Pulley design

Pulley design

Summary

The drive pulley imparts the driving force to the belt and may be located at the head or discharge end of the conveyor, in return strand, or at the tail or loading end of the conveyor. A snub pulley is located near the drive pulley to provide more arc of contact between the belt and pulley for maximum adhesion in driving the belt.

A head pulley is at the discharge end of a conveyor and in a simple conveyor is normally the drive pulley. A tail pulley is at the loading end of a conveyor and in a simple conveyor is normally the takeup pulley. A drum type welded steel pulley design with a solid hub was next introduced which appeared to be an improvement over the arm design.

This design also allowed for greater flexibility in end disc and rim thicknesses. Cast iron pulleys followed the fabricated wood pulley in the progression of design. They were cast in one piece, turned, bored, and furnished keyseated and set screwed, keyseated only, set screwed only or with a plain bore, bronze bushed, with a solid or clamp type hub.

Standard construction for single armed pulleys provided for 65 lbs. After pulley problems developed maximum tension was considered rather than effective tension. The majority of all pulleys used fall within this standard. The ratings are based on shaft, end disc and rim strength. The equations used to establish these ratings are based on a compromise by committee members of the Mechanical Power Transmission Association at the time this standard was developed.

Other pulley designs, such as, a spun-end disc, magnetic separator, special self cleaning, engineered class high tension, non-rotating shaft, split steel, and motorized pulleys may be furnished, however, these designs do not fell within the scope of the aforesaid standard for welded steel pulleys with a compression hub.

Self cleaning type or wing pulleys as generally referred to, are normally used to prevent material from being forced into the belt and from building up on the pulley face. These pulleys can be straight face or crown and normally have a number of wing plates that extend radially from the longitudinal axis of the hubs and are equally spaced about the pulley circumference.

There are a variety of hub designs that have been used in belt conveyor pulley design and can be divided into two basic types, solid and compression. Shaft design plays a major role in the design of a pulley. The structural rigidity of a shaft and pulley require that they be treated as a composite structural assembly. Pulley design considers shaft diameter, however, shaft design is based on the shaft alone without support from the pulley. Shafts can be subjected to three types of stresses, simple flexure or bending, simple torsion and combined as a combination of bending and torsion.

Pulley shafts are subjected only to bending or combined loading. The accepted formula used in determining the diameter of a solid circular shaft in combined bending and torsion is :. Shaft deflection is best expressed as slope either in degrees or inches per inch. Generally, however, it is expressed in inches per inch and is normally determined at the center of the end disc. Numberous pulley geometries are capable of satisfactory service at various slopes, and specifying maximum shaft slope is not necessarily the best practice.

In the past conveyor designers may have specified shaft slopes which they considered as conservative, however, the resulting calculated end disc stress was determine to be too high for satisfactory service.

Lagging is a covering that is applied to the pulley rim. In many applications pulley lagging can improve conveyor performance as well as increase the life of the pulley and the belting.

When used on drive pulleys, it increases the coefficient of friction between the pulley face and belt. It is this friction that determines the amount of slack side tension T2 required in order to prevent slippage between the belt and the pulley when carrying a load, resulting tension Te.

The higher the coefficient of friction, the lower the T2 value and subsequently a lower T1 value. This results in selecting a lighter weight belt.Loos and Company has over 50 years of experience in the wire and cable industry. With our knowledge and experience, we can offer the highest quality products available on the market. Our general product lines and capabilities are listed above. As a manufacturer we can provide customized products for any application.

Here at Loos and Company, we get questions almost every day asking what size cable to use over a specified pulley, or what size pulley to use with a specific cable diameter or construction.

These questions are important because by using a properly designed pulley system, you will be able to get a longer service life out of your cable. The working life of the individual wire strands is greatly reduced as the pulley or sheave diameter is diminished. Pulley systems are used in a wide variety of industries, from aircraft controls and stage rigging to material handling and fitness equipment.

pulley design

The one thing these industries have in common is that they utilize these pulleys in a capacity where human safety is a concern; so designing a system that can provide a long service life and not accelerate cable failure is a must. With nearly 60 years of experience in the cable industry, Loos and Company can work with you to recommend the proper material to create the pulley system you need in your application. We have a full team of experts on hand to answer any questions you have.

