides of the pulley groove, and most of the belts (excluding the classical cross sections) run approximately flush with the top of the pulley. See diagram A. Diagram A. The pulley groove must be deep enough to provide a space below the belt, ensuring that belt contact is on the sides only. This space also assists in heat dissipation from the belt. The groove angle of the pulley is made slightly smaller than the belt section angle and the belt tends to wedge itself into the groove. Additionally, when tension is applied to the belt, the compression zone underneath the reinforcing cords will tend to bulge into the pulley sidewalls. Therefore this 'wedging' of the belt into the pulley groove enables the belt to grip the pulley and thus, transmit power. Principles of wedging with a V-belt ADVANTAGES OF V BELT DRIVES V-elt drives provide many maintenance advantages that help in the daily struggle to reduce equipment repairs and to hold forced downtime to the lowest possible level. They are an economical method of transmitting power. They are clean - No lubrication is required. They are efficient - Drive efficiency averages 94.98%. They possess smooth starting and running characteristics. They cover extremely wide horsepower ranges. They permit a wide range of driven speeds, using standard electric motors. They dampen vibration between driving and driven machines. They are quiet in operation. They act as a "safety fuse" in the power drive because they refuse to transmit a severe overload of power, except for a very brief time. V Belts wear gradually, making preventative or corrective maintenance simple and easy to plan in advance. LESSON A9025 Introduction to V-Belts Series 90 Training page 3

6 V Belt Construction Wrapped Belt Raw Edge Cog Belt 1. Cover - Woven cotton fabric impregnated with neoprene. 1. Tension Section - Specially woven dayflex stress-relieved fabric. 2. Tension Section - Synthetic rubber compounded to stretch as belt bends around sheaves. 2. Cords - Synthetic high modulus cords form the strength member to carry high loads with minimum stretching Cords - High strength synthetic fibre cords carry the horsepower load and minimise stretching. Compression Section - Synthetic rubber compound to support cords evenly and compress while bending around sheaves Compression Sections - Exclusive Stiflex rubber compounds and precision moulded cogs increase flexibility while supporting cords evenly. Raw Edge Sidewalls - Provide uniform antislip surface, greater flexibility and allow more cord width. Inside V-Belts Cut a V Belt apart and you will find reinforcing cords which carry the tensile load and the body, which surrounds, protects and supports the tension cords. The design may also include a fabric cover which completely surrounds the body of the belt. Each element of the belt has specific characteristics and a unique function to perform. Reinforcing Cords These are made of polyester, fibreglass and aramid fibres (Kevlar, Flexsten). Each has its own advantages and limitations (see page 22). The key to these physical properties are tensile strength, stability and flexibility. The cords are twisted from continuous filaments and are subsequently treated chemically to improve adhesion to the rubber. Polyester is further heat treated to achieve desired properties. For Example, the polyester cord is processed 3 different ways to obtain low, medium and high pullout. This physical characteristic comes in to play in an application such as the auxiliary drive on an Automobile engine. A high pullout cord is used in Fan Belts to help maintain proper tensions on LESSON A9025 Introduction to V-Belts Series 90 Training page 4

7 the drive system. Otherwise, the temperature extremes experienced by the belt would cause it to alternatively stretch and shrink. Shock resistance and dimensional stability are critical V-belt characteristics that are also determined by a complex combination of physical properties including tensile strength, elasticity and cord geometry. Fibreglass cord, for example has good shock resistance because filament flexibility and twist, and, cord configuration combine to provide an unusually high degree of shock absorption. On the other hand, steel cord, which would seem to possess good shock tolerance, failed the test, and is used only for special belts. Today, Aramid cords exhibit about the same capabilities as fibreglass but have a lower elongation rate. Aramid cords are difficult to cut, and when used in 1 raw edge cogged belts the exposed ends often appear frayed and worn. Polyester, fibreglass, and aramid fibre development is directed toward improving adhesive systems and cord geometry. Since power is transmitted via the angled sidewalls of the belt, it is desirable to have the compression area under the cords as large as possible. Therefore, Carlisle place the reinforcing cords as close as possible to the top of the belt, ensuring that the belt will have the highest possible load rating and consequently, the longest possible service life. Body Materials These include two basic elastomeric Compounds: blends of natural rubber and styrene-butadiene rubber (SBR) and neoprene, which is used for the majority of heavy-duty V-belts. Polyurethane, has been used for some extreme-duty belts but it is considered a specialty material. The term 'natural rubber' pertains to both plant-derived and synthetic elastomers, such as neoprene. Neoprene is a root describing a family of about 24 polymers related elastomeric compounds. As with synthetic fibres used for tension cords, body materials are furnished in an unfinished state. Belt construction involves making the various components more pliable, and then vulcanization, a chemical cross-linking process carried out at high temperatures. Fully vulcanized rubber is hard and would be useless as belt body material; but the process which continues during the useful life of the belts can be stopped when the required physical properties are obtained. High temperatures accelerate the vulcanization process, and the belts become more and more brittle until they finally crack and fail. Most belt material R&D is related to control of the vulcanization process and improvement of high temperature performance. Cover Wrapped belts are entirely covered with a woven cotton bias cut fabric. This is required to protect the neoprene based rubber compounds of the belt during operation. Additionally, the cover is self impregnated with neoprene to improve its adhesion to the belt. Raw edge belts are covered on the outside circumference only with Carlisle's own special woven stressrelieved, bias- cut fabric. Because the rubber compound forming the base material of the belt is of the highest quality and strength available, a complete cover is not required to protect the sidewall from damage and abrasive wear. LESSON A9025 Introduction to V-Belts Series 90 Training page 5

8 Types of V-Belts Type Description Part Number Example Industrial Belts Classic Blue Label The V Belt is surrounded by a double wrap of fabric. These are available in M, C, A, B, C, D, E sections A50 A - Section 50 - Inside circumference Super Blue Ribbon Super Rated, Oil & Heat Resistant, Static Dissipating. Double covers for longer life. AP64 A - Section P - Super Blue Ribbon 64 - Inside Diameter Gold Label Cog Belt Double Angle Super II V Belts The V Belt has no fabric cover and the body is strengthened by including fibre in the Neoprene rubber. They are identified by including an X in the part number. They are available in A, B, C, D sections. The V Belt looks like two standard belts are joined back to back. It is only available in fabric wrap. These belts are suitable in serpentine type applications as they can drive on both the inside and outside surfaces. The feature of this belt is that the reinforcement cords are in the centre of the belt as opposed to wrap or raw edge belts which have reinforcement cords in the top 1/3 of the belt. AX50 A - Section X - Cogs 50 - Inside circumference AA50 AA - Section 50 - Inside circumference AS50 A - Section S - Super II 50 - Inside circumference LESSON A9025 Introduction to V-Belts Series 90 Training page 6

9 Type Description Part Number Example Industrial Belts Urethane UFL Belts 3M355 3M Urethane UFL type 555 Belt Pitch Length Ideally suited for light applications providing a compact drive with minimal tension loss and superior resistance to environmental aging. Offers unlimited design opportunities. Power Wedge Raw Edge (Power Wedge Cog Belt) Power wedge belts were developed to enable the design of more compact drives able to transmit greater power than existing wrap belts. This was achieved by increasing the compression section below the reinforcing cords. Metric: SPAX1500 SP Super Power A Section X Cog 1500 PCD Imperial: 5VX /8 Top Width V V Belt X Cog 530 PCD(53 inch) Power Wedge- Wrap (Blue Label Double Wrap) Wrapped version of the raw edge power wedge belt. These belts are dimensionally different to the standard wrap belt in both width and depth. SPA2500 SP Super Power A Section 2600 PCD Wedge Band Aramax (Up to 12 ribs) A banded belt consists of between 2 and 8 individual belts or ribs being joined together with a bounded reinforced tie band. Aramax refers to the exclusive cord from Carlisle which provides maximum protection against belt breakage due to shock loads. 5R8VK3150 5R No of ribs 8 Top Width VK Armex Type 630 PCD LESSON A9025 Introduction to V-Belts Series 90 Training page 7

10 Type Description Part Number Example Industrial Belts Gold Label Cog Band RBX83 RB - B section Gold Label X - Cog 83 - inside circumference Super V- Band Variable Speed Cog Banded version of The Energy Saver. Combines with longer life and superior performance of the Cog-Belt with the stability of banded construction. Gold Label s unique construction (combining the superior flexing of precision moulded cogs with the tenacious gripping power of raw edge sidewalls) provides significantly longer belt life, higher efficiency and horsepower ratings and opportunities to save time, energy and space. The SuperVee-Band line is specifically designed to handle the toughest industrial applications, including rock crushers, vibrating equipment, saws and pumps. Anywhere you need the performance and reliability of a classical belt combined with applications that experience pulsating or stalling characteristics, the Super Vee-Band is ready to work for you. Raw Edge sidewalls with AccuForm finishing improve gripping contact with the pulley sidewalls, resulting in the belt s smooth, quiet operation. The all-neoprene rubber compounds with unitized bonding provide superior oil and heat resistance while supplying static dissipation characteristics. 3RCP Number of ribs RCP - Banded C Section Premium inch inside length Imperial V Belt top width in 1/16 of an inch 28 - Intended pulley angle V - V Belt Belt Pitch length in 1/10th of an inch Metric - 22V1525A22 22V - Top Width in MM Pitch length in mm A22 - Intended Pulley Angle LESSON A9025 Introduction to V-Belts Series 90 Training page 8

11 Type Description Part Number Example Industrial Belts Poly Rib Industrial The Poly-Rib V-Belt represents the state-of-the-art in V-belt technology and was developed to provide even greater powertransmission and speed capabilities with more compact and lighter drives. Imperial: 1060M ' Belt Length M - Belt Section Ribs Metric: 14PM Ribs P - Metric Dimensions M - Belt Section Belt Length in mm Agricultural Belts XDV Xtra Duty Belts XDV V-Belts represent the pinnacle for premium FHP applications and provide exceptional service in the harshest environments. They are durable even when subjected to extreme temperature, high humidity, moisture, grit, oil and grease. The XDV Belt is designed for tough single belt drives, typical of lawnmowers, garden tillers, snow-blowers, garden tractors, etc. Features of the XDV include a premium base cushion for applications requiring a back-side idler. 48X /8ths inch top section X - XDV type inch outside length Note: FHP= Fractional Horse Power LESSON A9025 Introduction to V-Belts Series 90 Training page 9

12 Type Description Part Number Example Automotive Belts Auto V Belts (Metric) The V Belt has cogs on the top. These belts are manufactured with pre-stretched cord to eliminate regular tensioning. 11A0900C 11 - Top width in mm A - Automotive Effective Length C - Cog Construction Auto V Belts (Imperial) The V Belt has cogs on the top. These belts are manufactured with pre-stretched cord to eliminate regular tensioning Top width in 1/32 of an inch effective length in inches and 1/10 inch Automotive Poly Vee Belts These belts are found on many modern motor vehicles and are popular because of their compact size and extended service life. 6PK Number of ribs P - Poly Rib K - Automotive Belt Effective length Note: PCD = Pitch Circle Diameter - this is the circumference of the belt measured at the reinforcement cords. Metric/Imperial All V Belt and Lawn & Garden sizes are imperial. However, we have shown the metric sizes in top widths and depths. Automotive and Power Wedge have an imperial part number and metric part number. You will need to convert imperial numbers to metric using your catalogue as we charge out all these belts under their metric part number. Some of our stock will have the imperial part number as do some applications catalogues. LESSON A9025 Introduction to V-Belts Series 90 Training page 10

