Gates Around the World

Did you know that Gates is an industry leader not just here in the United States but in countries around the world.  From California to Shanghai and everywhere in between, Gates has resources to assist you with your power transmission or fluid power needs.  To locate the Gates facility nearest to you, simply visit www.Gates.com and use the upper "Select Region" tab to navigate to your specific region.  Once there, you will find a plethora of helpful information including Gates products, services, and customer contacts.  This information can be used to troubleshoot a drive, locate the correct replacement products, and even locate a Gates representative that can provide you direct assistance with any of your needs.

For further information, or for assistance with a belt drive selection contact Gates Product Application Engineering at ptpasupport@gates.com or 303-744-5800.

Estimating Horsepower Loads for Pumps

The power requirements for pumps should always be obtained from manufacturers if possible, but this may not always be feasible when quick field estimates are needed. The following equation can be used to estimate the power required to drive pumps:

Estimate the pump power requirement by dividing horsepower calculated above by the pump efficiency. An efficiency of approximately 70% can be used for centrifugal pumps, and approximately 80% for vane and gear pumps. Efficiency of reciprocating pumps can  vary significantly depending on pressure and stroke length.  Approximate efficiencies are included in the following table:

This approximation for pump power requirements can be used for quick estimations, or when accurate data cannot be obtained from pump manufacturers. For further information, or for assistance with a belt drive selection contact Gates Product Application Engineering at ptpasupport@gates.com or 303-744-5800.

BIRD™: Belt Installation and Rotation Device

When you’re in charge of safety, you’re in charge of protecting people’s lives. Especially in highly volatile environments like oil drilling, mining, construction, and manufacturing. One small oversight could shut down your operation—and cost you millions in lost production, downtime, or even someone’s life. At Gates, we take safety seriously.


That is why Gates has introduced the BIRD™, the Belt Installation and Rotation Device, which is a switchable magnetic clamp equipped with permanent magnets and is designed for attachment (by hand) to metallic sheaves and sprockets.

The BIRD is a specially designed, tightly compacted device, which creates a magnetic field that develops an incredible attractive force on ferromagnetic materials.




And just as the BIRD is a tool for safety, Gates recommends practicing safety when using this device. The BIRD may only be used to rotate metallic sheaves and sprockets. Proper use includes adherence to the start-up, operating, environment, and maintenance conditions specified by Gates. The user bears sole responsibility for understanding this operating manual as well as for the proper use and maintenance of the BIRD.


Please contact Gates Product Application Support at 303-744-5800 or ptpasupport@gates.com if you have any questions prior to using this device.

Calculating Proper Belt Length

We are often contacted to calculate the belt length of a specific drive given the center distance, and pulleys sizes are known.  Of course, we are glad to help in any way possible but if this calculation is needed after hours, or a phone is not readily available to you, it can be made through the equation below.

Where:

Lp = Belt pitch length (inches)

C = Center distance (inches)

D = Large pulley diameter (inches)

d = Small pulley diameter (inches)

For additional information on this or any other topic please contact Gates Product Application Engineering by phone at 303-744-5800 or by email at ptpasupport@gates.com.

Not All Sprockets Have Flanges

Did you know that not all sprockets have flanges? In belt drive systems Gates typically only recommends the smaller sprocket to have flanges on both sides.  This is to account for any belt tracking issues that may occur if alignment between the sprockets is slightly off.  When misalignment becomes worse, the belt tends to track in one direction rather than remain neutral on the sprocket.

Flange Cutoffs

Belt	Grooves
8MM Poly Chain	90à
14MM Poly Chain	90à
2MM PowerGrip GT2	62à
3MM PowerGrip GT2	48à
5MM PowerGrip GT2	80à
5MM PowerGrip GT2 AL	36à
8MM PowerGrip GT2	90à
14MM PowerGrip GT2	90à
3MM PowerGrip HTD	50à
5MM PowerGrip HTD	36à
20MM PowerGrip HTD	112à
MXL	72à
XL	32à
L	60à
H	60à

Ventilation for Belt Drives

Increasing ventilation around belt drives can help reduce belt operating temperatures in applications with high ambient temperatures, or on applications operating in enclosures. This can be accomplished by adding vents to belt guards, by providing a cooler external air source, or by even adding fins to sheaves.

V-Belts and Low Temperature Operation

In extremely low temperature operations, the rubber material in V-belts becomes stiff. At sufficiently low temperatures, the rubber will actually reach a glass point, where (as the name implies) the rubber is hard and will shatter like glass if it is bent.