Keep up on our always evolving product features and technology. Enter your e-mail and subscribe to our newsletter. Supplier Portal provides you with the information you need to become an approved supplier, as well as the latest program information for current suppliers. Email: sales loosco. Facebook Twitter Linkedin. Menu Loos and Company Headlines Blog. Our Products Loos and Company has over 50 years of experience in the wire and cable industry.

Loos HotWire: LoosCo. All other things being equal, the larger the D:d, the longer the cable will remain in service in your specific application. There are some specific recommendations available on our website for the D:d to use in your design depending upon what cable diameter and construction you are using. This guide is a great place to start when considering the performance of your system. Pulley Groove: An improper pulley groove will put extra stress on a wire rope and lead to premature wear.

Multiplying the.

Pulley Design Software

By adding. This will be your pulley groove dimension. Cable performance design: This comes down to two words: jacket and lubrication. When a cable goes over a pulley, you want to make sure it is as smooth as possible and that the jacket will not crack. Loos and Company uses the highest quality jacketing material an aerospace grade nylon material to ensure the cable is smooth and lasts as long as possible. It is also important to lubricate all of the wires which make up the cable, as is the standard process here at Loos and Company.From tank treads to bike gears to fishing lines, pulleys are used all over the place when it comes to mechanical transmissions.

All types of pulley mechanisms consist of some sort of flexible belt chain, cable, rope, etc. In this Instructable I'll go over some basic pulley concepts and interesting mechanisms, and hopefully you'll be able to design your own pulley systems and make stuff like this!

Did you use this instructable in your classroom? Add a Teacher Note to share how you incorporated it into your lesson.

The pulley is one of the six simple machines. Basically, all that a pulley is is a wheel spinning around an axle to aid the motion of a belt. The sprockets on a bike, for example, are a type of pulley, because when they spin, they drive other sprockets on the bike, that in turn rotate the rear wheel.

So to make a basic pulley, all you need to do is loop a rope over some sort of wheel and axle. Two pulleys can be used to create a simple belt and pulley system, in which a belt is looped between the two pulleys. One pulley is the "driving pulley", and as it spins, it transmits power through the belt either via friction or teeth, thus spinning a "driven pulley".

I'll be showing how you can use pulleys to make some pretty insteresting mechanisms later on. Pulleys are probably most commonly used for lifting heavy loads and transmitting power across axes. Elevators, cranes, and boats all use pulleys because a pulley changes the direction of the applied force on the belt. Because the rope or belt is looped around the circumference of the pulley, the force of the object on one end of the rope can loop around the pulley to the other end.

Certain types of pulley systems, like the block and tackle to be explained latercan actually lessen the applied force needed to lift an object via a system of moving pulleys and lines, which can be very useful in high-load situations.

Designing with Belts and Pulleys

Pulleys are also one of a few different methods of transmitting rotation from one axis to another. Belts and pulleys can be used to transmit power over larger distances and in constricted spaces, which is one advantage they have over gears.

Because most pulleys are driven by the friction between the pulley and the belt, if a part of a mechanism jams, then the motor. The Speed Ratio is the ratio of angular velocity of the input pulley of a system to the angular velocity of the output pulley. If you've calculated gear ratios, it is almost exactly the same! This is all based on a pulley's reference diameter, as defined below:.

This is what you will use to calculate the speed ratio. The speed ratio is equivalent to the reference diameter of the output pulley over the reference diameter of the input pulley in a two pulley system.The typical setup of a belt and pulley system consists of two pulleys and a belt connecting them together.

Some important terms are the pitch diameter, which is the diameter of the pulley; the center distance is the distance between the center of the two pulleys; the minimum wrap angle is a measure of how much of the smaller pulley is being gripped by the belt; the belt length is simply the length of the belt if it was cut and laid flat; and the pitch is the number of teeth per some length. For instance, a 3 mm pitch means 1 tooth for every 3 mm.

pulley design

There are some general guidelines that are applicable to all timing belts, including miniature and double-sided belts:. A final word about environmental considerations: Belt and pulley systems are suitable for use in a variety of environments.

Special considerations may be necessary, however, depending on the application. A few of the more common environmental factors are:. Connect with Design World on Social Media. Search Design World. We use cookies to personalize content and ads, to provide social media features and to analyze our traffic.