13 Running Multiple Belts When a customer has a drive which uses multiple belts, there is a need to match the belts so that the power is distributed evenly through each of the belts. This avoids placing extra strain on some of the belts, which would accelerate wear. To address this challenge, Carlisle has developed the Chek-Mate belt matching system. Whenever the Chek-Mate symbol appears on a Carlisle V-belt, it means that the belt will match with all other Carlisle Chek-Mate belts of the same size. Therefore you are able to eliminate belt matching and still obtain Carlisle quality. The Carlisle Chek-Mate one-match system applies to Carlisle Gold Label Cog-Belt, Power Wedge Cog- Belt and Super Power Wedge. Soon this quality assurance will also be available on additional Carlisle belt types. The Chek-Mate system meets the Rubber Manufacturing Association's (RMA) matching tolerances for V- belt~ lengths, which are as follows: X section Length (Inches) Tolerance(Inches) < A, B, C & D > < V, 5V & 8V (SPZ, SPB, SPP) > % of V-belt transmissions don't need matched belts if they are all Carlisle Chek-Mates. Exceptions are high-power drives (eg. crushers, wood chippers, etc.) where the V-belt drive is required to transmit the full rated power of the motor. In such cases only matched belts should be used, and the customer will know if they have been specified by the equipment manufacturer. If 100% matching is required, all Carlisle V-Belts carry a tube number which, when used with identical Carlisle V-Belts carrying the same tube number, means that all of the belts were manufactured in the same batch on the same tube. The Chek-Mate system enables customers to save time, reduce their inventory and increase belt life. LESSON A9025 Introduction to V-Belts Series 90 Training page 11

14 Blue Label (Wrap) Belts Classic Blue Label The V Belt is surrounded by a double wrap of fabric. These are available in M, C, A, B, C, D, E sections. A50 A - Section 50 - Inside circumference The classical blue Label V-belt is of a wrap-moulded construction type and is designed to compete in the general application market. Dayco Classical Blue Label V-belts have the reinforcing cords positioned at the top of the belt. This ensures that that they will possess the highest load capacity, and achieve the longest service life possible when using belts of wrapped type construction. Since the wrap moulded belt has an inbuilt clutching factor, this is the preferred type of belt for use in heavy clutching applications, where shock loads are applied and the drive is required to provide an overloading resistance. It is also suitable for drives where pulley alignment is doubtful. Batch Numbers for Blue Label belts Carlisle use a batch numbering system to indicate the date of manufacture of the belt. This may be useful when supplying multiple belts to a customer as slight variances may occur in the lengths of belts manufactured in different batches. Batch codes are not used to match Chekmate belts as they are only date codes. Example Batch Code: 8S 04/110 VI 8 Year of manufacture Uses the sequence M I T S U B A P W C O G where M = S Month of manufacture - April January, I - February etc. 04 Working week of month 01, 02, 03, Belt position on the sleeve VI Day in week in roman numerals I, II, III, IV, V, VI where I =Monday, II - Tuesday etc Usually, we only explain the first 2 characters as that gives the year and month of manufacture. This avoids getting in to discussions where customers request a belt of the exact same batch code which could be impossible to find and is irrelevant anyway given the chekmate e-system detailed on the previous page. Belt Sizes When ordering V-belts, customers sometimes quote outside circumference as this is easier for them to measure so be sure to clarify the measurement as either IC or OC. If the measurement is given as outside circumference, use the following table to calculate the IC. M section -Deduct 1.57 inches from OC to arrive at IC A section -Deduct 2.16 inches from OC to calculate IC B section -Deduct 2.75 inches from OC to calculate IC C section -Deduct 3.53 inches from OC to calculate IC D section -Deduct 4.71 inches from OC to calculate IC E section -Deduct 7.00 inches from OC to calculate IC Super Blue Ribbon Belts LESSON A9025 Introduction to V-Belts Series 90 Training page 12

15 Super Blue Ribbon Super Rated, Oil & Heat Resistant, Static Dissipating. Double covers for longer life AP64 A - Section P - Super Blue Ribbon 64 - Inside Diameter These belts are often referred to as the Lawn and Garden range because they are commonly found in lawn mowers and other mechanised gardening equipment. However, they are not exclusively limited to this type of application. Their popularity in Australia in the Lawn and Garden industry is because of their construction. They have super strength cords to withstand overloads, shocks, vibrations and pulsations. They also possess a double wrap cover to provide longer life, resist extreme temperatures, humidity and excessive oil, and have a high static conductivity. Identification They are available in A, B, C and D sections (See above), and are distinguished from the Classical Blue Label V-Belts by the addition of the suffix 'p' to the belt cross section. Like the Classical Blue Label V- Belts, the Dayco Numbering system consists of the belt cross section followed by the belt length in inches, measured on the Inside Circumference (IC). Gold Label Cog Belt Gold Label Cog Belt The V Belt has no fabric cover and the body is strengthened by including fibre in the Neoprene rubber. They are identified by including an X in the part number. They are available in A, B, C, D sections. AX50 A - Section X - Cogs 50 - Inside circumference The Gold Label Cog-Belt is the premium belt tor industrial applications. Its combination of moulded cogs & raw edge construction endows the Raw Edge Cog-Belt with far superior performance than wrapped belts, and some of these performance advantages are detailed below: (i) They require less power during operation. Moulded cogs provide extreme flexibility & less energy is required to bend belt around pulley. Raw Edge construction minimises belt slip & less energy is wasted whilst belt is slipping. (ii) They run cooler, increasing belt life. Raw Edge construction minimises belt slip and subsequent heating of belt. Moulded Cogs provide greater surface area for heat dissipation. (i i i) Can be used with sub-standard pulleys. Due to higher grip of Raw Edge belts, can still maintain drive on sub-standard pulleys where wrap - belts would slip and ultimately fail. LESSON A9025 Introduction to V-Belts Series 90 Training page 13

16 (iv) Can be used with smaller diameter pulleys. Moulded Cogs provide greater flexibility & reduce force needed to bend belt. (v) Increased service life. Higher grip due to raw Edge construction means less tension is required on belt drives. Therefore belt is under less stress. (vi) Higher power ratings. Increased grip due to Raw Edge construction means that Gold Label Cog-Belts rated approx. 30% higher in hp ratings than comparable wrap belt. As with the Classical Blue Label V-Belt, the Gold Label Cog-Belt features the reinforcing cords positioned at the top of the belt section. Although the Gold Label Cog-Belt features many advantages over traditional wrapped belts, there are some limitations as to their use, which are as follows: (i) Not recommended for clutching applications. Since the Raw Edge construction minimises belt slip, wrapped belts should be used if clutching (slipping) or easy starting is required by a drive. (ii) Not recommended where pulley alignment is doubtful. Where pulleys are misaligned the belt will tend to slip and skid over the pulley sidewalls. Again, wrapped belts should be used for such an application, since Raw Edge belts will resist such slipping. Identification The Gold Label cog-belt is available in A, B, C and D sections. However, to differentiate it from the wrapped belts an X is added to the Part NO. It therefore consists of the belt cross-section followed by the belt length in inches, measured on the INSIDE circumference (IC). (see example above) Remember: When a customer specifies a belt length, check which part of the belt they have measured - either inside circumference or outside circumference. If given the outside length, convert this to the inside length using the table on page 12. Where an X is used in a Carlisle Part NO, the belt utilises Raw Edge Cog type construction. LESSON A9025 Introduction to V-Belts Series 90 Training page 14

17 Double Angle Double Angle The V Belt looks like two standard belts are joined back to back. It is only available in fabric wrap. These belts are suitable in serpentine type applications as they can drive on both the inside and outside surfaces. AA50 AA - Section 50 - Inside circumference Carlisle Double Angle belts are used to transmit power from both sides of the belt, and so can be used in serpentine type drives. For Serpentine drives, they flex equally well in both directions. Identification Serpentine drive They are made in A, B, and C cross sections and the part number consists of doubling the letter designator and then adding the belt inside circumference. (see example above) Super II Blue Label Belts Super II V Belts The feature of this belt is that the reinforcement cords are in the centre of the belt as opposed to wrap or raw edge belts which have reinforcement cords in the top 1/3 of the belt. AS50 A Section S Super II 50 Inside circumference The Super II V Belt has multiple fabric material layers in the top and bottom of the belt, which assists in minimizing stretching. The Polyester cord in the centre of the belt enables the belt to resist extreme shock loads and also assists in reducing stretching. It also increases flexibility, an advantage in backside idler applications. The material is a superior grade 100% neoprene rubber compound, which resists cracking better than ordinary wrapped V Belts, and is also more resistant to dirt, oil and greases. This redesigned construction gives Super II belts more advantages over conventional type belts including: Longer Belt Life Greater strength Superior stretch resistance\fewer belt re-tensioning Better heat dissipation Less drive maintenance Increased productivity Excellent for backside idler drives Controlled slip under high loads Improved flexibility Reduced downtime LESSON A9025 Introduction to V-Belts Series 90 Training page 15

18 Carlisle Super II B-Belts are available in AS, BS and CS sections and these are the same dimensionally, as the A, B and C type belts. Identification The Carlisle identification system for Super II V-Belts consists of the belt cross section, followed by the letter S to indicate Super, and then the belt inside circumference in mm. (see example above) Urethane UFL Belts Urethane UFL Belts 3M355 3M Urethane UFL type 555 Belt Pitch Length Ideally suited for light applications providing a compact drive with minimal tension loss and superior resistance to environmental aging. Offers unlimited design opportunities. Carlisle UFL Urethane V-Belts are available in 3M, 5M, and 7M sections as illustrated above. Identification The Carlisle identification system for UFL Urethane V-Belts consists of the belt cross section, followed by the belt length in mm. See example above. Power Wedge Raw Edge and Wrap Power Wedge Raw Edge (Power Wedge Cog Belt) Power wedge belts were developed to enable the design of more compact drives able to transmit greater power than existing wrap belts. This was achieved by increasing the compression section below the reinforcing cords. Metric: SPAX1500 SP Super Power A Section X Cog 1500 PCD Imperial: 5VX /8 Top Width V V Belt X Cog 530 PCD(53 inch) LESSON A9025 Introduction to V-Belts Series 90 Training page 16

