E2/70495 About Gates expertise in ACCESSORY BELT DRIVE TECHNOLOGY
WHAT AUTOMOTIVE INDUSTRY SPECIALISTS SAY Whether you are a distributor, automotive engineer, garage mechanic or car manufacturer, you are undoubtedly confronted with the ever growing complexity of today s accessory belt drive systems. In this brochure, three experts in the automotive industry explain what the current challenges and needs are and which solutions Gates offers you. With minimum available space and maximum wear and heat, your belt drive faces difficult challenges. Car specialists know how today s engine design CHALLENGES drive system suppliers to come up with innovative and performing accessory belt drive solutions. The quality of an OE (Original Equipment) supplier with the flexibility of a thinking partner is needed to ensure stable performance. The Gates team of engineers knows how to exceed the S of car manufacturers and spare parts suppliers. The best belt is the one that comes with the biggest added value, I want expert training and information, not just an off-the-shelf product. Our customers know what they want. They prefer the added value of Gates.
CHALLENGES -> Page 4-5 S -> Page 6-7 -> Page 8-14 FAST -> Page 15 S FAST CHALLENGES CONTENT OVERVIEW
CHALLENGES According to this FIELD EXPERT Maximising belt performance in a confined space is a major challenge for belt manufacturers. CHALLENGE CHALLENGE 1: Deal with an ever more compact and sophisticated engine One single belt has to drive a multitude of accessories with different power needs. To power modern engines efficiently, complex belt routings are needed, which create demanding conditions for belts and metal components. Belt performance is even more stretched in vehicle models where the tensioning device has been left out to save space. ACC PS WP PUL p 4
CHALLENGES S FAST CHALLENGES CHALLENGE CHALLENGE 2: Endure the heat under the bonnet An increasing number of active applications are crammed into a limited amount of space under the bonnet. This activity in a confined space raises the temperature under which belts have to perform. These challenging conditions increase wear to belts and metal components. Excessive bending and heat may cause belt cracking CHALLENGE CHALLENGE 3: Live up to the demand for durable, maintenance-free and High-performance drive systems Packing more accessories and pulleys into a limited space is good for car manufacturers, but raises the challenge for spare parts suppliers. How do you ensure optimum power transmission in a highly complex accessory belt drive system, where the slightest mistake in tensioning or alignment can lead to engine malfunction or worse? Rising temperature and diminishing space TEMPERATURE SPACE TIME TIME p 5
WHAT IS ED TODAY Meet the technical TRAINER In today s automotive industry, success depends greatly on professional and reliable partners ensuring stable performance, easy installation and maintenance, increased power transmission and OE quality. : Stable and reliable PERFORMANCE Each car driver needs a belt that delivers stable performance. Today s challenging accessory belt drive system (ABDS) design requires a high-quality accessory belt drive solution. The belt and metal components have to be easily and safely adapted to fast-changing needs and more stringent requirements of today s OE and replacement markets. : Easy installation and maintenance To ensure perfect belt positioning and tensioning, you need clear and concise information. You also need high-quality tensioning and installation tools to avoid making costly mistakes. Wrong belt tension and misalignment can cause noise and damage to other drive system components. p 6
FAST S S : EXPERT ADVICE AND TRAINING Information and tools are not enough. You have to be regularly kept up to date with training and feedback from experts. : Increased power transmission Extra engine accessories require extra power. This power has to come from a belt that is already under a lot of pressure. This means you need a belt that can drive all the accessories with different power needs. : OE quality Your belts need to be resistant to temperatures and shocks and be able to handle complex drive routings and different speeds. Belts have to be extremely reliable, delivering higher power transmission under difficult circumstances. The belt you need has to be made from a material that combines robustness with flexibility and resistance to high and low temperatures. In addition, it has to show a good resistance to wear, oil, ozone, flex fatigue and pilling. Moreover, you need the same reliable, robust, high-quality belt, whether you are dealing in original equipment or servicing the aftermarket. p 7
