MECHANICAL DRIVES 1 INTRODUCTION TO V-BELT DRIVES LEARNING ACTIVITY PACKET BB502-XD04AEN

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1 MECHANICAL DRIVES 1 LEARNING ACTIVITY PACKET INTRODUCTION TO V-BELT DRIVES BB502-XD04AEN

2 LEARNING ACTIVITY PACKET 4 INTRODUCTION TO V-BELT DRIVES INTRODUCTION In the previous LAP, you learned how to couple two shafts which are in line with each other. Another method of shaft-to-shaft power transfer is to couple two shafts which are parallel with each other. There are three common methods of doing this: chain drive, gear drive, and belt drive. In this LAP you will begin your study of one of these methods: The Belt Drive, specifically the v-belt drive. The belt drive is the most common of the three methods, and the v-belt drive is the most common type of belt drive. The v-belt is popular because it is inexpensive, requires no lubrication, accepts greater misalignment than chains or gears, and absorbs shock loads. ITEMS NEEDED Amatrol Supplied 950-ME1 Mechanical Drives 1 Learning System Amatrol or School Supplied Assorted Hand Tools FIRST EDITION, LAP 4, REV. B Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered trademarks of Amatrol, Inc. All other brand and product names are trademarks or registered trademarks of their respective companies. Copyright 2012 by AMATROL, INC. All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any means, electronic, optical, mechanical, or magnetic, including but not limited to photographing, photocopying, recording or any information storage and retrieval system, without written permission of the copyright owner. Amatrol,Inc., 2400 Centennial Blvd., Jeffersonville, IN USA, Ph , FAX

3 TABLE OF CONTENTS SEGMENT 1 BELT DRIVE CONCEPTS OBJECTIVE 1 Describe the function of the three basic components of a belt drive OBJECTIVE 2 Defi ne pitch and explain its importance OBJECTIVE 3 Defi ne the pitch circle, pitch diameter and pitch length of a belt drive and explain their importance OBJECTIVE 4 Describe how to calculate the pulley ratio and explain its importance SKILL 1 Calculate pulley ratio OBJECTIVE 5 Describe how to calculate the shaft speed and torque of a belt drive system SKILL 2 Calculate the shaft speed and torque of a belt drive system SEGMENT 2 V-BELT OPERATION OBJECTIVE 6 List fi ve types of belt drives and give an application of each OBJECTIVE 7 List three types of V-belts and give an application of each OBJECTIVE 8 Describe the operation of a fractional HP V-belt drive OBJECTIVE 9 Describe how to install and align a V-belt drive SKILL 3 Install and align a fractional HP V-belt drive with a fi nished bore SEGMENT 3 BELT TENSIONING OBJECTIVE 10 Describe how to determine belt tension for an application SKILL 4 Determine the belt defl ection force for a given application OBJECTIVE 11 Describe three methods of adjusting belt tension SKILL 5 Adjust belt tension using an adjustable mounting base SEGMENT 4 BELT TENSION MEASUREMENT OBJECTIVE 12 Describe three methods of measuring belt tension and give an application of each SKILL 6 Use a belt tension tester to measure belt tension Activity 1 V-belt drive analysis 3

4 SEGMENT 1 BELT DRIVE CONCEPTS OBJECTIVE 1 DESCRIBE THE FUNCTION OF THE THREE BASIC COMPONENTS OF A BELT DRIVE As shown in figure 1, a belt drive consists of three basic components: Belt - The belt is a continuous loop of material, usually rubber and other materials, which is stretched between the two sheaves. It transmits speed and torque by means of the friction between it and the sheave grooves. Driver Sheave - The driver sheave, also called a pulley, is a grooved disk which is attached to the shaft of the drive or prime mover. It turns with the drive shaft and causes the belt to move. Driven Sheave - The driven sheave (pulley) is a grooved disk which is attached to the driven shaft. It turns when the belt moves and in turn causes the driven shaft to rotate. The relative diameters of the driven sheave and the driver sheave determine the speed and torque which are transmitted to the driven shaft. The ratio of the sizes of the sheaves can be selected to either decrease or increase the speed and torque delivered to the driven shaft. DRIVEN SHEAVE DRIVER SHEAVE V-BELT Figure 1. Basic Components of a Belt Drive 4

5 OBJECTIVE 2 DEFINE PITCH AND EXPLAIN ITS IMPORTANCE The method by which you can calculate the speed and torque delivered to the driven shaft by an adjacent shaft drive (either belt, chain, or gear) is based on a concept called pitch. Pitch is defined as the distance between a point and a similar corresponding point. Examples of pitch are shown in figure 2. These include: screw threads, chains, and gears. PITCH CHAIN PITCH THREAD PITCH GEAR Figure 2. Mechanical Components with Pitch Although the v-belt itself does not have a pitch associated with it, the belt drive does have three other features which are derived from pitch. They are: pitch diameter, pitch circle, and pitch length. These features are used to calculate speed and torque. 5

6 OBJECTIVE 3 DEFINE THE PITCH CIRCLE, PITCH DIAMETER AND PITCH LENGTH OF A BELT DRIVE AND EXPLAIN THEIR IMPORTANCE The features pitch circle, pitch diameter, and pitch length are based on the basic concept that speed and torque can be transmitted from one shaft to another shaft by imagining the surfaces of two disks in contact with each other. As shown in figure 3, the friction between the disks causes the drive disk to make the driven disk turn. Assuming that the two disks have no slip between them, the surface speeds of the contacting edges of the two disks are the same. In order for the driver disk to turn the driven disk, the drive motor must create a torque which causes a force where the two disks contact each other that will in turn create a torque in the driven disk. This force is the same on both disks at the point where the disks contact each other. DRIVER DISK DRIVEN DISK FRICTION CONTACT Figure 3. Power Transmitted by Two Disks in Contact with Each Other 6

7 The pitch circle is then defined as the circle that goes through the place on each disk where the speed and force are transmitted. In the case of the two disks shown below, the pitch circle represents the outer surface of each disk. The pitch diameter, PD, is simply the diameter of the pitch circle. DRIVER DISK PITCH CIRCLES DRIVEN DISK D1 D2 PITCH DIAMETERS Figure 4. Pitch Circle and Pitch Diameter of Solid Disks 7

8 The belt drive also transmits speed and torque using the same concepts which describe the two disks in contact with each other, except that the two disks are separated. The belt acts as an extension which contacts the pitch circles of the two disks. This means that you can treat them as if they were in contact with each other. Unlike the two disk example, however, the pitch circle of the belt drive is not the outer edge of the hub. The pitch circle of a belt drive is described by the place in the belt which represents the center of the force that is being transmitted through the belt. In the case of a v-belt, the pitch circle is located somewhere inside the outer diameter of the sheave, as shown in figure 5. BOTTOM OF SHEAVE GROOVE PITCH DIAMETER PITCH CIRCLE PITCH CIRCLE PITCH DIAMETER Figure 5. Pitch Circle and Pitch Diameter of a V-Belt Drive 8