19 Power Wedge- Wrap (Blue Label Double Wrap) Wrapped version of the raw edge power wedge belt. These belts are dimensionally different to the standard wrap belt in both width and depth. SPA2500 SP - Super Power A - Section PCD When tension is applied to the belt, this zone will bulge into the pulley groove sidewalls. Therefore, the amount of deformation of the compression zone is increased, giving greater belt grip and subsequently greater power transmission capabilities. Power-Wedge belts can therefore transmit significantly higher power than comparable Classical belts (M, A, B, C D, and E) of the same top width. In this way lesser belts are required, resulting in cheaper drives possessing smaller external dimensions. Additionally, the Con-Flex Raw Edge Cog type construction of the Power-Wedge Cog belt delivers approximately 30% more power than ordinary belts featuring Wrap type construction. Raw Edge Cog- Belts offer several other advantages over Wrapped belts which are discussed here. The Power-Wedge Cog-Belt is the standard type carried by Carlisle. The Super Power-Wedge is only stocked for applications, featuring longer belt lengths and/or larger belt cross-sections where flexibility and compactness are less critical. Identification As can be seen below, the range of Power-Wedge sections have significantly deeper sections than the alternative Classical sections, and are available to both ISO and IMPERIAL dimensions. The Carlisle Numbering system for these belts consist of the belt cross-section followed by the belt length in either mm, if to ISO standard, or 1/10ths, if to IMPERIAL standard. The belt length is measured on the length, or neutral axis, which is where the reinforcing cords are placed in the belt. Conversions for Inside and Outside lengths are provided in the belt size listings. Please refer to the part number example above. Wedge Band Aramax Wedge Band Aramax 5R8VK3150 (Up to 12 ribs) A banded belt consists of between 2 and 8 individual belts or ribs being joined together with a bounded reinforced tie band. Aramax refers to the exclusive cord from Carlisle which provides maximum protection against belt breakage due to shock loads. 5R - No of ribs 8 - Top Width VK - Armex Type PCD The Carlisle Wedge Band Raw Edge Cog is a banded version o the Power-Wedge Cog-Belt and combines the superior performance of the Raw Edge Cog-Belt construction and deep Power-Wedge belt section, with the stability of a banded V-Belt. Additionally, the Carlisle Wedge-Band V-Belt is also available with Wrapped construction for drive applications featuring longer belt lengths and/or larger cross-sections, where flexibility and compactness are less critical. LESSON A9025 Introduction to V-Belts Series 90 Training page 17

20 Identification The Carlisle Wedge Band, V-Belt is available in 3VX, and 5VX belt sections with raw edge Cog Construction and in 3V, 5V arid 8V sections with Wrapped construction. The Carlisle Part Numbering system consists of the number of ribs required (2, 3, 4 or 5), followed by the belt cross-section and the belt length. The belt length is measured in 1/10th of an inch on the pitch length. Conversions in the belt tables provide the necessary information for converting IC and DC to pitch length. Gold Label Cog Band Gold Label Cog Band Banded version of The Energy Saver combines with longer life and superior performance of the Cog-Belt with the stability of banded construction. Gold Label s unique construction (combining the superior flexing of precision moulded cogs with the tenacious gripping power of raw edge sidewalls) provides significantly longer belt life, higher efficiency and horsepower ratings and opportunities to save time, energy and space. RBX83 RB B section Gold Label X - Cog 83 - inside circumference Identification The Gold Label Cog-Band belt is available in BX, CX and DX cross-sections, with the prefix "R" used to designate banded construction. The Carlisle Part Numbering system for the Gold Label Cog-Belt consists of the Number of Ribs required (2, 3, 4 or 5), followed by the belt cross-section and the belt length. The belt length is measured in Inches on the Inside Circumference (IC). See the example above. About Banded V Belts Machine induced vibrations or shock loads can frequently cause V-Belts to whip, turnover or even jump off the drive, creating a safety hazard and, of course, damaging the V-Belts. Whip and Turnover may also be experienced on long span drives and on vertical drives. On multiple belt drives, this whipping can be reduced or eliminated by using Banded V-Belts. A banded V-Belt consists of between 2 and 5 individual belts or ribs as they are also known, being joined together with a bonded, reinforced tie-band. These belts will ride slightly higher in the pulley groove to provide clearance between the band and the pulley. Because of this, pulley grooves should not be worn or dished out more than 1/64", and alignment of the pulleys is more critical than for individual belts. Only pulleys to RMA - MPTA dimensions should be used with Carlisle Banded V-Belts. Additionally, Banded V Belts may also be used on drives requiring matched sets. If drives possess more than 5 belts, the drive can be built up using a combination of several banded belts. Eg. Drive requires 12 V-Belts Supply: 2 off 5 rib Banded V-Belt +1 off 2 rib Banded V-Belt LESSON A9025 Introduction to V-Belts Series 90 Training page 18

21 Super V-Band 3RCP 240 The Super Vee-Band line is specifically designed to handle the toughest industrial applications, including rock crushers, vibrating equipment, saws and pumps. Anywhere you need the performance and reliability of a classical belt combined with applications that experience pulsating or stalling characteristics, the Super Vee-Band is ready to work for you. 3 - Number of ribs RCP - Banded C Section Premium inch inside length The Carlisle "Super" Vee-Band is a banded version of the Super Blue Ribbon V-Belt and eliminates Belt whip and turnover on classical drives. (There is no banded version of the Classical Blue Label) Identification The Super Vee-Band V-Belt is available in BP, CP arid DP cross- sections with the prefix 'R' used to designate banded construction. The Carlisle Part Numbering system for the Super-Vee-Band V-Belt consists of the number of ribs required (2, 3, 4 or 5), followed by the belt cross section and the belt length. The belt length is measured in inches on the Inside Circumference (IC). See the example above. Variable Speed Cog Variable Speed Cog Raw Edge sidewalls with AccuForm finishing improve gripping contact with the pulley sidewalls, resulting in the belt s smooth, quiet operation. The allneoprene rubber compounds with unitized bonding provide superior oil and heat resistance while supplying static dissipation characteristics. Imperial V Belt top width in 1/16 of an inch 28 - Intended pulley angle V - V Belt Belt Pitch length in 1/10th of an inch Metric - 22V1525A22 22V - Top Width in MM Pitch length in mm A22 - Intended Pulley Angle In 1928, Carlisle's predecessor, Dayco assisted in the development of some of the first variable speed devices. Now, over 80 years later, Carlisle remains the recognised leader in meeting variable speed device manufacturer's stringent performance requirements. LESSON A9025 Introduction to V-Belts Series 90 Training page 19

22 The illustration on the right depicts a variable speed drive with a spring mounted on the driven pulley and the shifting device on the driver pulley. Low Speed: Minimum Output and Minimum belt speed. High Speed: Maximum Output and maximum belt speed. Due to the relatively high forces acting perpendicular to, or across the belt section, whilst the speed ratio is changing, variable speed drives require much wider belts than for normal V- Belt drive applications. Belts this wide require extreme crosswise rigidity to prevent squashing or distortion, which would throw the strength section of the belt out of line. They also require greater lengthwise flexibility, with the proper amount of "give", to enable them to bend around the smallest pulley dimension without excessive strain or distortion. A variable speed belt must be constructed so that the compression stresses are low and distortion minimised, therefore making positive contact between the V-Belt sides and the pulley. Carlisle variable Speed V-Belts therefore feature Raw Edge Cog type construction, and the belt built in three main sections as follows: (i) Tension Section - made of specially woven fabric Stretches up to 176% more than ordinary bias cut fabric, improving flex life. (ii) Strength Section - Synthetic Hi-Modulus cabled cords form the strength member to carry high loads with minimum stretching. (iii) Compression Section - 'Stiflex' rubber compounds and precision moulded cogs increase flexibility and provide the crosswise rigidity needed to support the cords uniformly. In addition, Raw Edge sidewalls with 'Accuform' finishing improve gripping contact with the pulley sidewalls, resulting in smoother and quieter operation. LESSON A9025 Introduction to V-Belts Series 90 Training page 20

23 Agricultural Applications Not all Variable Speed Cog-Belts are suitable for agricultural use. A special Heavy-Duty belt has been designed for agricultural applications and is manufactured directly to OEM specifications, differing in construction to the standard Carlisle belt. Identification Carlisle variable Speed Cog-Belts re available to both ISO and IMPERIAL standard dimensions. ISO standard belts are intended to be used in 26 degree angle pulleys. The Carlisle numbering system for ISO Variable speed Cog Belts consists of the top width in mm, followed by the Suffix 'W' to designate ISO dimensions, and finally, the belt length in mm. Imperial Standard belts can be used with a variety of pulley angles and this information is included in the part No 0 The Carlisle numbering system for Imperial Variable Speed Cog Belts consists of the belt Top Width in 1/16ths inches followed by the pulley angle in Degrees, followed by the suffix 'V' to designate Imperial dimensions, and finally the belt length in 1/10ths inch which is measured on the pitch length. See the example above. Poly Rib Industrial V-Belts Poly Rib Industrial The Polly-Rib V-Belt represents the state-of-the-art in V-belt technology and was developed to provide even greater power transmission and speed capabilities with more compact and lighter drives. Imperial: 1060M = ' Belt Length M = Belt Section 14 = 14 Ribs Metric: 14PM = 14 Ribs P = Metric Dimensions M = Belt Section 2690 = Belt Length in mm Carlisle Poly-Rib V-Belts provide 50% more power in 2/3rds the space required for conventiona1 V-Belt drives, and are recommended for high speed and/or high ratio applications that conventional Belts can t accommodate. They also offer oil and heat resistance and smooth vibration-free performance in a single belt. They do, however, require close alignment of pulleys during installation. LESSON A9025 Introduction to V-Belts Series 90 Training page 21

24 Here are some of the advantages of Poly-Rib Belts: Uninterrupted strength - uses high strength cord and the ribs reinforce each other. Length Stability - maintains constant pitch diameter, unlike multiple belts which may move up and down in the grooves Compact Drives - Saves space More Power - 30% to 50% higher than standard belts for the same width. Poly-Rib belts are ideal where: Present drive is overloaded More power is required in the same space V-Belt life is limited Identification Carlisle Poly-Rib industrial v-belts are available in J, L and M cross-sections as outlined below, along with the standard belt widths for each belt section. However, if a non-standard width is required, a standard belt can be easily trimmed. Eg., A belt having 18 ribs can be cut in half to provide 2 belts with 9 ribs. The Carlisle Part Numbering system for Poly-Rib V-Belts includes both ISO and IMPERIAL Standard Dimensions. Imperial Part numbers consists of the Belt Length in 1/10th:- inch measured on the Pitch Length (PL), followed by the belt cross-section, and finally the belt width code for the No. of ribs - see the example above. Metric or ISO cross section consist of the belt width code for the No., of Ribs, followed by the suffix 'P' to designate Metric dimensions, followed by the belt cross-section, and finally the belt length in mm measured on the pitch Length (PL). If the outside length is quoted by a customer, the following values may be subtracted to determine the pitch length, and hence, the Carlisle Part No.: J Section: Subtract 1/2" (12.7mm) from OC to get PL L Section: Subtract 1" (25.4mm) from OC to get PL M Section: Subtract 2" (50.8mm) from OC to get PL XDV Xtra Duty V-Belts XDV Xtra Duty Belts XDV V-Belts represent the pinnacle for premium FHP applications and provide exceptional service in the harshest environments. They re durable even when subjected to temperature extremes, high humidity, moisture, grit, oil and grease. The XDV Belt is designed for tough single belt drives, typical of lawnmowers, garden tillers, snow-blowers, garden tractors, etc. Features of the XDV include a premium base cushion for applications requiring a backside idler. L434 L4 - belt section inch belt length Note: FHP = Fractional Horse Power LESSON A9025 Introduction to V-Belts Series 90 Training page 22