Micro-V XF products meet the automotive industry s challenges and needs. Here are the facts: FACT Fact 1 : Gates is the number 1 supplier of multi-ribbed belts for accessory belt drive systems Gates has everything you need to tackle the challenges you are faced with. Gates has the experience to guarantee you a fully reliable accessory belt drive system (ABDS). It is no coincidence that Gates is the number 1 supplier for accessory belt drive system products, offering you the biggest added value through superior products, service, training and expertise. Gates has 100 years experience as belt specialist, and has always been part of new automotive technology developments. Gates offers more car park coverage (98%+) than any other manufacturer. Gates Micro-V XF multi-ribbed belts are engineered especially for today s demanding accessory engine drives. Gates is the second largest OE manufacturer for automatic tensioners in the world. Gates offers you DriveAlign tensioners that ensure stable performance. Micro-V XF kits, including one or more Gates Micro-V XF multi-ribbed belts and matching metal components, are perfect for quick and safe replacements in the aftermarket. Because Gates delivers both to the OE and the aftermarket, we are considered to be the true ABDS specialists. This strong reputation in the market is backed up by a broad range of solutions, uniquely stable performance and a perfect belt fit. Gates is continuously developing new ABDS technologies for car manufacturers, including the EMD start-stop system, elastic multi-ribbed belts, EuroGrip flexible couplings, and double-sided Micro-V belts for complex serpentine drives. Words from our customers Having the world leader as my strategic partner of choice is reassuring: Gates use their market experience to help me tackle the issues the industry is facing. Through their professional solutions, I am able to service every need any garage mechanic may have regarding the accessory belt drive system. FACT Fact 2 : Gates Micro-V XF multi-ribbed belts are EPDM, for unmatched heat, wear and flex fatigue resistance Gates is the only manufacturer who exclusively uses EPDM (ethylene propylene diene monomer) for the entire multi-ribbed belt range. Gates prefers to offer its customers EPDM, because it is a high-quality material which shows excellent resistance to wear, oil, ozone and pilling. EPDM belts also boast spectacular resistance to flex fatigue and high and low temperatures, as opposed to chloroprene. p 8
FAST EPDM resistance to high temperature is 6 times better than chloroprene Objective: Test crack resistance and general belt performance at elevated temperature Test end: 4 severe rib cracks or until the belt fails to transmit power Belt: 3 rib K section Tester Type: 4 Pt Waterbrake Load: 8.2 KW Speed: 4900 RPM Temperature: 120 C Horizontal Tension: 50 Kg MV-83 400 300 200 100 0 CR EPDM EPDM resistance to low temperature is 8 times better than chloroprene Objective: Test crack resistance and general belt performance at sub-zero temperature Test end: 4 severe rib cracks or until any belt delamination occurs Belt: 3 rib K section Tester Type: Dead Weight Cycle: 1 Min. on - 29 off Speed: 270 RPM Temperature: -35 C Horizontal Tension: 30 Kg Centers: Locked MV-63 2000 1500 1000 500 0 CR EPDM > 2000 cycles, no cracks EPDM is more than 400 times better resistant to ozone than chloroprene Objective: Evaluate undercord material resistance to ozone Test end: When cracks are observed at 7X magnification MV-63 1000 800 600 400 EPDM 200 0 CR EPDM technology and the specially welded back fabric ensure an exceptionally high level of robustness: Back fabric (welded) ensures a high resistance to wear and prevents hump noise on the application Polyester tensile cords give an optimum load-carrying capacity at higher tensions and low stretch Fibre-reinforced EPDM belt ribs equal an optimum high/low temperature resistance, excellent wear and pilling resistance, a good resistance to oil drops, very high ozone resistance and minimal belt slip The low belt profile gives both a splendid flexibility and increased belt stability as well as an optimum resistance to vibrations and noise p 9
Words from our customers Using high-quality materials is a smart investment. I see a direct effect in my profit account through improved power transmission and safety. FACT Fact 3 : Micro-V XF belts exceed OE tolerance requirements and ENSure A perfect fit The ADVANTAGE OF THE GATES consolidation principle There are at least 1,575 different OE lengths. This is not realistic to handle. Consolidation is necessary to avoid massive stocks with too many references. By carefully balancing the number of references to the needs of the market, the Gates consolidation principle saves space and unnecessary stock investments. Tolerances are a normal occurrence in belts. The belt gets longer after some time, due to wear and stretch. Small length differences never compromise belt behaviour. Standard tolerance for OE belts is +/- 5 mm. Gates Micro-V XF range works with narrower tolerances. It is a misconception to believe that small length differences cause belts to fail. The real causes of belt problems and failures are these: 1. Wrong belt installation tension. Gates stresses the importance of correct installation tension, preferably using the Gates sonic tension tester STT-1, one of the Krikit tension gauges or by replacing the tensioner by a Gates DriveAlign tensioner. 