9 The term pitch length is the length of the belt which is described by the point inside the belt that passes through the pitch circles of the two sheaves, as shown in figure 6. INSIDE OF BELT PITCH LENGTH OUTSIDE OF BELT Figure 6. Pitch Length of a V-Belt Drive The pitch diameter is important because it allows you to calculate the speed and torque which are transmitted to the driven shaft. The pitch circle is important only because it allows you to determine the pitch diameter. The pitch length is important because it is used to size the belt. 9

10 OBJECTIVE 4 DESCRIBE HOW TO CALCULATE THE PULLEY RATIO AND EXPLAIN ITS IMPORTANCE One of the reasons to use a belt drive is to make the speed or the torque of the driven shaft higher or lower than the speed or torque of the driver shaft. This is accomplished by making the relative sizes of the sheaves or pulleys different. The ratio of the pitch diameters of the two sheaves is called the pulley ratio, as shown in the following formula. It is important because it can be used to directly calculate the speed and torque of the driven shaft given the speed and torque of the driver shaft. FORMULA: PULLEY RATIO Pulley Ratio = Pitch diameter of driven pulley Pitch diameter of driver pulley As an example of how to calculate the pulley ratio, look at the belt drive system shown in figure 7. The pitch diameters of the driver and driven pulleys are 2 inches and 6 inches respectively. This means that the pulley ratio is 3 (PR= 6/2). This is often stated as a 3:1 pulley ratio. DRIVER PULLEY D = 2 in. DRIVEN PULLEY D = 6 in. Figure 7. Calculation of Pulley Ratio 10

11 NOTE It is important to remember that the pulley ratio is determined using the pitch diameter, which is not the same as the outer diameter of a pulley. If you use the outer diameter, your answer will have a slight error. To understand why the pulley ratio affects shaft speed, look at case A of the two solid disks in figure 8. In this example, the circumferences of the two disks turn the same amount because the disks are in contact with each other. Because the disks are equal in size, one revolution of the driver disk causes the driven disk to also turn one revolution. If, however, the disks are not the same size, as shown in case B, the circumferences will still turn by the same amount but the amount of revolutions will be different. In case B, the driven disk is 2 times the diameter of the driver disk. This means that its circumference is also 2 times as large. Therefore, for each turn of the driver disk, the driven disk rotates by an amount that is equal to the circumference of the driver disk, which is one half the circumference of the driven disk. This means that the driven disk only rotates one half turn. CASE A D1 SPEED = D2 SPEED D1 = 2 D2 = 2 CASE B D1 SPEED = 2 x D2 SPEED D1 = 2 D2 = 4 Figure 8. Effect of Relative Disk Size on the Speed of the Driven Shaft 11

12 The same relationship also applies to belt drives, as shown in figure 9. As the outer edge of the drive pulley rotates, the belt transfers an equal amount of movement to the outer edge of the driven pulley. If the pulleys are of different sizes, the driven shaft rotation speed will be different than the driver shaft rotation speed. The larger pulley decreased the speed delivered to the driven shaft. DRIVER PULLEY PD = 2 1 DRIVEN PULLEY PD = 4 2 S = 1000 RPM 1 S 2 = 500 RPM Figure 9. Effect of Relative Pulley Size on the Speed of the Driven Shaft 12

13 In a similar manner to speed, the pulley ratio also affects the torque transmitted to the driven shaft. To understand why, you should recall that the force applied to the surfaces of the two pulleys is the same. Since the torque radius is the radius of the pulley, the torque in one pulley will be different than another if its radius (or diameter) is different. In the case of the example in figure 10, the torque in the driver pulley is 5 in-lbs (T=5x1=5). The torque in the driven pulley, however, is 15 in-lbs (T=3x5=15). The larger pulley increased the torque delivered to the driven shaft. DRIVER PULLEY D1 = 2 DRIVEN PULLEY D2 = 6 T1 = 5 in-lbs T2 = 15 in-lbs Figure 10. Effect of Pulley Ratio on Torque of Driven Shaft From these discussions, you can say that the larger pulley turns slower but has greater torque. This is a common sense concept that you can use on the job to determine in general how power is being changed by the mechanical drive system. 13

14 SKILL 1 CALCULATE PULLEY RATIO Procedure Overview In this procedure, you will determine the pulley ratio of a number of belt drive applications. You will use it in the next skill in this LAP to calculate the speed and torque of belt drive shafts. 1. Calculate the pulley ratio of the belt drive shown in figure 11. Pulley Ratio (PR) = DRIVER PULLEY DRIVEN PULLEY PD = 2.5 PD = 4 Figure 11. Belt Drive Application In this case, the pitch diameter of the driver sheave is 4 inches and the pitch diameter of the driven sheave is 2.5 inches. The pulley ratio is therefore (PR=2.5/4= 0.625). 14

15 2. Calculate the pulley ratio of the belt drive shown in figure 12. Pulley Ratio (PR) = DRIVEN PULLEY DRIVER PULLEY PD = 3 PD = 6 Figure 12. Belt Drive Application The pitch diameter of the driver sheave is 3 inches and the pitch diameter of the driven sheave is 6 inches. The ratio is therefore 2 (PR=6/3=2). 15

16 3. Calculate the pulley ratio of the belt drive shown in figure 13. Pulley Ratio (PR) = DRIVER PULLEY DRIVEN PULLEY PD = 4 PD = 4 Figure 13. Belt Drive Application The solution is PR = Calculate the pulley ratio of the belt drive shown in figure 14. Pulley Ratio (PR) = DRIVER PULLEY DRIVEN PULLEY PD = 2 PD = 8 Figure 14. Belt Drive Application The solution is PR =

17 OBJECTIVE 5 DESCRIBE HOW TO CALCULATE THE SHAFT SPEED AND TORQUE OF A BELT DRIVE SYSTEM The relationship between pulley sizes and shaft speeds of a belt drive as described in the previous objective can be expressed in the following formula: FORMULA: BELT DRIVE SPEED Driver Rotational Speed (RPM) = Driven Rotational Speed (RPM) Driven Pitch Diameter Driver Pitch Diameter Notice that the formula shows the shaft speeds are inversely proportional to the pitch diameters. This means that an increase in pulley size causes the speed to decrease. Also, notice that the right hand side of the formula is actually the pulley ratio, so the formula can also be stated as follows: FORMULA: BELT DRIVE SPEED Driver Rotational Speed (RPM) Pulley Ratio Driven Rotational Speed (RPM) = The calculation of shaft torque is performed using a formula which is similar to the shaft speed formula, except that the torque is directly proportional to the pitch diameters. The torque formula is therefore as follows: FORMULA: BELT DRIVE TORQUE Driven Rotational Torque (ft-lbs) Driven Pitch Diameter = Driver Rotational Torque (ft-lbs) Driver Pitch Diameter As with the speed formula, the torque formula can be modified to use the pulley ratio as follows: FORMULA: BELT DRIVE TORQUE Driven Rotational Torque Pulley Ratio Driver Rotational Torque 17