25 Carlisle GPL Premium V-Belts are recommended for heavy duty Lawn and Garden equipment, especially where superior load carrying capacity and/or heavy clutching is required. Length stable Aramax (Araclid Fibre or' Kevlar') cords provide higher tensile strength and require fewer take-ups. The cords are positioned close to the central axis of the belt to permit their use on reverse bend or serpentine drives. Identification Carlisle GPL Premium V-Belts are available in L3, L4 or L5 cross- sections, as illustrated above. The GPI Premium V-Belt is a performance leader and is a premium replacement to give maximum service life on FHP drives. For such applications the following interchanges apply: L3 replaces 3L Section L4 replaces 4L Section L5 replaces 5L Section The Carlisle Part Numbering system for the GPL belt consists of the belt cross-section followed by the belt length inches, measured on the Outside Circumference (OC). See Example above. A fourth numeral, if shown, indicates additional 1/10ths inch in Outside Circumference. Automotive Belts Auto V Belts Metric Auto V Belts Imperial The V Belt has cogs on the top. These belts are manufactured with pre-stretched cord to eliminate regular tensioning. The V Belt has cogs on the top. These belts are manufactured with pre-stretched cord to eliminate regular tensioning. 11A0900C 11 - Top width in mm A - Automotive Effective Length C - Cog Construction Top width in 1/32 of an inch effective length in inches and 1/10 inch All the belts previous discussed in this lesson so far, are Carlisle Brand, supplied by PT Australia which is a division of BSC Motion Technology. The Automotive belts carried by BSC are all Dayco brand and we purchase them from Dayco Australia. Dayco was the first to develop the raw edge sidewall construction V-belt, which facilitated controlled slippage around pulleys. Top Cog V-belts Raw edge construction is combined with the Dayco patented cogged top design to ensure the top performance that today s vehicles and drivers demand. The Dayco Top Cog V-belt delivers more flexibility, and increases airflow around the belt, so it runs cooler and lasts longer than competitors V-belts. Three piles of neoprene impregnated fabric resist heat, oil, and grease, and a specially formulated treatment of the polyester cord provides strength, stability, and reliability. Gold Label V-belts Top Cog Gold Label V-belts the gold standard of performance - are the industry leader in truck and heavy duty applications. Designed with greater absorbance to shock load that is prevalent in diesel engines, Gold Label has a higher resistance to heat, oil, grease and contaminants than any other V-belt on the market. LESSON A9025 Introduction to V-Belts Series 90 Training page 23

26 Identification These Automotive belts are available in both metric and imperial types. However, we carry them only under the metric part number so you need to look at The Manual listing where you will find the conversion list. Metric - The part number begins with the top width in millimetres, then the letter 'A' for Automotive, then the effective length in millimetres, then the letter 'C' to indicate top cog construction. Imperial - The part Number is a 5 digit number - the first two numbers indicate the top width and the remaining 3 digits indicate the effective length in inches and 1/10ths inches (335 = 33-1/2 inches) - see the example above. Automotive Poly V-Belts Automotive Poly Vee Belts These belts are found on many modern motor vehicles and are popular because of their compact size and extended service life. 6PK Number of ribs P - Poly Rib K - Automotive Belt Effective length Dayco developed the first Polyrib or Multirib belt for the Ford Mustang in the USA in The multiple rib and flat design provides better belt to pulley contact for less slippage than conventional V- belts. Multiple ribs also eliminate the need for matching and allows for controlled slippage in overload situations, such as when an A/C compressor engages. Today, as in 1979, this belt sets the industry standard. The grooved design provides flexural stress relief for increased flexibility in both normal and backside bending. The grooves also render the belt less susceptible to environmental factors such as dust and splash induced slip. Dayco s superior manufacturing technology uses rubber impregnated fabric backing that maximizes load carrying capability and minimizes noise often associated with competitors belts. The cord is saturated with a specially formulated treatment that insures length and belt stability for the life of the belt. Identification The part numbers for these belts consist of a digit indicating the number of ribs, the letters PK indicating Poly Rib Automotive and the belt length in millimetres. See the example above. Timing belts play an important role in Automotive applications and these will be covered in the next lesson. LESSON A9025 Introduction to V-Belts Series 90 Training page 24

27 Tension Cord Materials Material Advantages Limitations Applications Polyester Good flexibility - Suitable for small diameter sheaves. Versatility -Good range of properties for general purpose applications High elongation - polyester cords will stretch about 14% before breaking. Fibreglass or aramid materials will only stretch about 3-4% before breakage occurs. This elasticity allows polyester to tolerate misaligned drives better than the other materials mentioned. Tensioning of polyester belts is not as critical as for fibreglass or aramid belts. Polyester shrinks when heated; if a polyester belt heats up while slipping, the cord shrinkage will (at least partially) retension the belt. Low modulus - Not suitable for synchronous belts Multi-belt drives. Cogged, raw-edge belts are primarily reinforced. Light duty drives for which flexibility is more important than strength. Fibreglass High modulus - Glass reinforced belts have dimensional stability; tooth pitch on synchronous belt is maintained under load. High-strength - Glass has the highest actual breaking strength (in psi) of the three major reinforcing fibres. Good flexibility - Suitable for small diameter sheaves. Good shock resistance - Twisted cords have better resistance to shock than basic filaments. Relatively low elongation and susceptible to damage from misaligned drives, a frequent field problem. However, matched sets are available. To minimize the possibility of misalignment damage, manufacturers recommend maximum drive widths. General trade applications where flexibility, rather than strength is the key requirement, as in fhp applications. Fixed centre. limited take up drives. Synchronous belts: drives subject to shock loading. LESSON A9025 Introduction to V-Belts Series 90 Training page 25

28 Aramids (Kevlar, Flexsun) Very high tensile strength. Stronger per unit weight than both steel and fibreglass: this, in combination with other advantageous properties, has enabled manufacturers to build stronger, more stable belts than previously possible. Exceptional stiffness - Dimensionally stable. High modulus. Strong adhesion to neoprene or polyurethane elastomers used in belt bodies. Good heat resistance. High relative cost. Relatively low elongation. Aramid reinforced belts are intolerant of drive misalignment. Relatively low ultimate strain. Requires careful attention to tensioning. Flexibility- Limited to larger diameter sheaves than polyester or fibreglass belts. Severe duty, limited take-up drives Single belt drives Drives with tensioning or clutching idlers. Synchronous belts. The physical properties provided by these materials are tensile strength, stability and flexibility. The cords are twisted from continuous filaments and are subsequently treated chemically to improve adhesion to the rubber. Polyester "is further" heat treated, and processed in three different ways, to achieve the desired properties listed below: (a) Low Pullout The polyester cord is processed in a relaxed state. It will therefore stretch on a drive but have very little shrinkage. Applications: Lawn and garden belts (except GPL & FHP sections) (b) Medium Pullout The polyester cord is processed under some tension. This will allow both shrinkage and stretch to a certain degree, typical of Super Blue Ribbon and other industrial belts. Applications: Industrial where regular maintenance is available for the correct tensioning of belts in service. (c) The polyester cord is processed with most of the stretch taken out. The belt therefore has a 'memory' and when stretched will try and shrink back to its original position, thus maintaining tension on a drive. High Pullout Applications: Automotive where belt tension is not checked regularly, and high speed creates high centrifugal force tending to stretch the belt. LESSON A9025 Introduction to V-Belts Series 90 Training page 26

29 A Test Page Name in full: Employee No (from Pay slip): Branch (e.g. QAA) Date (dd/mm/yy): Intro to V Belts Roller Chain Questions Q01. Changing to a more efficient belt construction can result in a reduction in energy of. Answers A. 1% to 2% B. 2% to 3% C. 4% to 12%. D. 113% to 18%. E. Greater that 18% Q02. The modern V Belt runs on a. A. Toothed Sprocket B. Vee Pulley C. Flat roller Q03. What part of the Pulley makes contact with the V Belt? A. Pulley Bottom B. Pulley Sides C. Top Edge Q04. Why is there a space between the bottom of the belt and the pulley? A. Ensures that the Belt is in contact with both sides of the pulley. B. Aids in heat dissipation. C. Helps to ensure that the wedging effect takes place. D. All of the above Q05. Which type of V-Belt has a cover of woven fabric, impregnated with neoprene? A. Wrapped Belt B. Raw Edge Belt Q06. What part of the V-belt transmits the power? A. Top Q07. Double Angle belts are suitable for use in what type of drive where others cannot be used? C. Automotive Belt B. Bottom C. Sides LESSON A9025 Introduction to V-Belts Series 90 Training page 27

30 Q08. If you have a clutching application, which belt should not be used? A. Blue Label (Wrap) Belts B. Gold Label Cog Belts C. Power Wedge Raw Edge Belts Q09. Which type of belt is suitable for rock crushers, vibrating equipment, saws and pumps? A. Urethane UFL Belts B. Super Blue Ribbon Belts C. Super Vee-Band Belts D. Variable Speed Cog Belts Q10. Variable Speed V-Belts are normally Wrapped type. True or False? Q11. What type of belt is a 3RCP 240? A. True. B. False. A. Classic Blue Label B. Double Angle C. Power Wedge Double Wrap D. Super V-Band E. XDV Extra Duty Belt Q12. Why would you not use an Industrial belt, eg. A50, in an automotive application? For example, a Fan Belt application? A. Auto Belts are Pre Stretched, Industrial belts are not. B. Auto Belts are Dayco Brand, Industrial are Carlisle. C. Auto Belts were the first type of belt to be manufactured. Industrial came later. LESSON A9025 Introduction to V-Belts Series 90 Training page 28

31 Correspondence Course LESSON A9025A Timing and Other Belts Part K POWER TRANSMISSION II Lessons A9025 to A9027A Table of Contents Automotive Timing Belts 10 Dual HTD 8 Dual Traditional 7 Durolink 11 Metric Dual 10 Metric AT Series 10 Metric T Series 10 RPP Panther Belts 9 RPP Silver Drive Belts 8 Synchro-Cog HTD 8 Synchro-Cog RPP 9 Synchro-Cog Traditional 7 Structured Training Plan This lesson is Part 2 of the twenty fifth series of Correspondence lessons in the BSC Structured Training Plan. Objectives The objective of this lesson is to provide an introductory to timing belts, the different belt types and their part numbering systems. Pre-requisites Completion of Lessons A A9025. Methods Achievement of the objectives is by presentation of lessons in an 'On-Line' or Correspondence Course format. The lessons in a Correspondence Course style are conducted for internal students in a lecture situation. Assessment A formal test is provided with this lesson. LESSON A9025A Series 90 Training

32 LESSON A9025A Timing and Other Belts Series 90 Training page 2

33 Synchronous Belt Drives Timing Belts Synchronous belt drives, or timing belts as they are more commonly known, operate on a tooth-grip principle. The moulded teeth of the belt are designed to mesh perfectly with identical grooves in the pulley upon which they are installed. The teeth enter and leave the pulley grooves with a smooth rolling action with negligible friction. this ensures a positive perfectly synchronized drive, similar to chain and sprocket, and gear transmissions. In order to satisfy the wide range of speeds, loads and applications, synchronous belts are manufactured in a variety of sizes and dimensions. The three principal dimensions of the belt are: 1. Pitch Length - circumferential length measured along the pitch line - see the illustration left and PCD below. 2. Pitch - distance between two adjacent tooth centres. 3. Width - the top width of the belt. Synchro Cog HTD Two styles are illustrated - Syncro Cog (left) and HTD type (right) PCD The PCD (Pitch Circumferential diameter) is a measurement commonly found in V-belt dimensional tables. With belts other that Timing belts, PCD actually refers to the circumference of a pulley measured at the point on which the belt actually runs in the pulley. Thus, it would be less than the diameter of the pulley. PCD is also used to describe the circumference of timing belts and in this case it refers to the circumferential length measured at the position of the cord within the belt. Construction Carlisle synchronous belts have a thin flexible neoprene backing to protect the tension members from dirt, oil and grease. The Moulded teeth are also made from Neoprene and are precisely formed and accurately spaced. A continuous, helically wound tensile member provides the load carrying element, while tough nylon fabric facing provides a wear resistant surface to the belts tooth surfaces. LESSON A9025A Timing and Other Belts Series 90 Training page 3