You consent to our cookies if you continue to use this website. Ok No Read more.A pulley is a wheel on an axle or shaft that is designed to support movement and change of direction of a taut cable or belt, or transfer of power between the shaft and cable or belt. In the case of a pulley supported by a frame or shell that does not transfer power to a shaft, but is used to guide the cable or exert a force, the supporting shell is called a block, and the pulley may be called a sheave.

A pulley may have a groove or grooves between flanges around its circumference to locate the cable or belt.

The drive element of a pulley system can be a ropecablebeltor chain.

Basic Pulley Mechanisms

Pulleys are also assembled as part of belt and chain drives in order to transmit power from one rotating shaft to another. A set of pulleys assembled so that they rotate independently on the same axle form a block. Two blocks with a rope attached to one of the blocks and threaded through the two sets of pulleys form a block and tackle. A block and tackle is assembled so one block is attached to fixed mounting point and the other is attached to the moving load.

The ideal mechanical advantage of the block and tackle is equal to the number of parts of the rope that support the moving block. In the diagram on the right the ideal mechanical advantage of each of the block and tackle assemblies [7] shown is as follows:.

pulley design

A rope and pulley system—that is, a block and tackle —is characterised by the use of a single continuous rope to transmit a tension force around one or more pulleys to lift or move a load—the rope may be a light line or a strong cable. This system is included in the list of simple machines identified by Renaissance scientists.

If the rope and pulley system does not dissipate or store energy, then its mechanical advantage is the number of parts of the rope that act on the load.

This can be shown as follows. Consider the set of pulleys that form the moving block and the parts of the rope that support this block. Thus, the block and tackle reduces the input force by the factor p. A gun tackle has a single pulley in both the fixed and moving blocks with two rope parts supporting the load W.

A double tackle has two pulleys in both the fixed and moving blocks with four rope parts supporting the load W. The simplest theory of operation for a pulley system assumes that the pulleys and lines are weightless, and that there is no energy loss due to friction. It is also assumed that the lines do not stretch. In equilibrium, the forces on the moving block must sum to zero. In addition the tension in the rope must be the same for each of its parts.

This means that the two parts of the rope supporting the moving block must each support half the load. Diagram 1: The load F on the moving pulley is balanced by the tension in two parts of the rope supporting the pulley. Diagram 3: The gun tackle "rove to advantage" has the rope attached to the moving pulley. Diagram 3a: The Luff tackle adds a fixed pulley "rove to disadvantage.

The mechanical advantage of the gun tackle can be increased by interchanging the fixed and moving blocks so the rope is attached to the moving block and the rope is pulled in the direction of the lifted load.V belts also style V-belts, vee belts, or, less commonly, wedge rope solved the slippage and alignment problem.

It is now the basic belt for power transmission. They provide the best combination of traction, speed of movement, load of the bearings, and long service life.

They are generally endless, and their general cross-section shape is trapezoidal hence the name "V". The "V" shape of the belt tracks in a mating groove in the pulley or sheavewith the result that the belt cannot slip off. The belt also tends to wedge into the groove as the load increases—the greater the load, the greater the wedging action—improving torque transmission and making the V-belt an effective solution, needing less width and tension than flat belts.

V-belts trump flat belts with their small center distances and high reduction ratios. The preferred center distance is larger than the largest pulley diameter, but less than three times the sum of both pulleys.

V-belts need larger pulleys for their thicker cross-section than flat belts. For high-power requirements, two or more V-belts can be joined side-by-side in an arrangement called a multi-V, running on matching multi-groove sheaves. This is known as a multiple-V-belt drive or sometimes a "classical V-belt drive". V-belts may be homogeneously rubber or polymer throughout, or there may be fibers embedded in the rubber or polymer for strength and reinforcement.

The fibers may be of textile materials such as cotton, polyamide such as Nylon or polyester or, for greatest strength, of steel or aramid such as Twaron or Kevlar. Membership Register Login. Copyright Notice. Should you find any errors omissions broken links, please let us know - Feedback Do you want to contribute to this section?Leverage the capabilities of an experienced wire rope pulley manufacturer and supplier for your wire rope pulley design applications through our wire rope pulley catalogue.

High-quality cable rope pulleys prolong cable life and enable your applications to achieve their performance potential. Carl Stahl Sava Industries is a wire rope pulley systems manufacturer that understands the critical role both large and small wire rope pulleys play in your applications.

Get more familiar with our complete family of cable pulley systems, and rope pulley design capabilities below and browse our wide selection today! Carl Stahl Sava Industries is proud to offer pulleys for virtually any wire rope and custom, miniature cable assembly application.