18 It is important to note that the changes in the torque and speed which are transmitted to the driven shaft are actually related to each other by way of the mechanical power. The power that is transferred between the two shafts is the same, except for minor losses, as shown in figure 15. Since power is equal to speed times torque, any change in speed caused by a pulley ratio must carry with it an equal and opposite change in torque. Otherwise, the law of conservation of energy would be broken. PUMP (DRIVEN) ELECTRIC MOTOR (DRIVER) OUTPUT SHAFT POWER 9.8 KW 500 RPM 196 ft-lbs INPUT SHAFT POWER 10 KW 1000 RPM 100 ft-lbs 0.2 KW FRICTION LOSS Figure 15. Power Transmitted by a Belt Drive 18

19 SKILL 2 CALCULATE THE SHAFT SPEED AND TORQUE OF A BELT DRIVE SYSTEM Procedure Overview In this procedure, you will use the formulas just described to determine speed and torque of either the driver shaft or the driven shaft. On the job, you will sometimes know the driver data and will need to determine the driven data. In other cases, it will be the reverse. 1. Calculate the driven shaft speed of the belt drive system shown in figure 16. Driven Shaft Speed: (RPM) DRIVEN PULLEY TORQUE = 200 ft-lbs SPEED = 1750 RPM DRIVER PULLEY PD = 2 PD = 4 Figure 16. Belt Drive System The solution is as follows: Pulley Ratio (PR): 4/2 = 2 Driven Shaft Speed = 1750 RPM / 2 Driven Shaft Speed = 875 RPM 19

20 2. Calculate the driven shaft torque of the belt drive shown in figure 16. Driven Shaft Torque: (ft-lbs) The torque of the driver shaft is 200 ft-lbs and the pulley ratio is 2. Therefore, the torque of the driven shaft is 400 ft-lbs (T = 200 2). 3. Calculate the driver shaft speed of the belt drive system shown in figure 17. Driver Shaft Speed: (RPM) TORQUE = 300 ft-lbs SPEED = 800 RPM DRIVEN PULLEY DRIVER PULLEY PD = 4 PD = 6 Figure 17. Belt Drive System The pulley ratio is 1.5. Therefore, the driver shaft speed is 1200 RPM. 4. Calculate the drive shaft torque of the belt drive shown in figure 17. Driver Shaft Torque: (ft-lbs) The torque of the driver shaft is 200 ft-lbs. 20

21 5. Calculate the driven shaft speed of the belt drive system given the following information. Driver Sheave: Torque = 200 ft lbs Speed = 3500 RPM Pitch Dia. = 2 in Driven Sheave: Pitch Dia. = 8 in Driven Shaft Speed: (RPM) The driven shaft speed is 875 RPM. 6. Calculate the driven shaft torque of the belt drive given the information in step 5. Driven Shaft Torque: (ft-lbs) The torque of the driven shaft is 800 ft-lbs. 7. Calculate the driven shaft speed of the belt drive system given the following information. Driver Sheave: Torque = 400 ft-lbs Speed = 1000 RPM Pitch Dia. = 3.5 in Driven Sheave: Pitch Dia. = 2 in Driven Shaft Speed: (RPM) 8. Calculate the driven shaft torque of the belt drive given the information in step 7. Driven Shaft Torque: (ft-lbs) The solutions are 1750 RPM and 228 ft-lbs. 21

22 SEGMENT 1 SELF REVIEW 1. Another name for a sheave is a(n). 2. The of the driven sheave and the driver sheave determine the speed and torque transmitted to the driven shaft. 3. A belt drive has three features derived from the concept of pitch: pitch diameter, pitch circle, and pitch. 4. The is determined by dividing the pitch diameter of the driven pulley by the pitch diameter of the driver pulley. 5. The Pulley Ratio is determined by dividing the rotational speed by the rotational speed 22

23 SEGMENT 2 V-BELT OPERATION OBJECTIVE 6 LIST FIVE TYPES OF BELT DRIVES AND GIVE AN APPLICATION OF EACH Belt drives are the most common type of adjacent or parallel shaft-to-shaft drives used because they are quiet, low in cost, and easy to maintain. The five types of belt drives you will most often encountered are: Flat belt V-belt Timing belt Round belt Ribbed belt Each of these is described as follows: Flat Belts The flat belt was the first type of belt drive used. It originated during the industrial revolution of the 19th century when factories transmitted power to individual machines with long rotating shafts running the length of the factory. The power from these shafts was transmitted to each machine by means of two pulleys and a flat belt. FLAT BELT Figure 18. Flat Belt Conveyor 23

24 Today, flat belts are rarely used to drive machines because they are not very efficient, they are bulky, they are not well suited to higher motor speeds, and they require more maintenance than other types of belt drives. However, flat belts are still commonly used as conveyors, as shown in figure 19. MOTOR FLAT BELT CONVEYOR Figure 19. Flat belts Are Often Used as Conveyors 24

25 V-Belts In the early part of the 20th century, central shaft systems started to be replaced by electric motors which were placed at individual machines. This made power transmission more efficient, flexible, and lower in first cost. It also permitted higher speeds, which could enable even higher efficiencies and higher machine productivity. In 1917, the Gates brothers (Gates Rubber Company) invented the v-belt to support this application. The v-belt is a wedge-shaped belt, as shown in figure 20, which is made from a combination of rubber and textile material. The v-belt is designed to grip the walls of a grooved pulley by wedging itself against the sides of a pulley groove as the belt is tightened. V-BELT Figure 20. V-Belt Shape The advantages of the v-belt over the flat belt are that it can: Operate at higher speeds Transmit power more efficiently Transmit power in a smaller size Require very little maintenance The v-belt drive is commonly used in applications such as fan drives, air compressors, and car engines. 25

26 Timing Belts One of the general problems of v-belts is they can slip during operation. The timing belt (or positive drive belt) solves this problem by using a belt and pulleys which have notches or teeth, as shown in figure 21. As the drive pulley turns, its teeth engage the teeth of the belt and pull it. With this design, the belt does not slip and a constant speed is maintained at the shaft. Because of the teeth, the timing belt does not require a high tension as v-belts do. This makes its operation more efficient as well as non-slip. POSITIVE DRIVE BELT Figure 21. Timing Belt 26

27 The timing belt is used in some car engines to maintain a constant speed between various devices that must operate together. It is also used in positioning applications, such as the axes of robots and electronic circuit board assembly machines, to accurately move to various positions. Figure 22. Timing Belt Drive on a Robot Axis Some other names by which timing belts are often called include: positive drive belts, synchronous drive belts, and gear belts. These all refer to the same type of belt design. 27

28 Round Belt The round belt uses a circular cross-section, as shown in figure 23. It is mainly found in very light duty applications, such as vacuums and printers, where either the load is light or slip and efficiency are not important. Its main asset is low cost. ROUND BELT Figure 23. Round Belt Ribbed Belt The ribbed belt has ribs that run longitudinally (along the length) on the belt. These ribs are designed to seat in mating grooves in the sheaves, as shown in figure 24. V-RIBBED BELT Figure 24. Cross Section of a Ribbed Belt 28