34 Advantages By combining the advantages of V-Belt drives with positive drives, Synchronous belts offer many advantages over ordinary V-belts, chain and gear transmissions: Non Slip Engagement - the teeth mesh with the belt and there is no slippage, which would cause variations in speed. This is a crucial factor in many industries including Printing, packaging and materials handling, where synchronisation is a necessity. Wide range of load speeds and capacities - whilst many Chain and Gear drives have a limited speed range, Synchronous belts can operate at from 0 to FPM and possess load carrying capacities from fractional to hundreds of horsepower. No Lubrication required - unlike Chain Drives, V-belt drives never need lubricating as there is no metal-to-metal contact. High Strength to Size ratio - synchronous belt drives have excellent mechanical efficiency for their size when compared to chain, gear or ordinary V-belt drives. Economical Operation - Since V belt drives do not require adjustable tensioning devices and lubrications, costs are reduced. Minimum Tension - Synchronous belts do not rely on friction for their pulling power. Side slack tension is nearly zero, and tight side tension is substantially reduced, resulting in improvements in belt life. Constant Driven Speeds - the toothed design means that the belts operate at a constant speed, so operation is smooth unlike conventional belts which are subject to jerking and vibration. Industrial Timing Belts Type Description Example Synchro-Cog Traditional Dual Traditional Synchro-Cog HTD MXL, XL, H, XH, XXH XK, L, H 400XL PCD (mm) XL - 1/5 inch Section Width (1/4 inch) 210H PCD (mm) H - H Series Width (2.00 Inch) now replaced with RPP HTD: 3M, 5M, 8M, 14M, 20M LESSON A9025A Timing and Other Belts Series 90 Training page 4

35 Industrial Timing Belts Type Description Example Dual HTD Not readily available - We usually sell RPP type instead 8M DL RPP Silver Drive Belts 1200SLV PCD (mm) SLV - Silver Drive Belt 8-8mm pitch 50 - Belt width (mm) SLV8, SLV14 RPP Panther Belts 1200PTD8M PCD (mm) PTD - Panther Drive Belt 8M - 8mm pitch 50 - Belt width (mm) PTH8-8M, PTH14M Synchro-Cog RPP 240RPP3-6 Single Belt Length RPP = RPP type 3-3mm pitch 6-6mm Width These belts are also available in a double width. 1440RPP8DD50 Dual RPP: 3M, 5M, 8M, 14M, 20M 1440 = Belt Length RPP = Profile 8 = 8mm Pitch DD = Double Sided 50 = Belt Width LESSON A9025A Timing and Other Belts Series 90 Training page 5

36 Industrial Timing Belts Type Description Example Metric AT Series AT AT - AT Series 5 - Section PCD (mm) Belt Length 10 - Width (mm) AT5, AT10, AT20 Metric T Series T T - T type 5 - Section PCD (mm) Balt Length 16 - Width T5, T10, T20 Metric Dual AT10-420DD-10 T2.5, T10, T20 AT - AT Series 5 - Section PCD (mm) Belt Length DD - Double Sided 10 - Width (mm) Automotive Timing Belts Part number not related to size 94 Series LESSON A9025A Timing and Other Belts Series 90 Training page 6

37 Industrial Timing Belts Type Description Example Durolink C-50 Durolink C - C section ft length Durolink - Durolink A B, C, M section Synchro-Cog Traditional Timing Belts Synchro-Cog Traditional 400XL PCD (mm) XL - 1/5 inch Section Width (1/4 inch) MXL, XL, H, XH, XXH The Synchro-Cog timing belt is Carlisle's standard timing belt for maintenance free performance in timing and positive drive applications. They are the most commonly used belts and are a flexible gear system with the precision of a cog wheel. These Trapezoidal profile belts are available in XL, L, H and XH profile. Identification Carlisle Synchro-Cog timing belt part numbers consists of the PCD, the letters as above, to indicate the type, and the belt width in decimal inches. Dual Traditional Timing Belts Dual Traditional 210H PCD (mm) H - H Series Width (2.00 Inch) XK, L, H A dual sided version of the Synchro-cog belt. These belts can be used in serpentine type applications, where driver or driven cogs may be on either side of the belt. Identification Carlisle Dual Traditional timing belt part numbers consists of the PCD, the letters as above, to indicate the type, and the belt width in decimal inches. LESSON A9025A Timing and Other Belts Series 90 Training page 7

38 Synchro-cog HTD Synchro-Cog HTD now replaced with RPP HTD: 3M, 5M, 8M, 14M, 20M These belts are not discussed in this lesson as they have been replaced with Synchro-Cog RPP. Dual HTD Dual HTD Not readily available - We usually sell RPP type instead. 8M DL These belts are not discussed in this lesson as they have been replaced with Synchro-Cog RPP. RPP Silver Drive Belts RPP Silver Drive Belts 1200SLV PCD (mm) SLV - Silver Drive Belt 8-8mm pitch 50 - Belt width (mm) SLV8, SLV14 RPP Silver Drive Belts. These high performance, parabolic profile belts offer up to 50% increased drive capacity than our standard RPP belt line. The secret is in the construction: the teeth are covered with a patented double fabric for remarkable resistance to tooth shear and wear. The result: a quieter-running, more compact, cost effective drive. Identification RPP Silver Drive Belts part numbers consist of the PCD in mm, the letters SLV indicating the type, the pitch (8 or 14) and the Belt Width in milimeters. LESSON A9025A Timing and Other Belts Series 90 Training page 8

39 RPP Panther Belts RPP Panther Belts 1200PTD8M PCD (mm) PTD - Panther Drive Belt 8M - 8mm pitch 50 - Belt width (mm) PTH8-8M, PTH14M Carlisle RPP Panther Belts were developed to replace chain and gear drives and to upgrade synchronised drive systems on V-Belt drives. Panther power means maximum operating efficiency, smooth performance, reduction in noise, wide range of drive speeds and no lubrication. Available in PTH8 & PTH14 pitch. Identification Carlisle RPP Panther Belts part numbers consist of the PCD in mm, the letters PTD indicating the type, the pitch (8 or 14) and the Belt Width in millimeters. Synchro-Cog RPP Belts Synchro-Cog RPP 240RPP Belt Length RPP = RPP type 3-3mm pitch 6-6mm Width RPP: 3M, 5M, 8M, 14M, 20M These belts are also available in a double width 1440RPP8DD = Belt Length RPP = Profile 8 = 8mm Pitch DD = Double Sided 50 = Belt Width The Carlisle RPP belts with the parabolic profile is the most modern and efficient power transmission system. The unique tooth profile provides reduced noise levels, Improved Power capabilities, greater resistance to tooth jump, and improves slow stress resistance. Identification The part number consists of the belt length, in millimetres, Type (RPP), the Pitch in millimetres and the Belt width. Where the belt is a double-sided belt, the letters DD are inserted after the pitch. LESSON A9025A Timing and Other Belts Series 90 Training page 9

40 Metric Polyurathane AT, Metric T and Metric Dual series. Metric AT Series Metric T Series Metric Dual AT5, AT10, AT20 T5, T10, T20 AT AT - AT Series 5 - Section PCD (mm) Belt Length 10 - Width (mm) T T - T type 5 - Section PCD (mm) Belt Length 16 - Width T2.5, T10, T20 Automotive Belts Automotive Timing Belts Part number not related to size 94 Series Timing Belts have been used on camshaft and injection pumps on automotive engines for around 30 years. Dayco manufactures timing belts for OEMs utilizing the latest technologies in design and materials. The basic function of a timing belt is to transmit synchronous movement from one driven shaft to another. This is achieved by meshing between the tooth of the belt and the tooth of the pulley. A timing belt has a complex structure and is made up of three elements. A rubber compound (usually highly saturated nitrile) that makes up the toothed part and the back of the belt. Nylon (sometimes a double layer) is extremely flexible and used to cover the teeth. High modular fiberglass cords, which are resistant to tensile stress and will not deform give the belt its outstanding stability. LESSON A9025A Timing and Other Belts Series 90 Training page 10

41 Identification These Automotive V Belt part numbers are not related to size or in any order of size. The only way to determine the part number of a particular belt size is to look it up in the catalogue. The Manual has a complete listing on pages 34 to 38 of the Power Transmission book. Durolink Belting Durolink C10-50 Durolink C - C section ft length A B, C, M section Durolink belting is designed for the industrial drives where endless belts are not physically suitable, or for use in emergency situations where endless V- belts are not readily available. The Durolink V-Belt is manufactured by apple Belting using a unique process developed by their engineers, which allows for a truly consistent belt. This belt generates better performance and ease of replacement. Durolink is the only static conductive belt of its kind in the market. The belting fits standard pulleys (SPZ, SPA, SPB, or SPC). It can be used on multigroove sheaves. Just use the same number of links on each belt. Identification The Numbering system for Durolink belting could not be simpler. C-10Durolink means C section 10 Ft Length. They are available in A, B, C and M sections in the following lengths: 10Ft coil pack 25ft coil pack 50 Ft on re-usable spool 100 Ft on re-usable spools 20 Meters on re-usable spools LESSON A9025A Timing and Other Belts Series 90 Training page 11

42 LESSON A9025A Timing and Other Belts Series 90 Training page 12

43 A9025A - Test Page Name in full: Employee No (from Pay slip): Branch (e.g. QAA) Date (dd/mm/yy): Timing and Other Belts Questions Q01. Which 3 principal dimensions are required to identify Timing Belts? Answers A. Pitch Length B. Pitch Q02. List 3 advantages which Timing Belts have over Chains. A. C. Pitch Distance D. Width E. Outside Diameter B. Q03. What is the Pitch of a timing belt? A. Circumference of the belt C. B. Circumferential length measured along the pitch line. C. Distance between 2 adjacent tooth centers. Q04. What do you understand by the term PCD? A. The circumference of a pulley measured at the point on which the belt actually runs in the pulley. B. The circumferential length measured at the position of the cord within the belt. Q05. What is the part number for an XL series Synchro-cog traditional timing belt with a PCD of 150mm and a width of 50 mm? A. XL150X50 B. 150XL55 C. 150XL050 D. 150x50XL Q06. How is the part number related to the belt size? A. Not related at all B. Last 3 numbers indicate the PCD C. Belt is 942MM PCD by 68MM Width LESSON A9025A Timing and Other Belts Series 90 Training page 13

44 Q07. What type of belt is a 94221? A. Automotive B. Metric Dual C. Durolink D. Synchro-Cog RPP Q08. What pitches are RPP Panther belts available in? A. 6 and 8mm. B. 8 and 10mm. C. 10 and 12mm. D. 8 and 14mm. E. 6 and 12mm Q09. What is the width of Durolink C-10DUROLINK Chain? A, 10 mm B. 13 mm C. 17 mm D. 22 mm Q10. What type of belt replaced Synchro Cog HTD? A. RPP Silver B. RPP Panther C. Synchro Cog RPP D. Metric AT Series LESSON A9025A Timing and Other Belts Series 90 Training page 14