2. Misalignment. This is also the major cause of noise, a big issue when it comes to multi-ribbed belts. Using the DriveAlign laser alignment tool saves time and costly repairs. This tool quickly identifies the two most common types of misalignment in serpentine belt systems parallel offset and angular that reduce belt and pulley service life and produce unwanted noise. Noise can also be caused by low tension, which can be avoided by using the sonic tension tester STT-1 or the Krikit tension gauges. 3. Damage to other drive system components. Make sure that there is no damage to the other components. It is highly probable that the source of damage to one element in the drive will also have affected the other components of the system.? Consolidation principle The consolidation principle allows you to fully serve the market, while keeping stock costs low through a lower number of references. No consolidation principle Investments in belt stock rise sharply. p 10
FAST Specialised application research team By constantly scanning the market for new belt developments, the Gates specialised application research team ensures there is a performant Gates belt solution for every market need. The team determines what references Gates has to add to its range in order to be able to guarantee the most well-thought-out range. The team avoids adding too many references to keep stock costs low, while offering optimal coverage in the market and making sure you have the perfect belt for each application. The team-driven approach works. Gates range of 563 multi-ribbed belts covers about 22,000 applications, or more than 98% of the European car park. THE APPLICATION RESEARCH TEAM OE DATA research FIELD RESEARCH GATES REFERENCE AVAILABLE GATES REFERENCE not AVAILABLE New reference created CATALOGuING MARKET IS SERVED! FACT Fact : GATES, YOUR COMPLETE SYSTEM SUPPLIER What makes an engine perform at its best? When belts, tensioners and pulleys work together smoothly. Gates not only offers you a comprehensive belt range, but also engineers a wide array of metal components in close collaboration. This universal approach to ABDS production ensures a flawless engine performance. Because Gates simultaneously produces belts, tensioners, idlers and pulleys, all products perform seamlessly together on the belt drive system. p 11
DriveAlign tensioners Gates is a world-leading OE manufacturer for automatic tensioners. Gates DriveAlign tensioners offer precise OE fit for a very wide array of applications. In fact, Gates engineers analyse the failure modes of OE designs and make any necessary adjustments to match the performance of the original tensioner or even outperform it. Major product innovations include: Unique sealing Prevents contamination of internal parts Special damping mechanism Designed to increase belt and tensioner life Round wire spring Chrome-silicon torsion spring for less flex fatigue Solid pulleys Reduce surface wear Precision bearings Minimise friction for reduced bearing wear and noise Micro-V XF Kits With the Micro-V XF multi-ribbed belt kit, Gates offers the aftermarket all components for a complete overhaul of the accessory drive in one box. No need to order loose parts any more: the metal components and multi-ribbed belts come in one package, fit for the application. Time-saving and convenience in just one kit! Gates Micro-V XF kits offer you: All application-specific multi-ribbed belts and metal components necessary for a complete overhaul, combined in one package OE quality products, based on years of experience as an OE supplier for both belts and tensioners All the correct components right at hand Stretch Fit multi-ribbed belts More and more car manufacturers are bringing vehicle models into the market that are not equipped with a tensioning device. Also for these special accessory belt drive systems, Gates offers the ideal response with the Stretch Fit multi-ribbed belt programme. Stretch Fit belts are pre-tensioned over the pulleys, thus maintaining tension that is sufficient for efficient power transmission over a long period of time, yet low enough to allow for easy installation and to prevent component failure. p 12
FAST FACT Fact : Precise tools and in-depth training ensure perfect INSTALLATION and easy maintenance ABDS TOOLS Gates ensures you can rely on a wide range of professional tools for: belt installation, tensioning, alignment and maintenance. You are provided with universal and engine-specific Stretch Fit installation tools. For tensioning and alignment, you can rely on tension gauges Krikit I & II, sonic tension tester STT-1 and the time-saving DriveAlign laser alignment tool. Belt maintenance is kept safe and easy with the Dr. Gates professional tool kit and a special tool set for serpentine belts. training Gates Expert team Gates has created a Pan-European expert team to offer you technical support and training. They develop training initiatives and