29 This type of belt has a greater area of the belt in contact with the sheave, which means that there is less wear on the belt or sheaves. The sheaves are more compact and higher pulley ratios can be used, typically as high as 40:1. OBJECTIVE 7 LIST THREE TYPES OF V-BELTS AND GIVE AN APPLICATION OF EACH There are three main types of v-belts: Fractional horsepower (FHP) v-belt Conventional (Standard multiple) v-belt Wedge v-belt Each type of belt is designed for a particular type of power range and duty cycle. These belts look similar, differing mainly in dimensions and internal construction. Fractional Horsepower (FHP) V-Belt The fractional horsepower (FHP) v-belt, also called a light duty belt, is designed for low power applications, below 7.5 Hp, which run intermittently. One application is a small air compressor or a fan. Conventional (Standard Multiple) V-Belt The conventional v-belt, also called a standard-multiple or standard duty v-belt, is designed for continuous duty service and can be used in applications up to 300 Hp. They can be used singly, but are often used in sets of more than one belt, as shown in figure 25, which is where the term multiple comes from. Figure 25. Multiple Belt V-Belt Drive 29

30 The conventional v-belt is the type of belt you will find most often in industrial applications. It is used for air compressors, fans, and much more. Wedge Belt In 1958, a new family of v-belts called wedge v-belts, also called heavy duty or narrow-series v-belts, was jointly developed by Gates Rubber Company and Dodge Company. This belt improved the power-carrying capability of the v-belt for a given cross section size, allowing smaller sheaves to be used. The wedge belt is designed for continuous duty service and can be used at power levels up to 500 Hp. It is used in both single and multiple sets, like the conventional v-belt. The wedge belt is used in industrial applications where either heavy duty shock loads might occur, there is a need for a smaller size, or if the load is higher than what can be handled by a conventional belt. OBJECTIVE 8 DESCRIBE THE OPERATION OF A FRACTIONAL HP V-BELT DRIVE The fractional v-belt drive, as well as other types of v-belt drives, transmits power by increasing the distance between the two sheaves so that tension is created on the belt. This tension causes the belt to be pulled down, or wedged, into the groove of the sheave, creating enough friction to keep the belt from slipping when the turning sheave is placed under a load. TENSION FORCE ON V-BELT BELT FORCE ON SHEAVE GROOVE WALL BOTTOM OF SHEAVE Figure 26. Wedging Action of V-Belt Drive 30

31 It is important to note that the wedging action of the v-belt creates friction between the sides of the sheave, not the groove bottom. The v-belt should ride high in the groove, with its top near the top of the sheave, as shown in figure 26. Normally, the v-belt does not touch the bottom of the sheave. The belt used on a FHP v-belt drive consists of polyester or some other textilebased cording, rubber filler compound, and a neoprene envelope, as shown in figure 27. This neoprene envelope makes the outside of the belt smooth. Because FHP belts are made for light duty service, they are usually smaller, the cords are fewer and not as strong as in the conventional and wedge belts. FABRIC OR NEOPRENE COVER TENSION SECTION POLYESTER CORDS COMPRESSION SECTION Figure 27. Typical V-Belt Construction 31

32 The sheaves used for FHP drives are usually made of either stamped steel halves which are pressed together, die cast zinc, or die cast aluminum. In any case, the sheaves are normally attached to the shafts with an integral hub which has the keyseat built into sheave, as shown in figure 28. This is called a finished bore or fixed bore hub. HUB Figure 28. FHP Sheave with Finished Bore Integral Hub FHP belt sizes are designated by a number and an L in the part number while conventional belts are designated by just a letter (e.g. A, B, C, D). You will learn more about part numbering systems in a later LAP in this curriculum. It is important to know that two sizes of L belts, the 4L and 5L, are the same size as two sizes of conventional belts, the A and B respectively. As a result, most manufacturers are phasing out the 4L and 5L belts and using the A and B belts with FHP sheaves of those sizes. 32

33 OBJECTIVE 9 DESCRIBE HOW TO INSTALL AND ALIGN A V-BELT DRIVE V-belt drives are easy to install but it is important to do it correctly in order to have the maximum life. Regardless of the type of v-belt you are using, the installation steps are similar. These steps are as follows: Step 1. Mount and level the motor and the driven component. Leveling the shafts is actually part of the alignment of the sheaves, which is step 5 of this process. However, it is easier to place a level on the shaft before the sheaves are attached. As a part of this process, the motor and driven component should also be checked for a soft foot and excessive run-out. Step 2. Inspect the sheaves for cleanliness and wear. Clean or replace if necessary. If the sheaves have nicks, burs or gouges, replace the sheave. This can cause the belt to be cut. If the sheave is excessively worn, replace the sheave. Wear can be checked with a sheave gauge, as shown in figure 29. You will learn more about sheave gauges and belt wear in another LAP. PD OVER PD 13.0 to STANDARD V SECTION PD 12.0 to Figure 29. Sheave Gauge Check for Sheave Groove Wear Make sure that the sheave does not have any dirt, oil, grease, or rust on it. Dirt and rust can cause the belt to wear quickly. Oil and grease will actually attack the belt material and destroy it. Use a stiff brush to remove dirt and rust. Wipe clean all oil and grease. 33

34 Step 3. Mount the sheaves onto the shafts. The sheaves should be attached to the shafts using either a finished bore hub or a bushing. Bushings are commonly used on industrial v-belt drives that use conventional or wedge belts. Figure 30. Installation of FHP Sheave After you install the sheaves, make sure that the sheaves don t wobble by rotating the shafts and observing the motion of the sheaves. If they do, reinstall them or use other sheaves. Step 4. Mount the belt. To mount the belt, first loosen the mounting bolts of the motor and slide it toward the driven shaft. This will reduce the center distance between the two sheaves so that the belt can be slipped loosely over the sheaves without forcing it. Next, place the belt over the sheaves. The belt should never be forced onto the sheaves. If you do this, the belt will be damaged, either by creating a nick in the belt or by breaking or weakening the internal fibers. In either case, this can severely lower the life of the belt. Also, the belt should never be run on while the sheaves are rotating. This has the same effect as forcing on the belt. 34

35 Step 5. Align the sheaves. Just as with couplings, it is important to align sheaves. Misaligned sheaves will cause the belt and the bearings to wear quickly. This misalignment can appear in several ways, as shown in figure 31. The goal of alignment is to avoid twisting the belt. ANGULAR MISALIGNMENT GROOVE MISALIGNMENT PARALLEL MISALIGNMENT Figure 31. Types of Misalignment 35

36 The sheaves can be aligned by first leveling the two shafts using a spirit level. If this has already been done as part of mounting the motor, you can skip this step and go to the next step. That is to place a straight edge against the faces of the sheaves to align the sheave grooves and check the parallelism of the shafts, as shown in figure 32. The faces of the sheaves should be made so that they are flush against the straight edge, as shown in figure 32. This means that the shafts are parallel and the sheave grooves are aligned. The faces of the sheaves are aligned when four corners are in contact with the straight edge. STRAIGHT EDGE 4 CORNERS OF SHEAVES Figure 32. Alignment of Sheaves with Straight Edge 36