45 Correspondence Course LESSON A9026 Introduction to PULLEYS Part K POWER TRANSMISSION II Lessons A9025 to A9027A Table of Contents Adjusta-Sheave Series 18 Key Steel 27 Aluminoline Series 16 Mi-Lock Pulleys 9 Aluminium V-Pulleys 5 Stepped Pulleys 23 Band Saw 23 Tapered Bushes 25 Belt Drive Systems 3 Timing Sprocket Pulleys 19 Block 3 V-Pulleys 4 Cast Iron V-Pulleys 9 Variable Speed V Pulleys 15 Crown Face, 23 WB Series 16 Econoline 14 Weld On Hubs 29 Hexadrive Series 17 Wire Rope Sheaves 31 Hi-Ratio Series 17 Woodruff Keys 27 Idler Pulley Units 21 Structured Training Plan This lesson is the twenty sixth of a series of On Line lessons in the BSC Structured training plan. Objectives The objective of this lesson is to introduce you to the range of pulleys carried by BSC. Pre-requisites Completion of Lessons A A9025. Methods Achievement of the objectives is by presentation of lessons in an 'On-Line' or Correspondence Course format. The lessons in a Correspondence Course style are conducted for internal students in a lecture situation. Assessment A formal test is provided with this lesson. LESSON Series 90 Training

46 LESSON A9026 Introduction to Pulleys Series 90 Training page 2

47 Introduction A pulley (also called a block) is a mechanism composed of a wheel (called a sheave) with a groove between two flanges around the wheel's circumference. A rope, cable or belt usually runs inside the groove. Pulleys are used to change the direction of an applied force, used singly or in combination to transmit energy and motion, or realize a mechanical advantage in either a linear or rotational system of motion. Belt Drive Systems In belt drives, pulleys are attached to shafts at their axes, and power is transmitted between the shafts by means of endless belts running over the pulleys. The motion of the driving pulley is, generally, transferred to the driven pulley via the friction between the belt and the pulley. The Driver pulley receives energy from the power source and transfers it to the Driven pulley via the belt. A Driven pulley is the fixed pulley in a belt drive system that receives energy from the driver pulley via the belt. V-Belt Drive V-belt drives are also called Friction belt drives because power is transmitted as a result of the belt's adherence to the pulley. They should never be lubricated, as they depend on friction to transmit power. V-Belt drive pulleys are designed with one or more grooves, allowing V-belt to wedge into each groove for power transmission. Timing belt drives, also called Synchronous belt drives, on the other hand, are belt drives in which the teeth of a timing belt mesh with the grooves in a pulley to transmit power and therefore do not depend on friction. Timing Belt Drive LESSON A9026 Introduction to Pulleys Series 90 Training page 3

48 V-Pulleys V-belt pulleys are made from materials such as aluminium, brass, cast iron, steel, stainless steel, plastic, or zinc alloy. Both single groove and multiple groove devices are commonly available. There are several basic types of V-Belts. Standard V-belt pulleys have one or more grooves and are designed for general-purpose applications. Variable speed pulleys have faces or flanges that adjust axially to vary pitch diameter. Idler pulleys are used as belt tensioners and contain bearings that allow free rotation. Multiple-size pulleys use step-down or cone configurations. Poly-V pulleys are used with mating belts for high-speed power transmission. Typically, both the section designation (H, J, L, M, or PK) and the number of ribs require specification and belt-pulley matching. Dimensions V-belt pulleys differ in terms of pulley size, belt angle, belt width, operating temperature, shaft mounting, and pulley web style. The most important dimensional specifications are pitch diameter, outside diameter, and bore diameter. Pitch diameter determines the strength-to-weight ratio and, for variable or step pulleys, is a maximum amount. Outside diameter (OD) is measured to the outside of the pulley flanges. Bore diameter is specified for devices with a centre hole for shaft mounting. Other mounting styles for V-belt pulleys use set screws, keyways, welds, quick-detach (QD) hubs, taper bushing, or simple bores. LESSON A9026 Introduction to Pulleys Series 90 Training page 4

49 Aluminium Die-Cast V-Pulleys Material Grade S Sections Suitable for M, A and B type belts Variations These pulleys can be supplied with a single groove (1A, 1B, 1M) or double groove (2A, 2B) Stepped This means that there are several different sized pulleys cast into the same wheel. These are usually used in pairs and enables the belt to be moved to different positions, thus altering the drive ratio. Two Step Four Step Five Step Six Step Crown Face Band Saw (2S) (4S) (5S) (6S) (CF) (2A) Bore We only carry imperial finished bore and keyed in stock. Pilot bore is also available (PB). If the customer requires blank bore, this can be made to order. 1/2" (1) No keyway as it isn't necessary with 1/2 shaft. 5/8" (2) Bore and Keyway 3/4" (3) Bore and Keyway 1" (4) Bore and Keyway They are available and are stocked at branches for specific METRIC (5) customer requirements. IMPERIAL (5) Non-standard. Any shaft size can be manufactured. LESSON A9026 Introduction to Pulleys Series 90 Training page 5

50 Size Range (inches) Pitch circle diameter (PCD). The pitch of a V Belt is slightly below the outside circumference so these sizes are slightly smaller than the Outside Diameter. Refer to the V belt lesson for more information about PCD. 1 1/4, 1 1/2, 1 3/4, 2 (02) 2 1/2, 2 1/4, 2 3/4, 3 (03) 3 1/4, 3 1/2, 4 (04) 4 1/2, 5 (05) 5 1/2, 6 (06) 6 1/2, 7 (07) 8 (08) 9 (09) 10 (10) 12 (12) 14 (14) 15 (15) 16 (16) 18 (18) Reference Duty see Pulley pages from BSC The Manual Catalogue. Light and Medium Method of Retaining on the Shaft Bore Keyway and grub screw. The pulley has a rectangular groove cut on the shaft side of the hub. This groove has a grub screw that runs from the OD of the hub to above the keyway groove. The shaft has a matching groove so that when both of them oppose they form a square which accepts the keysteel. The grub screw forces down on the keysteel and stops it from sliding out. When the shaft rotates, force is exerted onto the keysteel moving the pulley in unison with the shaft. The Grub Screw is supplied with the hub. Manufacturer Stenco is an Australian company and uses superior grade of aluminium than its competitors. As wear occurs at the keyway, the better the aluminium grade the longer the life. Stenco can be identified by their distinctive maroon faces. LESSON A9026 Introduction to Pulleys Series 90 Training page 6

51 Part Number Examples: A. Standard Pulley 1A where: 1A = Section (Single Groove A) 040 = PCD (4") 1 = Bore Code (1/2") B. Pulley (Metric Bore) 1A x 25mm where: 1A = Section (Single Groove A) 040 = PCD (4") 5 = Bore Code (Metric) 25mm = Shaft Size LESSON A9026 Introduction to Pulleys Series 90 Training page 7

52 LESSON A9026 Introduction to Pulleys Series 90 Training page 8

53 Cast Iron V-Pulleys (MI-LOCK) Material Grade S Sections Suitable for M, A and B type belts Variations These pulleys can be supplied with a single Groove (1A, 1B, 1M) or double groove (2A, 2B) Stepped Pulleys As with the Aluminium pulleys, there are several different sized pulleys cast into the same wheel. These are usually used in pairs and enabled the belt to be moved to different positions, thus altering the drive ratio. Two Step (2S) Four Step (4S) Five Step (5S) Six Step (6S) Crown Face (CF) Band Saw (2A) LESSON A9026 Introduction to Pulleys Series 90 Training page 9

54 Method of Retaining on the Shaft A. Single Pulley No. 1 and No. 2 Bush There are four components to assemble and charge out. Pulley, Bush, Retainer and Bolt set (Short). The three bolts (short) are placed through the three holes in the retaining ring. The retaining ring is placed over the short tapered surface on the bush. The long tapered surface is then placed in the pulley which has a matching taper. The three bolts which pass through the ring are threaded into the matching holes (Threaded) in the pulley face. The bolts are then tightened to leave an overall length of No. 1 short 31mm, No. 2 short 36mm. As the bush is forced into the match taper, the split in the bush allows it to tighten around the shaft holding it in place. There is no keyway used in this system. B. Two Pulleys You can only bolt two pulleys together if they have matching entry and bolt pattern. So No. 1 and No. 2 can't be bolted together. There are four components to assemble and charge out. 2 Pulleys, Bush and Bolt set (Long). The three bolts (Long) are placed through the three (unthreaded) holes in the one pulley. The short tapered surface of the bush is placed in that pulley. The second pulley is located on the long taper and the bolts threaded into the three matching threaded holes. The pulley is tightened until there is an overall width of No.1-48mm, No. 2-50mm. Manufacturer PTA is our prime source, however, they are also available from Fenner. LESSON A9026 Introduction to Pulleys Series 90 Training page 10

55 Part Number Pulley BFP followed by a section PCD is less then 10mm 0 starts the size eg. 071 B = Bi F = Fit P = Pulley Bush BFB No. 1 followed by size eg. 1 1/8 BFB No. 2 followed by size eg. 24(mm) B = Bi F = Fit B = Bush Retainer BR01 BR02 Bush Retainer Bush Retainer Bolts Short No. 1 Short No. 2 Long No. 1 Long No. 2 Short Single Pulley Short Single Pulley Long Two Pulleys Long Two Pulleys Part Number Example 1A where: 1A = Section (Single Groove A) 040 = PCD (4") 1 = Bore Code (1/2") LESSON A9026 Introduction to Pulleys Series 90 Training page 11

56 Standard Cast Iron V-Pulleys (Tapered bush and Pilot Bore) Material Fine Grain Cast Iron - Grade Sections Suitable for SPZ, SPA, SPB and SPC type belts. Banded Power Wedge Belts will not run in our standard pulleys. The part number of the belt reverts from metric to RMA as they are only made in RMA sizes. Same applies to the pulley which has to be manufactured for 3V, 5V or 8V. You must quote that it is a banded belt when placing the order. Variations BSC carries only taper lock bushes. Other types have to be imported. These pulleys are solid or may have spokes when you buy in. They will have 4 light holes as standard, in the webbing. The webbing can be ordered thicker and without the light holes if required. Our standard stock pulleys are balanced. If you buy in, check that they are also balanced. Bore Pilot bore is not available as a tapered bush is used to retain the pulley onto the shaft. Check The Manual for a list of the sizes available. The chart also tells you which taper lock to use with each pulley. Size Range Standard sizes are shown in The Manual. Other sizes can be manufactured to special order. Note - special care should be exercised when Tapered Bush replacement is required as manufacturers differ in the bushes they use. Be aware that you need to select the size below the actual pulley outside diameter as the size is PCD which is less than the actual diameter. Reference See Pulley pages from BSC The Manual Catalogue. Duty Medium and Heavy LESSON A9026 Introduction to Pulleys Series 90 Training page 12

57 Method of Retaining on the Shaft Our standard stock is Tapered bush. However, you can order Bored, keyed and grub screwed, which is the US system. Some manufacturers use Ringblock which is an expanding inner ring. Tapered Bush There are 2 1/2 inch blank holes the depth of grub screws and one threaded 1/2 inch hole through the length of the taperlock bush. The 1/2 inch hole blanks have matching holes in the pulley, and are threaded. When the screws are tightened up, the split in the bush allows it to grip the shaft. The key way and key steel are held in place as the clamping effect as there is no grub screw through the hub. The clamping and key steel means that the pulley will turn when the shaft turns. To remove, slacken off all screws and place one in the jack off hole. This hole is threaded full length in the bush and there is a blank dowel in the pulley. When the grub screw bottoms in the pulley dowel hole, the thread in the tapered bush draws the bush. Manufacturer PTA is our prime source, however, they are also available from Fenner and other suppliers. Part Number Tapered Bush type pulley eg. 1 SPA100x2 SPZ Section 100 PCD x3 3 Grooves eg. 2 SPA150x1 SPA Section 150 PCD x1 1 Groove LESSON A9026 Introduction to Pulleys Series 90 Training page 13

