Handbook Timing Belts

Raimund Perneder • Ian Osborne

Handbook Timing Belts

Principles, Calculations, Applications

123

Raimund PernederMilinowskistr. 37a14169 BerlinGermanye-mail: raimund.perneder@t-online.de

Ian OsborneTransmission DevelopmentsDawkins RoadBH15 4HF PooleUKe-mail: iosborne@transdev.co.uke-mail:

ISBN 978-3-642-17754-5 e-ISBN 978-3-642-17755-2DOI 10.1007/978-3-642-17755-2Springer Heidelberg Dordrecht London New York

� Springer-Verlag Berlin Heidelberg 2012This work is subject to copyright. All rights are reserved, whether the whole or part of the material isconcerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcast-ing, reproduction on microfilm or in any other way, and storage in data banks. Duplication of thispublication or parts thereof is permitted only under the provisions of the German Copyright Law ofSeptember 9, 1965, in its current version, and permission for use must always be obtained fromSpringer. Violations are liable to prosecution under the German Copyright Law.The use of general descriptive names, registered names, trademarks, etc. in this publication does notimply, even in the absence of a specific statement, that such names are exempt from the relevantprotective laws and regulations and therefore free for general use.

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Foreword

Today, timing belts are used in a wide range of innovative drive solutions for usein mechatronic systems that combine mechanics, sensors, control systems andservo technology with freely programmable and distributed drive solutions. Thetiming belt has become widely used in this framework and has contributed to manyindustrial drive innovations. For example, in automation and handling equipmentusing low-backlash robotic timing belt drives working under high dynamic loads,particularly during start-up. In continuous operation, timing belts offer lowmaintenance and guarantee accurate positioning at high speed.

This handbook is intended for application engineers in both design and devel-opment departments and is also suitable as a guide for students at universities,institutes of higher learning and technical colleges. When it comes to drive design,the target should always be an elegant solution, incorporating the use of simple androbust mechanical concepts that can be implemented both cost-effectively and alsosatisfy ‘‘innovative solution’’ criteria. Timing belts offer a wide variety of approa-ches to these problems. The information within this book has been derived fromyears of experience and enables the user to dimension timing belt drives utilisingproven generic examples from the power transmission, conveying and linear drivesectors. In addition, the investigation of non-optimum operating conditions andsources of timing belt damage provides production engineers with the ability tooptimize underperforming drives. This work also contains guidelines for the designof auxiliary components and the surrounding support structure. Having a goodknowledge of these mechanisms will aid functional drive dimensioning.

The handbook is based on the author’s 30 years of professional employment inthe mechanical power transmission sector. During this period, the timing belt, as anewly introduced drive component, has gradually established a prominent positionin the marketplace. Concurrently with this progress and market acceptance, timingbelt manufacturers have refined the manufacturing processes for production as theindustrial belt user has always looked for functional and economic solutions. Fromthe author’s own experience and due to numerous personal contacts withinindustrial companies, he has been able to document many examples of concepts

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and drives, which were initially compiled as a loose-leaf collection. Theseapplications comprise the main component of this handbook.

The units in the equations are defined in the SI system. Derivations have beenomitted. The numerical equations are presented so that the physical relationshipsare clear.

Thanks

For all the ideas for content and editorial design, I would like to thank all who haveparticipated in the origination of this book.

My special thanks go to Prof. Dr.-Ing. habil. Dr. hc. Werner Krause fromDresden Technical University for providing the impetus for this book project.Without his inspiration and encouragement this work would not have begun. Hesupported my efforts from the beginning and supported the technical content forstructure and linguistic implementation. Further special thanks go to Prof.Dr. Henning Meyer of Berlin Technical University, in my hometown, who pro-vided continued scientific support. He also established contacts with the publisherwhich developed into a most pleasant cooperation between a dedicated team ofstaff from Springer Verlag in Heidelberg and Berlin Technical University.

The origin of this work was significantly influenced by my long affiliation withWilhelm Herm. Müller GmbH & Co. KG and the Mulco Group companies. I thankall my colleagues and associates on behalf of my book project. In a professionalenvironment I offer my special thanks to Mr. Rudi Kölling of Breco Antriebs-technik GmbH for permission to reproduce the contents of their documentation.