37 If you do not have a straight edge, or the distance between sheave centers is too great, you can use a string. To use this method, first attach one end of the string to the shaft of the driven sheave, as shown in figure 33. Then pull the string taut and straight so that it touches both edges of the driven sheave. If the drive sheave edges do not touch, the sheaves are misaligned. Adjust the position of the drive shaft so that the edges of the drive sheave also touch the string. PULL LINE TAUT. TIE TO SHAFT Figure 33. Alignment of Sheaves with String 37

38 It is also a good idea to check the vertical alignment of each sheave. This can be done using either a framing square if the bedplate is level or a spirit level, as shown in figure 34. When you do this, rotate the sheave and check it in several positions to make sure that a high spot on the sheave does not give you a false reading. SHEAVE Figure 34. Measurement of Vertical Alignment of Sheaves Step 6. Apply initial tension to the belt. The proper belt tension is very important to the life of the drive. Some tension is necessary for the belt to grip the sheave. If the tension is too little, however, the belt will slip, causing the belt and the sheaves to wear quickly. If the tension is too high, the bearings and the belt will also wear quickly. Tensioning the belt is a 3-step process: Determine the tension needed Apply tension to the belt Measure the tension The belt should be tightened to approximately the correct amount as determined by several methods. It does not need to be precise at this point because the belt will stretch after it has been run. Step 7. Run the motor briefly to seat the belts. A new belt will quickly stretch and will be forced lower into the grooves when it is run under load. Both of these actions cause the tension to decrease. 38

39 Step 8. Stop the motor and retighten the belt to the correct tension. After about 1 minute, stop the drive and check the tension again. Adjust the tension so that it is within the acceptable range. Step 9. Retension the belt after 24 to 48 hours of operation. During the first few days of operation, the belt will stretch enough that it should be retensioned again. SKILL 3 INSTALL AND ALIGN A FRACTIONAL HP V-BELT DRIVE WITH A FINISHED BORE Procedure Overview In this procedure, you will perform steps 1-5 of the procedure to assemble and align a fractional horsepower v-belt drive, which will be used to drive the prony brake. You will not, however, run the drive in this skill. Instead, you will proceed directly to the next skill where you will perform step 6 of the procedure, which is to adjust the tension of the v-belt drive. You will run the drive later in this LAP. 1. Perform the following safety checkout to prepare for working with power transmission equipment. Make sure that you are able to answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Wearing safety glasses Wearing tight fi tting clothes Ties, watches, rings, and other jewelry are removed Long hair is tied up or put in a cap or under shirt Wearing heavy duty shoes Wearing short sleeves or long sleeves are rolled up Floor is not wet 2. Perform a lockout/tagout on the safety switch. 39

40 3. Perform the following substeps to mount the adjustable motor base. A. Locate the adjustable motor base shown in figure 35. Figure 35. Adjustable Motor Base 40

41 B. Position the adjustable motor base over the set of holes in the 950-ME Mechanical Drives System work surface as shown in figure 36. The outlines of the other components to be installed are shown as well. 1-INCH DIAMETER 5/8-INCH ENDS SHAFT PRONY BRAKE HUB 4-INCH PD SHEAVE 1-INCH BORE BEARINGS V-BELT 2-INCH PD SHEAVE MOTOR ADJUSTABLE BASE Figure 36. Location of Components on 950-ME Work Surface 41

42 C. Locate four bolts with the specification of 3/8-16UNC-2A X 2 Hex Head, along with compatible flat washers, lock washers, and nuts. D. Fasten the adjustable mounting base to the work surface by assembling the bolts, washers, and nuts. Use a criss-cross sequence to tighten the bolts. 4. Perform the following substeps to mount and level the motor on the adjustable mounting base. A. Place the motor on top of the adjustable mounting base s holes, as shown in figure 37. Figure 37. Placing the Motor on the Adjustable Mounting Base 42

43 B. Locate four bolts with the specification of 5/16-18UNC-2B X 1-inch long, along with compatible flat washers, lock washers, and nuts. C. Insert the two rear bolts with flat washers from the bottom as shown in figure 38 and secure using a flat washer, lock washer, and nut and handtighten both fasteners as shown in figure 39. Figure 38. Motor Mounted on Adjustable Mounting Base Figure 39. Motor Mounted on Adjustable Mounting Base 43

44 NOTE Make sure that the lock washer is between the nut and the flat washer. D. Gain access to the front motor mount holes by raising the front of the adjustable motor base. Run the top jam nut to the top of the adjustment screw and turn the lower jam nut to raise the adjustable portion of the motor mount. E. Insert the two front bolts and washers from the bottom as done in the rear. Using a flat washer, lock washer, and nut. Attach the motor to the adjustable mounting base, hand tighten both fasteners. F. Level the motor base by lowering the front of the adjustable motor base. Turn the lower jam nut on the adjustment screw to a portion that will allow access to all four bolt heads. After centering the bolts in the motor mounting slots, tighten all four nuts. G. Check the shaft for run-out. Record below the amount of run-out. Run-out: (in/mm) The run-out should be less than inches. H. Check for motor shaft end float. End Float (in/mm) It should be less than inches. I. Check the level of the motor shaft. Shim the motor feet as needed. Feeler gauge Leaf Thickness (in/mm) Effective Level Length (in/mm) Mounting Bolt Distance (in/mm) Shim Ratio Shim Thickness (in/mm) 5. Perform the following substeps to mount the shaft and pillow block bearings. A. Select four Standoffs from Shaft Panel 1. B. Make sure that the standoffs, pillow block mounting surface, and mounting area of the work surfaces, shown in figure 36, are free of dirt, rust and burrs. C. Place the four standoffs on the 950-ME1 work surface. D. Remove two pillow block bearings from Shaft Panel 1 having a bore size of 1-inch. E. Place the pillow block bearings on the standoffs. F. Locate four bolts with the specifications of 3/8-16UNC-2A x 4-1/2 Hex Head, along with the compatible flat washers, lock washers, and nuts. G. Fasten the pillow block bearings and the standoffs to the work surface by assembling the bolts, washers, and nuts. Hand tighten only. 44

45 H. Select an 8-inch long shaft from Belt Drive Panel 1 having a 1-inch diameter and 5/8-inch ends. Figure Inch Shaft and Bearings I. Slide the shaft through the two pillow block bearings. Position it as shown in figure 36. NOTE Notice that one end is longer than the other. J. Tighten the set screws on each bearing to lock the bearing to the shaft. K. Tighten the pillow block bearing mounting bolts. L. Turn the shaft by hand to make sure it turns freely. If not, loosen the bolts and adjust the positions of the bearings. M. Check the driven shaft for run-out. Run-out: (in/mm) The shaft should have no more than inches run-out. 45