58 Stationary Variable Speed V Pulleys (Standard V Belt) Variable Speed Pulleys are designed with two separate tapered plates forming each side of the pulley. By increasing the distance between the two plates, the belt can be made to run deeper or shallower into the groove. Changing the depth changes the apparent size of the pulley which in turn, changes the operating ratio. The effect of this is to alter the operating speed of the drive system. Variable speed pulleys offer several benefits: 1. Very economical and reliable method of speed change. 2. Allows the user to find the ideal speed without changing sheaves and belts. This is especially important on applications where final driven speed is critical and difficult to attain with two fixed-diameter sheaves. Speed range within the ration is infinite, and speed change is accomplished quickly, while the drive is running. 3. Can be used as a highly efficient belt tensioner, with no adjustment necessary. 4. Offers a form of soft start, eliminating belt slip and premature wear on belt drives with inherent high torque start-up requirements. Material Cast Iron/Steel/Aluminium - See Series detail on next page. Sections The groove will accept A, B or SPA. Variations Single or Double Groove Bore Pilot bore ex stock but most suppliers will have them bored to size, and a keyway and grub screw installed. Bore range is 10mm to 48mm. Size Range Outside Diameter - 85mm, 100mm, 115mm, 125mm, 140mm, 150mm, 165mm, 180mm, 200mm. Catalogue The Manual pages - Pulley section Method of Retaining on the Shaft Bore to size, keyway and grub screw. Part Number Example VSP 140 AB VSP = Variable Speed Pulley 140 = OD AB = Accepts A, B and SPA belts Application The thread on the OD of the hub varies the PCO. This allows fine tuning of the speed on equipment like Air Conditioning plants. LESSON A9026 Introduction to Pulleys Series 90 Training page 14

59 Vari Speed V Pulleys BSC has access to a range of variable speed pulleys, each of which offer features and benefits to cover a wide range of applications. Check with your state engineer or PT expert if you are not sure which type to recommend, to meet your customers requirements. Here is a Link to The Manual pages on variable Speed Pulleys. Econoline Series The Econoline Pulley series provides reliable variable speed service with a proven design at an economical cost. Consisting of a wide selection of models, the Econoline series is ideal for both adjustable and fixed centre drives using classic A and B (or 4L and 5L) section drive belts. This series also offers: driven speed ratios from 1.6 to 1 up to 2.7 to 1 and horsepower ranges from fractional through 5 1,750 RPM motor speed. The flanges are constructed of durable cast iron. Typical applications of this maintenance-free pulley include: conveyors, mixers, small machine tools, mower traction drives, printing equipment, packaging machines, and belt tensioners. A recent addition to the range - A two-side moveable Econoline version has been added in three sizes: five-inch, six-inch and seven-inch. These new models are ideal in applications where belt alignment is critical. Materials Steel/Cast Iron flanges Sections A and B Bore 1/2 inch, 7/8 inch, 1-1/8 inch or 1-3/8 inch. The 1/2 inch can be treated as pilot bore and machined to size. Duty Light and Heavy LESSON A9026 Introduction to Pulleys Series 90 Training page 15

60 Aluminoline Series Aluminoline variable speed pulleys offer the best possible belt alignment with the least amount of overhung load. Used with A and B drive belts, these pulleys not only have anodized aluminium flanges which provide quiet operation with minimum vibration, but are rated for 1/3 through 1-1/2 HP motors. These two-side moveable pulleys offer greater speed ratios (up to 2.75 to 1). Due to the corrosion-resistant properties of these pulleys, they are ideal for use on agricultural machinery, food packaging and bottling equipment, baseball pitching machines, and a variety of other products. [ Materials Aluminium Sections A and B Bore 1/2 inch, 7/8 inch, 1-1/8 inch or 1-3/8 inch. The 1/2 inch can be treated as pilot bore and machined to size. Duty Light and Heavy WB Series Pulleys in the WB series use wide variable speed belts for the most efficient transmission of torque through the widest possible speed range. This two-side moveable pulley series offers the best possible belt alignment when used with a grooved companion sheave. WB pulleys provide maximum service when lubricated through a convenient grease fitting and offer sizes ranging from 6 to 13 inches in diameter, with the largest model capable of 15 HP. All models greater than 1 HP feature durable cast iron flanges (Models 245 and 260 are made with lightweight, corrosion-resistant anodized aluminium flanges). These pulleys can be used on both adjustable and fixed centre drives. Typical applications include: conveyors, printing presses, mixers, packaging and bottle-filling machines, machine tools, and agricultural equipment. LESSON A9026 Introduction to Pulleys Series 90 Training page 16

61 Materials Steel/Cast Iron flanges Sections 1400V, 1922V, 2322V, 2926V Size 6 inch to 13 inch. Duty Light and Heavy Hi-Ratio Series Hi-Ratio drives provide the unique combination of broader driven speed ranges and lowest possible minimum driven speed. Three Drive packages are available, with horsepower ranges from 1/2 to 5, with a 1,750 RPM motor, and speed ratios up to 11.5 to 1. They are ideal for use on machine tools and mixing machinery. Materials Steel/Cast Iron flanges Duty Light and Heavy Hexadrive Series Hexadrive pulleys are the most durable variable speed pulleys available. The hexagon-shaped centre shaft efficiently transmits torque through the six hex flats for top performance and long life. The surface of the shaft is covered with a resilient elastomer, which means there is no metal-to-metal contact on any sliding surface and lubrication is not necessary. These pulleys are available in adjustable or fixed centre drives and come in two styles: one-side moveable for V-Flat drives, and two-side moveable for V-V drives. Flanges are made of cast iron to provide a long-wearing belt contact area. These pulleys provide size ranges from 6" up to 12.5" in diameter, and a maximum rating of 30 1,750 RPM. Some typical applications include: agricultural equipment, food packaging machines, air handling systems, textile spinning frames, mixers, pumps, machine tools, and foundry snag grinders. LESSON A9026 Introduction to Pulleys Series 90 Training page 17

62 Materials Steel/Cast Iron flanges Sections 1442V, 1922V, 2926V, 3230V, 4430V. Size 6 inch to 12.5 inch. Duty Light and Heavy Adjusta-Sheave Series The Lovejoy Adjusta-Sheave can be a cost-saving alternative to a spring loaded pulley when speed change is infrequent. To change speeds, the drive must be shut down (unlike other variable speed pulleys). All models use wide variable speed belts. The Adjusta-Sheave design eliminates the need for internal drive keys, thus providing more efficient transfer of power and longer life. The two cast iron flanges are moveable, allowing perfect belt alignment at all times. Four models are available with ranges from 5 through 30 HP and speed ratios up to 2.5 to 1. Typical applications include: textile spinning frames, heating and air conditioning equipment, pumps, etc. Materials Steel/Cast Iron flanges Sections A and B Duty Light and Heavy LESSON A9026 Introduction to Pulleys Series 90 Training page 18

63 Timing Sprocket Pulleys Timing pulleys are used in power transmission systems where maintenance of speed ratio is an important design consideration. These pulleys have a spacing or pitch based on Imperial or Metric measurements and a toothed, trapezoidal form. Pitch is the distance from one tooth s centre to the adjacent tooth s centre. Timing pulleys are made of metal, plastic and combination materials. Factors such as environmental conditions, design horsepower, operating temperature, and cost determine the best material choice. Typically, metal pulleys are made of aluminium or steel. Plastic pulleys are made of acetal, nylon, or polycarbonate materials. Acetal pulleys provide chemical resistance, but melt at relatively low temperatures. Polycarbonate pulleys have excellent mechanical properties, but can be attacked by solvents and petrochemicals. Here is a link to the timing pulley pages in The Manual. Material Aluminium, Nylon, Steel, and Cast Iron, depending on the pitch, number of teeth, and shaft mounting method. Section Timing - Classical HTD MXL Aluminium or Steel HTD, RPP, Polychain Nylon, Aluminium or XL Steel 5m Aluminium, Steel L Cast Iron, Steel 8m Aluminium, Steel H Cast Iron, Steel 14m Cast Iron, Steel XH Cast Iron, Steel 20m Cast Iron, Steel XXH Cast Iron, Steel 2m Aluminium, Steel AT 2.5m Aluminium, Steel 5m Aluminium, Steel AT5 Aluminium, Steel 10m Aluminium, Steel AT10 Aluminium, Steel 20m Steel AT20 Aluminium, Steel Tapered Bush entry will be Steel or Cast Iron. Variations Pulley width 025 (1/4 inch), 037 (3/8 inch), 050 (1/2 inch), 075 (3/4 inch), 100 (1 inch), Inch 150 (1-1/2 inch), 200 (2 inch), 300 (3 inch), 400 (4 inch), Metric 20mm, 30mm, 40mm, 50mm, 55mm, 85mm, 115mm, 170mm Poly Chain 12mm, 20mm, 21mm, 36mm, 37mm, 62mm, 78mm, 90mm, 125mm Single, Double and Stepped available LESSON A9026 Introduction to Pulleys Series 90 Training page 19

64 Belt Types (Different sprockets) Classical (MXL, XL, L, H, XH, XXH) AT Series (AT5, AT10, AT20) Metric Timing (1.5m, 2m, 2.5m, 5m, 10m, 20m.) HTD (5m, 8m, 14m, 20m) RPP will run in HTD pulleys but RPP are available as an Import item Polychain 8m and 14m special width Bore Pilot Bore, Finished Bore, Keyway and grub screw. Tapered bore and QD (USA Import) Size Range (Teeth) All sizes can be manufactured with required bore and material teeth is generally available off the shelf but you should check supplier stock or price list for a complete stock range. Duty Light Medium, Heavy (Panther, Polychain) Method of retaining on shaft Bored Keyway and Grub Screw Tapered Bush, QD hub (ex USA) Part Number Examples: Imperial Timing Example 1 Example 2 Example 3 First 2 or 3 digits = Teeth Number 25 XL 037 PB 24 L 100 TL 28 H 300 X1 1/2 Alpha Digits = belt pitch teeth teeth teeth Last three digits = Width XL - 1/5 pitch L - 3/8 pitch H - 1/2 inch pitch PB = Pilot Bore 037-3/8 wide inch width inch width TL = Taper Lock PB - Pilot Bore TL - Taper Lock X1 1/2-1-1/2 inch X25 = Finished Bore bored keyway and grub screw Metric Timing Example 1 Example 2 Example 3 As above 25 T5 25 PB 30 ATS 32 X m 85 TL teeth teeth teeth TS - 5mm pitch ATS - 5mm pitch 14m - 14 mm pitch 25-25mm wide 32-32mm wide mm wide PB - Pilot Bore X19-19 mm finished bore TL - Taper Lock Polychain As above Example 1 8m 38S 12 TL 8m - 8mm pitch 38S - 38 teeth mm wide TL - Taper Lock LESSON A9026 Introduction to Pulleys Series 90 Training page 20

65 Idler Pulley Units Idler Pulleys are free running pulleys, commonly made from pressed steel, which are used to take up the slack in belt drives. Other uses are to route the path of the belt away from other obstructions and to increase the contact area of the belt on a drive or driven pulley. Material Pressed Steel Section These pulleys are available in V configuration, flat/flat face configuration and semi-circle format. The V configuration is suitable for the running edge of the V belt. The Flat configuration can be used against the back of a V Belt. The Semi-circular configuration can be used with round belting. Variations These idlers may incorporate either a standard single row or double row ball bearing. The flat face idler is a variation of the ribbed flat face idler which allows some sideways movement of the belt. Belt Types These Idlers can be used with any type of belt A roller chain idler is also available. This is a sprocketed (toothed) idler which may be made from plate steel or pressed steel. Check The Manual pages. Martin Aetna LESSON A9026 Introduction to Pulleys Series 90 Training page 21