This is an extreme condition but approaching this state the rubber will go through various degrees of stiffness. As long as a drive is in operation, the heat generated through drive friction and bending will increase the internal belt temperature and maintain belt flexibility in temperatures well below the normally accepted minimum operating temperature. Trying to immediately transmit a load through a belt which has taken a cold set can cause belt failure because the belt is too rigid to bend.

Options to Reduce Overhung Load on Gear Reducers and Gearboxes

If calculated overhung loads are larger than those recommended by a gearbox manufacturer, there are three possible options that can be used to reduce overhung load:

1) Increase the diameters of the sprockets or sheaves on the drive.
2) Move the sheave or sprocket inboard, thereby moving the overhung load closer to the reducer.
3) Use a belt type with a smaller overhung load connection factor (and, therefore, less total operating tension).

Synchronous Belts vs. Ball Screws

From the design, construction, and first-cost standpoint, a synchronous belt drive can have distinct advantages over a ball screw in certain applications:

 - Significantly lower first cost
 - No lubrication or maintenance required
 - Clean running drive
 - Drive length design flexibility

Idler Bushings

Some belt drives require the use of an idler sprocket whether it’d be for tensioning or achieving sufficient belt wrap.

Gates does offer a handful of idler sprockets assemblies, however depending on the pitch and the width of the belt, there can be few options.

Gates also offers a number of idler bushings (see below) to allow for more flexibility when choosing idler sprocket tooth counts and widths. We offer idler bushings in both QD and TaperLock styles. Both assemblies are compatible with our idler bracket options.

If you are in need for a larger idler sprocket or have an old sprocket you want to reuse as an idler, our idler bushings may be for you.

For additional information on this or any other topic please contact Gates Product Application Engineering by phone at 303-744-5800 or by email at ptpasupport@gates.com.

Misalignment

Maintenance technicians may not always find it practical or possible to accurately calculate the total misalignment in a system while determining if it is in acceptable alignment. It is also difficult to visualize small fractions of an angle such as 1/2 and 1/4 degrees.

These can be more clearly illustrated with the following rules of thumb:

For v-belt drives, 1/2-degree angle = approximately 1/10-inch per foot between the drive shafts.

For synchronous, 60-degree angle, and V-ribbed drives: 1/4-degree angle=approximately 1/16-inch per foot between the drive shafts.

These rules can be used to estimate the amount of angular and parallel misalignment visually rather than having to calculate actual numerical values.

Alignment, Tracking, and Flanges

If  one side on a belt wears faster than the other, a tracking problem where the belt is riding against a sprocket flange may exist. This condition is typically caused by misalignment. In the most severe cases with heavily loaded drives, side thrust forces can actually push off the pulley flanges. 

If this type of belt wear is seen, or wear varies across the belt width, check the drive alignment and adjust as necessary to achieve proper alignment.

Belt Drive Inspection and Symptom Analysis

Gates recommends the following steps when inspecting a synchronous belt drive system:

With the power shut off, locked and tagged, and the machine components in safe positions, remove the drive guard and inspect the belt and sprockets for signs of unusual wear or damage.

Symptoms such as excessive belt edge wear, tooth shear, belt cracking and tensile break may indicate the need to correct alignment or to adjust tension to the correct values.

Poly Chain GT Carbon for Food Processing Operations

For high torque applications, food processors can use Poly Chain GT Carbon belts with carbon fiber tensile cords.   Carbon fiber tensile cords provide excellent resistance to moisture and chemicals, and polyurethane stands up well to most cleaners and sanitizers. This belt offers a number of properties that make it highly suitable for food processing operations, including:
 -Excellent resistance to oils, fats, fruits, juices, vegetables, dairy products, tomatoes, wine and vinegar
 -Good resistance to food industry soils and chemicals
 -Good resistance to high-pressure wash-down sprays
 -Excellent abrasion resistance
 -Operating temperature range of -65 degrees to +185 degrees Fahrenheit

Belt Drive Inspection

For critical drives a quick visual and hearing inspection should be performed periodically. A visual and hearing inspection consists of the following three items:

1. Look and listen for unusual noise and vibration while observing the drive.
2. Inspect the guard for loose parts and damage. Make sure it is clean. Any accumulation of foreign material on the guard acts as insulation and could cause excessive heat buildup in the drive.
3. Look for oil and grease contamination that could degrade the material components of a belt.