46 N. Level the driven shaft. Shim the bearing standoffs as needed. Place the shims between the work surface and the standoffs. Feeler gauge Leaf Thickness (in/mm) Effective Level Length (in/mm) Mounting Bolt Distance (in/mm) Shim Ratio Shim Thickness (in/mm) 6. Install the prony brake hub on the shaft and work surface in the location shown in figure 36. This brake will be used in later skills to demonstrate how the torque is affected by a sheave ratio. 7. Perform the following substeps to mount the driver sheave. These steps are the same steps you used to install the prony brake hub. A. Locate the 2-inch PD sheave and the 4-inch PD sheave from Belt Drive Panel 1. B. Locate the set screw hole which is drilled into the side of the hub of the 2-inch PD sheave, as shown in figure 41. Figure 41. Set Screw on Hub C. Use a hex key wrench to back out the set screw so that it is not extending into the shaft hole. D. Clean the motor shaft s key seat and the sheave hub s key seat with a wire brush to make sure that no dirt or burs are in the keyseats. 46

47 E. Select a 3/16 x 1 inch square key from your key stock. F. Slide the key into the keyseat of the motor shaft. The key should fit into the keyseat without forcing it and have no play. If it is too tight or too loose, select another key from your stock and try it. G. Remove the key from the shaft keyseat and insert it into the sheave hub keyseat. It also should slide in without forcing it and have no play. H. Remove the key from the sheave hub and insert it into the shaft keyseat. Line it up flush with the end of the shaft. I. Pick up the sheave with your hand and line it up in front of the shaft so that the hub s key seat is in line with the key on the shaft, as shown in figure 42. Hold the sheave so that the hub side points towards the shaft. Figure 42. Sheave Keyseat Lined Up with Shaft Keyseat 47

48 J. Then slide the sheave hub onto the shaft until the end of the sheave is flush with the end of the shaft, as shown in figure 43. The hub should slide on without using tools. If it doesn t, pull it off and check the dimensions. Figure 43. Sheave Hub Attached to Motor Shaft K. Tighten the set screw onto the key. L. Pull on the sheave to make sure it is securely fastened to the shaft. 48

49 8. Repeat step 7 in a similar manner to mount the 4-inch driven sheave. The setup should now look like figure 44. Figure 44. Current Setup 49

50 Check the sheave alignment by placing a straight edge flush against the driven sheave face. Then check the position of the face of the driver sheave, as shown in figure 45. The driver sheave must be adjusted so that it is aligned with the driven sheave. This is because in real world applications, it is usually easier to adjust the motor s position than it is to reposition the drive component. SHEAVES IN ALIGNMENT FLUSH ON DRIVEN SHEAVE STRAIGHT EDGE TOUCHING TWO POINTS ON DRIVER SHEAVE Figure 45. Straight Edge Check for Sheave Alignment 50

51 If the face of the driver sheave is also flush against the straight edge, the sheave grooves are aligned and the shafts are parallel. This means that the sheaves are aligned and you can skip to step 14. If, however, only one point of the driver sheave is touching the straight edge, as shown in figure 46, the shafts are not parallel. If no part of the driver sheave is touching the straight edge, the sheave grooves are also considered to be misaligned and the shafts may also not be parallel. SHEAVES OUT OF ALIGNMENT FLUSH ON DRIVEN SHEAVE STRAIGHT EDGE TOUCHING ONE POINT ONLY ON DRIVER SHEAVE Figure 46. Sheaves Out of Alignment 51

52 10. Loosen slightly all four fasteners which attach the motor to the adjustable mounting base. 11. Move the motor to a position where all 4 edges of the sheaves are touching the straight edge. 12. Tighten the nuts in a criss-cross pattern until they are tight. 13. Recheck the alignment with the rule after the bolts are tightened. Repeat the alignment steps if necessary. You may need to loosen the set screw on the 2-inch sheave and move it closer to the motor. 14. Obtain a 36-inch A belt from the Storage Unit. It is labeled A34 (4L36). 15. Perform the following substeps to mount the belt. A. Place the belt over the sheaves so that it rests in the sheaves grooves. You may need to adjust the motor s position to do this by loosening the upper jam nut and running it to the top of the adjustment screw, then raising the adjustable motor base until the belt can be placed over the sheaves, as shown in figure 47. Figure 47. Installing the Belt B. Lower the adjustable motor base until the belt straightens out and adjust the lower jam nut to support it in this position. The belt should be straight, but it should not have any tension in it yet. Leave your setup in place and proceed directly to the Self Review. After completing it, proceed to the next objective and skill. In the next skill, you will continue the installation process by tensioning the belt. 52

53 SEGMENT 2 SELF REVIEW 1. A common belt used for conveyors is the belt. 2. The belt is designed to grip the walls of a grooved pulley. 3. belts have notches that engage notches in the pulleys to prevent slipping. 4. A(n) v-belt is a light duty belt designed for low power applications and intermittent running. 5. A v-belt (should/should not) touch the bottom of the sheave. 6. A(n) is used to check a sheave for wear. 53

54 SEGMENT 3 BELT TENSIONING OBJECTIVE 10 DESCRIBE HOW TO DETERMINE BELT TENSION FOR AN APPLICATION The first step to perform in order to tension a belt drive is to determine how much tension to apply to it. Belt tension is measured by how much force is needed to deflect the belt a certain distance, as shown in figure 48. This is called the belt deflection force, and the method that is used to measure belt tension in this way is called the belt deflection method. DEFLECTION SMALL O RING LARGE O RING INCHES of SPAN 50 POUNDS LARGE END INCHES of SPAN 50 POUNDS Figure 48. Measurement of Belt Defl ection Force 54

55 The amount of belt deflection force is found in a table such as the one shown in figure 49. This table is available from belt suppliers and shows the specific force for each belt, according the belt s size, sheave size, operating speed, and whether or not it is new or old. Cross Section Sheave Diameter - INCHES Smallest Sheave Diameter Range RPM Range A, AX B, BX C, CX D V, 3VX V, 5VX Figure 49. Belt Defl ection Force Table Minimum Deflection Force - LBS Belt Deflection Force Unnotched Belts Notched Belts Used Belt New Belt Used Belt New Belt The force levels listed in the table refer to the minimum level of tension force. The upper limit of the acceptable tension force is 50% greater. This means that the tension of the belt should be between the force level listed in the table and a value which is 50% greater (e.g. Min value x 1.5). The ideal tension is the lower of the two values. It represents the least tension needed to transmit the force and allow no slipping. If the tension is greater, more energy is lost through friction. 55

56 SKILL 4 DETERMINE THE BELT DEFLECTION FORCE FOR A GIVEN APPLICATION Procedure Overview In this procedure, you will use the force table to determine the allowable force tension levels for several scenarios, including the belt you mounted in the last skill. 1. Determine the allowable belt deflection force for the following application. FEATURE Belt Size Sheave Diameter Operating Speed Belt Age SPECIFICATION A unnotched 3.2 inches 2000 RPM New Belt Deflection Force Range: (lbs/n) The belt deflection force should be between 5.5 and 8.25 lbs. 2. Determine the allowable belt deflection force for the following application. FEATURE Belt Size Sheave Diameter Operating Speed Belt Age SPECIFICATION D unnotched 19 inches 900 RPM Old Belt Deflection Force Range: (lbs/n) The belt deflection force should be between 25.6 and 38.4 lbs. 56