The Future

This work is intended for use as a handbook. From this the reader can easilydeduce that it is an exhaustive work about timing belt technology and essentiallycontains reliable information on all main and related topics. Unfortunately a100%-accurate work is not feasible. Therefore any technical errors are attributableto the author and translator. Identification of errors as well as suggestions andconstructive criticism, can be sent to the author at: raimund.perneder@t-online.de.

The potential for any revised edition of this handbook would be to enhancecurrent knowledge. The timing belt is a relatively new drive component andfurther developments are ongoing. This handbook is a balanced mix of knowledge/scientific theory and reflects current operational practice. It aims to promotetechnical discussion combined with practical solutions. Interested readers andtiming belt users are welcome to contact the author for confidential consultation.Any eventual release of information for the enrichment of the handbook would beleft to the discretion of the client.

I hope this handbook delivers as much benefit to the reader, as I have had thejoy of writing it.

Berlin, Germany, March 2011 Raimund Perneder

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Translator’s Note

I would like to thank Raimund Perneder for the opportunity of collaborating withhim on the translation of this most important work in the field of timing belttechnology. I would have not taken on this task if I had not have believed that thesubject matter was important to an English speaking audience. Translating fromone language to another is always fraught with problems and assumptions. It couldbe thought that the translation of technical subjects should be straightforward, butthe problem is that those technical subjects are held together by words and con-cepts that are not directly comparable from one language to another. This being so,I have tried to pitch the translation at an international audience where English maynot be the first language of the reader. To the native English reader some of thetext may seem to be florid or over-descriptive but that is for the convenience of thewhole audience.

I would like to thank my colleagues at Transmission Developments for theirsupport and help over the timeline of this project and my partner Vivienne for theproofreading, suggestions and innumerable cups of tea.

Poole, England, March 2011 Ian Osborne

Foreword vii

Contents

1 The Right Drive in One Mouse Click . . . . . . . . . . . . . . . . . . . . . . 1

2 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.1 Timing Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.2 Major Geometric Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 72.3 Belt Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.3.1 Imperial Pitch, Standard Profiles . . . . . . . . . . . . . . . . 152.3.2 Metric Pitch, Standard T Profiles . . . . . . . . . . . . . . . . 162.3.3 High Power Profile AT. . . . . . . . . . . . . . . . . . . . . . . 172.3.4 High Power Profiles H/HTD . . . . . . . . . . . . . . . . . . . 182.3.5 High Power Profiles R/RPP. . . . . . . . . . . . . . . . . . . . 192.3.6 High Power Profiles S/STD. . . . . . . . . . . . . . . . . . . . 202.3.7 High Power Profile Omega . . . . . . . . . . . . . . . . . . . . 212.3.8 High Power Profile GT3. . . . . . . . . . . . . . . . . . . . . . 222.3.9 High Power Profile Polychain GT2 . . . . . . . . . . . . . . 232.3.10 High Power Profile ATP. . . . . . . . . . . . . . . . . . . . . . 242.3.11 Special Profiles Self-Tracking Belts . . . . . . . . . . . . . . 252.3.12 Special Profile SFAT . . . . . . . . . . . . . . . . . . . . . . . . 262.3.13 Special Profile BAT . . . . . . . . . . . . . . . . . . . . . . . . . 272.3.14 Special Profile Eagle . . . . . . . . . . . . . . . . . . . . . . . . 282.3.15 Special Profile N10 . . . . . . . . . . . . . . . . . . . . . . . . . 292.3.16 Special Profile ATN with Insert Attachments . . . . . . . 30

2.4 Manufacturing Processes and Elastomers . . . . . . . . . . . . . . . . 312.4.1 Cast Timing Belts Manufactured From Thermoset

Polyurethane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312.4.2 Synthetic Rubber Vulcanised Timing Belts . . . . . . . . . 332.4.3 Thermoplastic Endless Polyurethane Extruded

Timing Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342.4.4 Extruded Polyurethane Open Length Timing Belts. . . . 36

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2.4.5 Other Manufacturing Processes . . . . . . . . . . . . . . . . . 362.4.6 Joining of Open Length Belts . . . . . . . . . . . . . . . . . . 372.4.7 Timing Belt Mechanical Joint System . . . . . . . . . . . . 382.4.8 Applications and Usage . . . . . . . . . . . . . . . . . . . . . . 392.4.9 Power Increases and Further Development . . . . . . . . . 39