technical service concepts to help you with new technology and boost your sales. Gates experts always stress the benefits of thorough drive system inspections and complete system overhauls as part of every scheduled accessory or synchronous belt change. What you get: Field support Training evenings in cooperation with Gates customers Problem-solving exponentia Gates has joined the exponentia programme, offering training modules and technical hotline to ensure a well-developed and well-trained distribution network and smooth information transfer to the customer. Online training and regular information updates As a Gates customer, you will receive regular technical bulletins to help you tackle new challenges of modern auxiliary belt drive systems. Words from our customers Everything works as promised: I get perfect belt tension, a flawless fit and excellent expert advice to keep my engines running at all times. I prefer Gates, because their quality solutions help me to ensure perfect belt installation every time. p 13
www.gates.com/europe www.gatesautocat.com inforequest@gates.com Words from our customers Gates supplies me with all the tools and training I need for an impeccable belt installation. I never need a login or password to look up data at www.gatesautocat.com. That speeds things up and gives me extra time for my core business. FACT FACT : Expert knowledge is easily accessible, SAVING YOU TIME All application data are freely and readily available in: printed version o Gates Drive Systems Catalogue E/70107 ED 2008 o technical bulletins online at www.gatesautocat.com o no password o no need to register o no login o always up-to-date The online multilingual application catalogue makes product search even easier and provides you with the most accurate and up-to-date information. This catalogue contains alphabetical application data, numerical application data, competitive and OE changeover data for belt drive and cooling systems. Gates also added the possibility to click through to the belt routing diagram and drawing or picture of the tensioner, kit components, hose, thermostat and radiator cap. There is also a direct link to online technical bulletins, offering detailed information and useful tips for installation and maintenance of Gates products. In addition, Gates offers complete marketing communications support to drive sales. This includes trade advertising campaigns, troubleshooting information, websites, press releases and trade press articles. LE PROGRAMME STRETCH FIT GATES Une gamme étendue de courroies Stretch Fit Avec la nouvelle gamme de courroies striées Stretch Fit, Gates entend offrir au marché indépendant de la rechange une solution professionnelle supplémentaire en regard des systèmes d entraînement auxiliaire. Les courroies Stretch Fit constituent la réponse idéale aux modèles de véhicules qui ne sont pas équipés de dispositif de tension. Des instructions d installation spécifiques sont imprimées à l intérieur de la manchette de la courroie et font référence à l outil d installation Stretch Fit approprié. Outils d installation Stretch Fit universels et réutilisables Pourquoi investir dans des outils jetables alors que vous pouvez compter sur les solutions durables, économiques et écologiques proposées par Gates? Les outils d installation Stretch Fit Gates sont: Universels Réutilisables Vendus séparément Facile à utiliser p 14 GATES, PRÉCURSEUR EN TECHNOLOGIE
CHALLENGES S S FAST FAST FAST FAST FCTS FAST FAST CHALLENGES CHALLENGES Engine designs become ever more compact and complex The larger number of accessories in a confined space raises temperatures under the bonnet, increasing belt wear Under these challenging conditions, drive systems must remain durable, maintenance-free and performant S Needs Engine performance must remain reliable and stable at all times Belts have to be easily installed and maintained You have to be kept up to date with expert advice and training Belts need to transfer power as efficiently as possible OE quality must be guaranteed Choosing guarantees a fully reliable accessory belt drive system belts exceed OE tolerance requirements and ensure perfect fit o The consolidation principle ensures you cover 98% of your car park, while keeping stock costs low o A specialised team develops training initiatives and technical service concepts to help you with new technology and boost your sales Gates is the number 1 supplier for accessory belt drive system products, offering you the biggest added value through: o Superior, reliable products o Full service: Gates is a complete system supplier o Precise tools and in-depth training, ensuring perfect installation and easy maintenance o Expert training: Gates offers you easily accessible expert knowledge p 15
- Aldous Huxley, 1927 - Facts do not cease to exist ù because they are ignored ú GATES PRODUCTS are the benchmark. That s a fact! Your distributor: The manufacturers reserve the right to amend details where necessary. Gates Corporation 2008 Printed in Belgium 06/08.