57 3. Determine the allowable belt deflection force for the following application. FEATURE Belt Size Sheave Diameter Operating Speed Belt Age SPECIFICATION B unnotched 5.6 inches 1750 RPM New Belt Deflection Force Range: (lbs/n) The belt deflection force should be between 7.9 and lbs. 4. Determine the allowable belt deflection force for the following application. FEATURE Belt Size Sheave Diameter Operating Speed Belt Age SPECIFICATION A unnotched 6 inches 2500 RPM Old Belt Deflection Force Range: (lbs/n) The belt deflection force should be between 5.4 and 8.1 lbs. 5. Determine the allowable belt deflection force for the belt drive you mounted in the last skill. FEATURE Belt Size Sheave Diameter Operating Speed Belt Age SPECIFICATION A unnotched 2.2 inches 1725 RPM *(New/Old) *Inspect the belt you are using to determine the age. Belt Deflection Force Range: (lbs/n) You should have selected a belt deflection force range of 2.8 to 4.2 lbs or 4.3 to 6.45 lbs depending on the condition of the belt you installed. 57

58 OBJECTIVE 11 DESCRIBE THREE METHODS OF ADJUSTING BELT TENSION Tension is applied to the belt by moving the driver motor away from the driven shaft. This can be done with either a pry bar, punch, or adjustable mounting base. While moving the motor, make sure to maintain sheave alignment by holding the straight edge against the sheaves, or at least rechecking the alignment after tensioning. THIS DIRECTION INCREASES TENSION PUMP (DRIVEN) MOTOR CENTER DISTANCE Figure 50. Belt Tension Adjustment 58

59 SKILL 5 ADJUST BELT TENSION USING AN ADJUSTABLE MOUNTING BASE Procedure Overview In this procedure, you will continue from the last skill to perform the next step in the process of installing a v-belt drive, which is to adjust the tension of the belt drive. You will not, however, run the drive until the next skill after which you have measured the belt tension to determine that it is correct. In this skill, you will measure belt tension by hand only. 1. Continuing from Skill 3, your v-belt drive should be aligned and the belt loosely mounted around the sheaves. If this is not the case, repeat Skill 3 to accomplish this. 2. Make sure the lockout/tagout is still in place. If not, perform a lockout/tagout. 3. Lower the bottom jam nut on the adjustment screw until the belt begins to feel springy when pushed on. Figure 51. Adjusting the Tension on the Belt 59

60 4. Tighten the top jam nut on the adjustment screw. 5. Check the sheave alignment with a straight edge to make sure it is still aligned. If the straight edge shows no light, the sheaves are aligned and this skill is complete. You can now proceed to the next objective. If the straight edge shows some light, the sheaves are not aligned. Loosen the motor s bolts and adjust it to re-align the sheaves. Then, retighten the motor s bolts. 60

61 SEGMENT 3 SELF REVIEW 1. The method used to measure belt tension is called. 2. The specific force for a belt is determined using the belt size, sheave size,, and whether or not it is new or old. 3. Tension is applied to a belt by moving the away from the. 4. One method of adjusting belt tension is using a(n) motor base. 61

62 SEGMENT 4 BELT TENSION MEASUREMENT OBJECTIVE 12 DESCRIBE THREE METHODS OF MEASURING BELT TENSION AND GIVE AN APPLICATION OF EACH Once the belt tension has been initially set, the next step is to measure the tension to make sure that it is correct. There are three ways that belt tension can be measured: Hand pressure Tension Tester Spring scale and straight edge Each of these methods is described as follows, along with its application: Hand Pressure Tension Measurement The most basic way to test the tension is to use your sense of touch. This is the method you used in the last skill to set the initial tension. To do this, you should strike the belt with your hand. It will feel alive and springy when it is tensioned correctly. If the tension is too low, the belt will feel dead. Too much tension will make it feel taut, with no give at all. Both fractional horsepower and conventional belts can be tested this way. Wedge belts cannot because the tension they require is too high. They require a tension tester. 62

63 Tension Tester Tension Measurement A more accurate method of tension measurement is the force deflection method, using a tension tester or belt tension checker. The tension tester is a handheld device which measures belt tension by measuring the force needed to deflect the belt a certain amount, as shown in figure 52. DEFLECTION SMALL O RING LARGE O RING INCHES of SPAN 50 POUNDS LARGE END INCHES of SPAN 50 POUNDS Figure 52. Tension Measurement with a Tension Tester 63

64 To actually perform the test, the tester should be placed in the middle of the belt span and forced down until the belt is deflected by the proper amount. The force indicated by the tension tester is then read. This force should be compared to a recommended force deflection range for that particular belt. This is available in the table shown in figure 49. The amount to deflect the tension tester depends on how far apart the centers of the sheaves are, or in other words the size of the belt span. As shown in figure 53, the belt should be deflected 1/64 of the belt span. The belt span is the distance between the points on the sheaves where the belt touches each sheave. BELT SPAN Figure 53. Belt Span The force should be at least as high as the recommended force level but no higher than 50% above it. If the belt speed exceeds the speed listed in the table, the tension should be reduced as recommended by the manufacturer. The tension tester is the preferred method for checking belt tension for any type of belt. Proper tension will lead to a longer life of the mechanical components in the system. 64

65 2 Spring Scale and Straight Edge Tension Measurement The spring scale and straight edge method is similar to the tension tester in that it is a type of force deflection method. With this method, The spring scale is used to deflect the belt, as shown in figure 54. The amount of deflection is determined in the same way as described with the tension tester, 1/64 of the belt span. The amount of deflection is measured by placing a straight edge across the belt span and measuring with a rule, as shown in figure 54. As you can see, this method is not as easy as using a tension tester. SPRING SCALE STRAIGHT EDGE Figure 54. Spring Scale and Rule 65

66 SKILL 6 USE A BELT TENSION TESTER TO MEASURE BELT TENSION Procedure Overview In this procedure, you will continue from the last skill to perform the next step in the process of installing a v-belt drive, which is to adjust the tension to the correct level. Once done you will run the drive. 1. Continuing from the previous skill, your v-belt drive should be aligned and the belt mounted and taut around the sheaves. If this is not the case, repeat the last two skills to accomplish this. 2. Perform the following safety checkout to prepare for working with power transmission equipment. Make sure that you are able to answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Wearing safety glasses Wearing tight fi tting clothes Ties, watches, rings, and other jewelry are removed Long hair is tied up or put in a cap or under shirt Wearing heavy duty shoes Wearing short sleeves or long sleeves are rolled up Floor is not wet 3. Make sure the lockout/tagout is still in place. If not, make it so. 66

67 4. Use the 36-inch steel rule to measure the belt span, as shown in figure 55. This will allow you to determine how far to deflect the belt when you measure the force. Belt Span (in/mm) Figure 55. Belt Span Measurement Your measurement should be approximately 12-1/2 inches. 5. Calculate the amount of deflection for your v-belt drive. Deflection distance (in/mm) This is equal to 1/64 of the belt span. Your answer should be approximately 3/16 of an inch. 67