Take a look below and see for yourself why the world over counts on Sava to keep your mechanical assembly needs moving at peak efficiency. If your application requires superior mechanical efficiency, our bearing-mounted, small nylon pulleys for wire rope are a cost-effective option.

Alternately, we offer the SP Series Pulleys for devices that do require more precision.

Basic Pulley Mechanisms

Because Sava is a pulley supplier that works with a number of industries, many of our customers design applications that will operate in corrosive environments or bear heavy loads. To meet even the most demanding environmental conditions, Sava offers our MP Series pulleys with bronze bushing, ranging from 0.

For devices involving loads up to lbs. We offer the option of internal lubrication and plastic seals. Sava also manufactures pulleys for larger cables. You can choose an optional bronze bushing or roller bearing for your application. Our small wire rope LP pulleys offer significantly increased mechanical efficiency, as compared with plastic pulleys, and are substantially less expensive than the bearing-mounted alternatives currently on the market.

Simple pulley systems

Our team understands that choosing the right pulleys for your cable assemblies requires thoughtful consideration, from bearing life, to minimum pulley diameter. Let Sava's engineering expertise guide you toward the best selection. When cable is used over pulleys, the cable life can be significantly prolonged by proper pulley groove design.

These same tests show that doubling a pulley diameter can increase cable bending life up to thirteen times what is otherwise typical. Also, pulley diameters less than sixteen rope diameters fall into a range in which cable life is relatively low. Cable life is reduced as the groove radius changes from the contour of the cable to a flat surface.

The radius of bend has an effect on the strength of the cable. In order to take this into account in selecting the size pulley to be used with a given diameter cable, the following table can be used as a guide:.

Valued-Added Pulleys For Any Application Carl Stahl Sava Industries is proud to offer pulleys for virtually any wire rope and custom, miniature cable assembly application. Applications supporting control mechanisms, drive systems, recorders, indicators, wire rope drive pulleys, and metering equipment.

Applications requiring larger cable for heavier loads are accommodated by our large cable pulleys. Applications using larger cables. Applications using small cables or cord. Choosing the Correct Pulley Our team understands that choosing the right pulleys for your cable assemblies requires thoughtful consideration, from bearing life, to minimum pulley diameter.

Talk to Sava's pulleys experts now and build it right the first time. Let's discuss your next project or get a quote today!


How to calculate pulley belt length and distance between wheels. Scroll to the bottom for the YouTube tutorial on this article. As shown in the image below, an induction motor is connected via a belt to drive two pulleys which will move centrifugal fan. These calculations are mainly for existing installations but you could also put it towards your design if you want to calculate what the length needs to be of the belt, as long as you already know the distance between the two pulleys and the size of the pulleys.

The second part, the distance between the pulleys, is if you already know what length belt you need and also you know the diameter of both the pulleys. You can do it manually OR you can download our excel sheet! I just want to point out that these calculations may vary slightly from the real world scenario, but this is the best calculation that you can perform to get the most accurate figure.

Designing with Belts and Pulleys

We also have Pulley 2 and we know the diameter of this pulley as well. We also know the centre distance between these two pulleys. If we need to calculate the distance between the centres of the two pulleys, then we can use the following calculations to approximate this. We will need to know the diameters of the pulleys as well as the belt length. The above image illustrates which dimensions we need and each is colour coded to half make it a little easier. If you are using the metric systemthen you can use the following calculations.

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Sign in. Log into your account. Password recovery. The Engineering Mindset. Dimensions known to calculate belt length. Dimensions known for pulley distance calculation. Thermal Comfort in Buildings. Star Delta Starters Explained. Air Cooled Chiller Design Data. Please enter your comment! Please enter your name here. You have entered an incorrect email address! You'll like these too! Paul Evans - Apr 14, 0.For a system with two shafts and two pulleys - as indicated with pulley 1 and 2 in the figure above:.

The revolutions of shaft 4 in a multiple belt transmission like indicated in the figure above where. Add standard and customized parametric components - like flange beams, lumbers, piping, stairs and more - to your Sketchup model with the Engineering ToolBox - SketchUp Extension - enabled for use with the amazing, fun and free SketchUp Make and SketchUp Pro.

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pulley design

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pulley design

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pulley design

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pulley design

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Designing with Belts and Pulleys

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