66 Bore Since the centre is a ball bearing, the idler bore size will be fixed by the dimensions of the bearing used. Size Range Type A - 90mm to 186 bb OD - 2-1/2 inch to 9-1/2 inch Type B - 92mm top 222mm Type D - 154mm to mm Flat Face Idlers - 5 inch to 8 inch Roller Chain Idlers - suitable for 40, 50, 2040, 2050, 2060, CA550, 45, 55, 550, 62, 62H chain., Teeth very from 6 to 18. Method of Retaining These bearings are a press fit on the shaft. Since there is no drive or driven action, there is no need for key ways, grub screws etc. Part Numbers BSC purchase idler pulleys from several sources, each of which have their own numbering system. Always check the catalogue in The Manual to determine the correct part numbers for the type and size of idler pulley you are supplying. LESSON A9026 Introduction to Pulleys Series 90 Training page 22

67 Stepped Pulleys, Crown Face, Band Saw Stepped Pulleys Stepped Pulleys, like the one shown in this picture, are used as a cheap and easy way of varying the speed of a drive system. They are usually installed in pairs so that the smallest pulley groove on one matches with the largest on the other. The drive ratio, and thus, the drive speed, can be altered by moving the belt to run between differing pairs of pulley grooves. Crown Face Idlers Crown Face Idlers have their outer surface slightly crowned (convex shape). The effect of this is to keep the belt centered on the pulley, since any movement of the belt off centre, whilst running, will automatically be countered by the crowning. Band Saw Idlers Band Saw Idlers are placed at the opposing end to the drive wheel and keep the tension on the saw blade. Material Aluminium (Grade S) Steel is available from QMN Sections A - SPA Variations Stepped Pulleys Bore 2 Step - 3-1/4 and 2-1/2 OD 4 Step - 3-3/4, 2-3/4, 2-1/2, 1-3/4 OD 4, 3-1/4, 2-1/2, 1-3/4 OD 4-1/2, 3-9/16, 2-3/4, 2 OD 5, 3-7/8, 2-13/16, 1-3/4 OD 5-1/2, 4-1/2, 3-15/16, 2-1/4 OD 7, 6, 5, 4 OD 5 Step - 6, 5-1/4, 4-1/2, 3-3/4, 3 OD 6 Step - 7, 6, 5, 4, 3, 2 OD 1/2 (1), 5/8 (2), 3/4 (3), 1 (4) - 1/2 inch does not have a keyway. Other sizes can be machined. Metric sizes are available. Steel stepped pulleys can be manufactured with tapered bush entry, as well as bore keyways and grub screws. LESSON A9026 Introduction to Pulleys Series 90 Training page 23

68 Size Range See above. Duty Light, Medium Method of retaining on shaft Aluminium and Steel - Bored with keyway and grub screw Steel can be made in a tapered bush format. Part Number Stepped 2S 4S 6S Two Stepped Four Stepped Six stepped Crown Face CF Band Saw 2A1006 2A1206 LESSON A9026 Introduction to Pulleys Series 90 Training page 24

69 Tapered Bushes Tapered bushes are locking devices used to secure the pulley on to the shaft. They slip into a matching tapered hole which has been machined into the bore of the pulley. Benefits Made from high quality material Quick to install and remove No Keyway to machine out Pre Machined - no costly remachining. Wide tolerance range can be used with Pulleys, sprockets, shaft couplings, hubs and adaptors Flat finished face - no bolt heads Taperlock grabs on the parallel shaft - no remachining required Wide range including smaller sizes Tapered Bush There are 2 1/2 inch blank holes the depth of the grub screw, in the side of the bush, and one threaded 1/2 inch hole which runs the length of the bush. The 1/2 inch hole blanks have matching holes in the pulley (threaded) with the bush. When the screws are tightened, the split in the bush, allow it to grip the shaft. The Keyway (often rectangular) and the key steel, is held in place by the clamping effect as there is no grub screw through the hub. The clamping and key steel means that, when the shaft turns, the pulley will also turn. To remove, slacken all screws and place one in the jack Off hole. This hole is threaded the whole length of the bush and blank dowel in the pulley. When the grub screw bottoms in the in the pulley, dowel hole, the thread in the tapered bush withdraws the bush. Material Cast Steel, Standard Stock Steel. Bore Bore sizes are listed in The Manual, which can be accessed here. Size Range This is also listed in The Manual, which can be accessed here. LESSON A9026 Introduction to Pulleys Series 90 Training page 25

70 Duty Medium and Heavy Method of mounting on shaft See Above Part Numbers Example Steel Bush BC 3030 F2 where: BC Bush Coupling 3030 Tapered Bush part number F Fore = shaft 2 2 Inch bore Steel 3030 F50 where: Steel Steel bore 3030 Tapered bush part number F fore K10-45 Series 50 50mm Bore For imperial sizes, refer to the keyway chart in the sprockets catalogue. Note - Steel tapered bushes should be used for safety when speed, load, and size are high, and all wall thickness in this steel is unbreakable. LESSON A9026 Introduction to Pulleys Series 90 Training page 26

71 Key Steel and Woodruff Keys Key steel is used as a locking insert to prevent a sprocket or pulley from rotation on a shaft. It is usually, although not always, held in place with a grub screw, which is tightened through the pulley hub and on to the the key steel. A second grub screw is usually inserted at 90 and this tightened directly on to the shaft. Material C1040 zinc plated standard stock Variations Stainless Steel is available in standard. Un-plated bright steel is available in 3 metre lengths. Metric Key steel is used with tapered bushes. This is a good indication of the sizes to carry. We stock Key steel in 1 ft lengths and also in 3 metre bright steel un-plated. Stepped key steel is also available but is an Import item. Size Range Imperial - 1/4 inch to 1.5 inch Metric - 4mm to 27mm Part Number Examples Imperial Metric KS 1/8 x 1/8 x 1Ft KS1/2 x 5/16 x 75mm KS Key steel KS Key steel Dimensions - 1/8 1/8 x 1/8 x 75 1/2 x 5/16 Dimensions - 1/2 inch x 5/16 inch inch x 1/8 inch 1Ft 1 foot length 75mm 75mm length KS16mm x 10mm x 75mm KS 7mm x 7mm x 1Ft KS Key steel KS Key steel 16mm X 10mm Dimensions - 16 mm X 10 mm 7mm x 7mm 75mm 75mm length 1Ft 1 foot length Dimensions - 7 mm x 7 mm LESSON A9026 Introduction to Pulleys Series 90 Training page 27

72 Key Steel Kits BSC has imperial and metric key steel kits available which contain 75 mm lengths of the following sizes: Imperial Metric Keymaster Maintenance pack no 1 Keymaster Maintenance pack no 2 3 1/8 x 1/8 3 4mm x 4mm 3 3/16 x 3/16 3 5mm x 5mm 3 1/4 x 1/4 3 6mm x 6mm 3 5/16 x 5/16 3 8mm x 8mm 3 3/8 x 3/8 3 10mm x 10mm 3 7/16 x 7/ mm x 12mm 3 1/2 x 1/2 3 8mm x 7 mm 3 1/4 x 3/ mm x 8mm 3 1/4 x 5/ mm x 8mm 3 1/4 x 3/8 3 12mm x 10mm 3 5/16 x 3/8 3 14mm x 9mm 1 5/17 x 7/16 3 5/16 x 1/2 3 1/2 x 3/8 Woodruff Keys Woodruff keys are made from the same material as key steel, but are half round shape and are inserted into a corresponding slot machined into the housing and shaft. They are not as popular as key steel because of the difficulty of machining. However, they are often found in machine tools. Part Numbers The part number consists of the letters WK and the size. E.G. WK 1/4 x 1 is 1/4 inch thick by 1 inch diameter LESSON A9026 Introduction to Pulleys Series 90 Training page 28

73 WELD ON HUBS There are two types of Weld on hubs which can be used with plate wheel sprockets. The W and WH series are used with standard plate wheels of either pilot bore or sized bore sprockets and have to be machined to suit the Weld-on Hub. The AVT/AWT/AXT/AYS series are supplied as matching pieces with the plate wheel and weld on hub or boss unit, having matching dimensions. In this lesson, we will only discuss the W and WH types as these are the types which you would use with pulleys. Application Weld on hubs are not normally used with new pulleys, but are a cost effective solution when repairing existing pulleys. Most pulleys are made from cast steel, which doesn't have the durability or strength of steel. Wear will occur in the V Pulley grooves and tapered bush entry. In fact, pulleys often get more wear in the tapered bush entry than in the pulley groove. You can make the pulley stronger than the original by welding a steel hub on to it. This naturally saves the customer hundreds of dollars. Any piece of equipment can be retained on the shaft, by welding a weld on hub. An example would be the tail drums on conveyors. Most customers have a lathe but none can machine a tapered bush entry. Material K1045 Variations WH - low torque small pulleys and convert plate sprockets W - High torque large pulleys and conveyor tail drums etc. Bore Available in all sizes to match our tapered bushes. Size Range Available in all sizes to match our tapered bushes. LESSON A9026 Introduction to Pulleys Series 90 Training page 29

74 Duty Light, Medium and Heavy. Method of Retaining Unit is welded into pulley or into plate sprocket. Various bore profiles are available (see diagram): Round Bore Has Grub Screws to hold unit on the shaft Square Bore Shaft is machined square. Held in place with grub screws Rectangular Bore Shaft is machined rectangular. Held in place with grub screws Tapered bush adaptor used with a standard taper lock bush Spline Bore Shaft is machined with matching splines Bolt-on Adaptor Bolts onto the sprocket or pulley. Part Number WH12 - Low Torque weld on hub - accepts BC1210 Bush W30 - High Torque weld on hub - accepts BC3030 Bush LESSON A9026 Introduction to Pulleys Series 90 Training page 30

75 Wire Rope Sheaves For application on cranes, lifting mechanisms, shiploaders, conveyor belt tensioning and shuttle trucks to name a few. They may be load carrying, equalising, or conveyor take-up sheaves. Sheaves can be stacked, side by side, in frames, though not shown on drawing, or in blocks. Streamlined design permits stacking within limited space. These items are a specialised item and you should always refer to your state engineering manager for assistance. You will not be tested on this product. Technical Data BEARINGS : INA SL04...Series double row sealed cylindrical roller bearings are used in standard range. INA Permaglide Bushes can be used where low loads and low R.P.M. allow teflon (P.T.F.E.) bushes to be used. Special bearing requirements on application. BEARING LIFE : Bearing life can be calculated for specific applications by our technical department. No general formula is applicable as safety factor, fleet angle and required life vary according to Australian Standards. FINISH : Standard paint is: 1. Prime coat - red oxide - zinc chromate 2. Industrial enamel finish coat. Special paint systems may be specified to order. Machine surfaces are protected with rust preventive fluid. ROPE GUARD : Prevents slack rope leaving sheave. Rope guards may be positioned at varying angles to suit angle of wrap. Where additional guards are required then this must be specified. LUBRICATION : Lubrication facility is available through shaft as shown. QUALITY CONTROL : High quality standards are maintained. Certified material and testing such as X-ray, Ultrasonic, etc., is available on request. LESSON A9026 Introduction to Pulleys Series 90 Training page 31