68 6. Perform the following substeps to test the tension of the belt with a tension tester. A. Locate the tension tester from the 950-ME, as shown in figure 56. Figure 56. Amatrol Tension Tester B. Position the large o-ring on the span scale at the belt span you calculated in step 4, as shown in figure 57. SMALL O RING LARGE O RING INCHES of SPAN 50 POUNDS LARGE END Figure 57. Positioning of Large O-Ring and Small O-Ring 68

69 C. Position the small o-ring on the deflection force scale to zero, as shown in figure 57. D. Place a straight edge across the belt, as shown in figure 58. The straight edge should rest on top of the belt. Figure 58. Straight Edge Placed on Belt E. Place the tension tester on the belt in the center of the span and orient it so that it is perpendicular with the belt, as shown in figure 59. Figure 59. Tension Tester Positioned on Top of the Belt 69

70 F. Apply a downward force on the tension tester with your hand so that the belt is deflected by an amount which causes the large o-ring to be even with the bottom of the straight edge, as shown in figure 60. Figure 60. Tension Tester Defl ected to O-Ring Setting G. Remove the tension tester from the belt and read the position on the force scale, as shown in figure 61. Force scale reading (lbs.n) Figure 61. Force Scale Reading 70

71 H. Compare your force reading with the force range you calculated in the previous skill. If your reading is within the range calculated, you have tensioned the belt to the correct level. If the force is above or below this range you need to readjust the tension on the belt and check the tension again. 7. Perform the following substeps to adjust the tension on the belt. A. Loosen the bottom jam nut on the adjustable motor base. B. Use a wrench to rotate the top jam nut of the adjustable base downward. C. Retighten the bottom jam nut. D. Repeat substeps A-C until the tension is correct. E. Recheck the sheave alignment. Adjust the motor base to correct any misalignment. 8. Strike the belt with your hand so that you can get a sense of how a correctly tensioned belt feels. 9. Install the guard. WARNING Do not operate the mechanical drive system without the guard in place. Also, do not attempt to open or bypass the guard at any time during operation. Performing any of these actions will create a hazardous situation. 10. Make sure the prony brake is set to zero ounces. 11. Perform the following substeps to start the motor. A. Connect the motor s power cord to the Motor Control Unit. B. Make sure the Constant Speed Motor switch is in the OFF or down position. C. Make sure that the safety switch power cord is plugged into a wall outlet. D. Remove the lockout/tagout. E. Turn on the safety switch. The Main Power Indicator on the Motor Control Unit should turn on. F. Make sure that no one is near the motor. G. Turn on the Constant Speed Motor by moving its power switch to the ON or up position. The motor should accelerate to full speed quickly and run at a constant speed. Notice how smoothly the v-belt operates. As you use other types of mechanical drives, you will see even better how quietly this type of drive operates. 71

72 12. Allow the motor to run for about 1 minute to allow the belt to seat. 13. Turn off the motor. The motor should coast to a stop. 14. Perform a lockout/tagout. 15. Remove the guard and repeat Step 6 again to retest the tension of the belt. Record your reading. Force scale reading (oz/g) You will probably find that the belt tension has been reduced. If it is less than the acceptable range, increase the tension and retest it to make sure that it is within the acceptable range. CAUTION Before you can adjust belt tension, the motor s locknuts must be loosened. Retighten them once the belt tension is adjusted. Once the belt tension is correct, you have completed the installation of the v-belt drive, except for retensioning the drive after hours. Leave your setup in place and go directly to the next activity to operate the drive and analyze its operation. 72

73 Activity 1. V-Belt Drive Analysis Procedure Overview In this activity, you will continue from the previous skill to measure the torque and speed output of the v-belt drive to prove that the formulas you learned in Segment 1 actually work. 1. Add about 1/4-inch of water to the inside of the brake drum. 2. Perform the following substeps to start the motor. A. Install the guard. WARNING Do not operate the mechanical drive system without the guard in place. Also, do not attempt to open or bypass the guard at any time during operation. Performing any of these actions will create a hazardous situation. B. Remove the lockout/tagout. C. Turn on the safety switch. D. Make sure that no one is near the motor. E. Turn on the Constant Speed Motor. The motor should accelerate to full speed quickly and run at a constant speed. 3. Measure the speeds of the motor shaft and the driven shaft using the tachometer. Record your readings. Driver Shaft Speed (RPM) Driven Shaft Speed (RPM) The unloaded speed of the motor shaft should be approximately 1790 RPM. Since the pulley ratio is 2:1, the speed of the driven shaft speed should be about 895 RPM. 73

74 This configuration causes the speed at the driven shaft to be decreased and its torque to be increased. This is the most common configuration of the v-belt drive, because many driven components operate at lower speeds than typical motor speeds and need higher torque. 4. Now measure the motor s electrical input current for each of the prony brake load settings listed in the following table. Start with a 0 ounce load for the first current reading and increase by 4 ounce increments until a 20 ounce load is reached SCALE READING (Ounces) MOTOR CURRENT (Amps) TORQUE (In-ounces) 5. Reduce the load on the motor to zero by turning the load nut counterclockwise until the scale reads zero. 6. Turn off the electric motor. 7. Perform a lockout/tagout. 8. Calculate the torque value for each scale reading in the table of step 2. Record your calculations in column 3 of the table in step 2. Use a value of 6.0 inches (15.24cm) for the torque radius of the prony brake to do your calculations. 9. Compare the electrical current readings in the table in step 3 to the electrical current readings you measured in LAP 2, when the motor was directly coupled to the shaft and prony brake. You should find that the current required to drive the belt is less than the current measured in LAP 2 because the belt drive pulley ratio reduces the torque required by the motor. 10. Perform the following substeps to test the effect of incorrect belt tension. A. Remove the guard. B. Loosen the bottom jam nut on the motor mount adjustment screw. 74

75 C. Use a wrench to turn the top jam nut 1 full rotation downward. This will increase the tension on the belt. WARNING Do not over-tighten the belt. The belt can break and cause a hazardous condition. D. Retighten the bottom jam nuts on the motor base adjustment screw. E. Reinstall the guard. F. Remove the lockout/tagout and restart the motor. G. Repeat the procedure to measure the change in current because of the increased tension on the belt. SCALE READING (Ounces) MOTOR CURRENT (Amps) TORQUE (In-ounces) H. Remove the load applied by the prony brake. I. Turn off the motor. J. Perform a lockout/tagout. K. Compare these results with the results obtain previously. Did the current increase or decrease? Did the torque increase or decrease? You should see that higher tension causes the motor to use more power. 11. Perform the following substeps to disassemble the v-belt drive. A. Remove the guard from the setup. B. Loosen the top jam nut and move the motor upward. This will make the belt loose. C. Carefully pull the belt off the sheaves. Make sure that you do not have to use force to remove the belt. Pivot the motor closer to the driven shaft if necessary. D. Use a hex key wrench to loosen the set screw on the hub of the motor sheave. 75

76 E. Carefully pull the sheave off the shaft, as shown in figure 62. Figure 62. Removal of Sheave If the sheave is stuck, tap out the key using a punch or remove the sheave with a gear puller. F. Remove the driven sheave in a similar manner as used to remove the driver sheave. 76

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