2.5 Tension Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412.6 Forces in Timing Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . 472.7 Force-Effect Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . 492.8 Pre-tension in Multiple Shaft Drives . . . . . . . . . . . . . . . . . . . 522.9 Tooth Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552.10 Belt Guiding and Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . 582.11 Irregularities, Vibration and Dynamics . . . . . . . . . . . . . . . . . . 662.12 Noise Behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732.13 Transmission Accuracy, Rotational Stiffness . . . . . . . . . . . . . . 782.14 Drive-Train Mechatronics . . . . . . . . . . . . . . . . . . . . . . . . . . . 842.15 Timing Pulleys, Tooth-Form Geometry. . . . . . . . . . . . . . . . . . 862.16 Tangential Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912.17 Belt Installation and the Adjustment of Pre-tension . . . . . . . . . 972.18 Minimum Diameters for Idler and Tension Rollers . . . . . . . . . 1022.19 Measuring the Belt Working Length . . . . . . . . . . . . . . . . . . . 1032.20 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

3 Timing Belt Drive Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . 1073.1 Belt Drive Geometries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1073.2 Screw Jacks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1183.3 Packaging Machine Mechanism . . . . . . . . . . . . . . . . . . . . . . . 1193.4 Press Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203.5 Cable Ferries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1213.6 Test Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1223.7 Adjustable Centre Distance Solutions . . . . . . . . . . . . . . . . . . . 1233.8 Injection Moulded Plastic Timing Pulleys . . . . . . . . . . . . . . . . 1253.9 Motor Glider Propeller Drive . . . . . . . . . . . . . . . . . . . . . . . . 1263.10 Industrial Robot Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1273.11 Timing Belt Drives In Automotive Applications . . . . . . . . . . . 130

3.11.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1313.11.2 Evolution of Camshaft Belt Drives. . . . . . . . . . . . . . . 1313.11.3 Oval Pulley Vibration Reduction Technology . . . . . . . 1343.11.4 Current Customer Requirements for

Timing Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . . 1373.11.5 OIL RUNNER Timing Belts . . . . . . . . . . . . . . . . . . . 137

3.12 Motorcycle Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1423.13 Pulley Shaft and Hub Locking Assemblies . . . . . . . . . . . . . . . 143

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3.14 Drive Test Rig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1473.15 Reactive Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1493.16 High Accuracy Timing Belt Drives . . . . . . . . . . . . . . . . . . . . 153

4 Timing Belts in Linear Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . 1594.1 Conversion of Motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1594.2 Dimensioning Linear Drives . . . . . . . . . . . . . . . . . . . . . . . . . 1604.3 Linear Positioning Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . 1704.4 Dynamics and Vibration Behaviour . . . . . . . . . . . . . . . . . . . . 1794.5 Positioning Accuracy Calculation Example . . . . . . . . . . . . . . . 1814.6 Linear Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1834.7 Automated Storage and Retrieval Systems . . . . . . . . . . . . . . . 1914.8 Area Gantry / X–Y Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 1984.9 Telescoping Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2004.10 Linear Differential Transmission . . . . . . . . . . . . . . . . . . . . . . 2024.11 Linear Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2044.12 Portal Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2054.13 Building Systems Technology . . . . . . . . . . . . . . . . . . . . . . . . 210

5 Timing Belts in Product Transportation . . . . . . . . . . . . . . . . . . . . 2135.1 State of Art . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2135.2 Transport Belt Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2145.3 Friction and Tribological Behaviour . . . . . . . . . . . . . . . . . . . . 2165.4 Conveying, Contact Surfaces and Backings . . . . . . . . . . . . . . . 2175.5 Slide Beds/Roller Beds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2185.6 Profiled Timing Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2195.7 Example Applications of Profiled Timing Belts . . . . . . . . . . . . 2235.8 Adjustable Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2285.9 Profile and Mechanical Attachments . . . . . . . . . . . . . . . . . . . 2305.10 Palletising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2345.11 Haul-off Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2365.12 Vacuum Belts, Magnetic Belts. . . . . . . . . . . . . . . . . . . . . . . . 239

6 Timing Belt Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2436.1 Sources of Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

6.1.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2436.1.2 Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2446.1.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2446.1.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

6.2 Fault Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

7 Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2517.1 Overview of Drive Design . . . . . . . . . . . . . . . . . . . . . . . . . . 2517.2 Balanced Drive Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2537.3 Tension Members and Tooth Stiffness . . . . . . . . . . . . . . . . . . 255

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References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Subject Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

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