Energy Savings with Synchronous Belts

Converting V-belt drives to synchronous belt drives can reduce energy usage.

To estimate the number of kilowatt-hours saved by using synchronous belt drives rather than V-belt drives, the following calculation can be used:
KWH= (motor hp x hours/year x .746 x.05)/motor efficiency

where constant .746 is the conversion factor from hp to KW and .05 is the estimated 5% energy savings gained by converting to synchronous belt drives.

Washdown Applications

Washdown applications can present challenges for drive systems. Rubber belts typically stand up well to washdowns with alkaline detergents. Organic solvents and strong acids used as sanitizers can attack the drive components, so one must exercise care when using these types of sanitizers. Exposed tensile cords along the sides of the belt can wick moisture into the belt over time, however, so maintenance personnel should inspect belts for wear regularly. Gates Poly Chain belts typically perform well in washdown environments and are excellent roller chain replacements.

Gates MachineWorks

Gates can provide power transmission hardware solutions for all types of non-stock bushings, sheaves, and sprockets. 

Contact the MachineWorks department to review and quote your specialty hardware requirements.  MachineWorks can provide parts in all materials, metallic and non-metallic, in all V and synchronous configurations.   From something as simple as a verbal description up to a detailed part drawing, MachineWorks is your source for non-stock parts - from 1 to thousands of parts.

You can contact MachineWorks by email or phone:

makemymetal@gates.com  (preferred)

303-744-0385

800-709-6001

One Race To Go - John Force Racing In the Hunt for Championships

With one race remaining in the NHRA season, John Force Racing is in position to compete for the season points championship in both the Top Fuel and Funny Car classes.

Brittany Force, driver of the Monster Energy Top Fuel dragster, is in second place - only 20 points behind the class leader.  That is less than 1 round of racing.  If Force wins 1 round more than the current points leader, she will take the season championship.

Robert Hight, driver of the AAA Funny Car, goes into the final race in Pomona, CA, with a 15 point lead over the second place team.  If Hight wins the same or more rounds of racing in the final race of the season compared to the second place team, he takes home the season points championship.

Join us in watching the drama unfold in the final race of the season, following the Gates sponsored John Force Racing teams.

Underwater Belt Applications

Have an underwater drive application and don't know what belt to use?


A good option for both fresh and salt water environments would be the Gates Poly Chain® GT® Carbon™ belt.

The Polyurethane in these belts assist in its ability to withstand the submersion, and is more resistant to wear and swelling than the standard rubber belts.




If you are designing for a drive underwater, there are a few things to adhere to; Mainly:

1. Use non-corrosive/anti-rust metals (i.e. stainless steel)
2. Do not exceed 10,000 feet of water depth
3. Do not exceed 4,400 psi of water pressure

If you have any questions regarding using belts underwater, or any questions in general, you can reach us at 303-744-5800 or ptpasupport@gates.com

Backlash

Q: What is Backlash?

A: The term “backlash” is used interchangeably with groove clearance, which is basically the gap between the belt tooth and the sprocket gap, and vice-versa.

In the world of registration and synchronization, the overall accuracy or precision of an indexing or position drive is quite vital, and is mainly determined by:

1. The clearance between the belt tooth and sprocket groove or “backlash”.
2. The spring rate or “stiffness” of the tensile member used.
3. The installation tension applied.
4. Tooth deformation due to the drive torque load.

Something else to consider regarding backlash would be the tensile cord material within the belt. The belt tensile member should have a high tensile stiffness, in order to prevent belt elongation under torque loading.

The values of backlash will differ between belt product lines and their respective pitches, so if any questions do arise, or for additional information on this or any other topic, please contact Gates Product Application Engineering by phone at 303-744-5800 or by email at ptpasupport@gates.com.

Gates Sponsored John Force Racing Teams Pushing for NHRA Championships

With two races remaining in the 2017 NHRA season, two of the four John Force Racing teams are closing in on the points lead. 

After winning the Top Fuel class in Dallas in her Monster Energy Top Fuel car, Brittany Force is in second place, 57 points behind the first place team in Top Fuel.

 

Robert Hight, driver of the AAA Funny Car, also won the Dallas event, closing to within 24 points of the first place team in the Funny Car category.

 

Both drivers and teams are now in second place, building momentum moving into the final two races of the season.

 

Gates Corporation is a proud sponsor of John Force Racing, and wishes the teams well as the season wraps up!

 

Calculating Tension from Hz

Calculating Tension from Hz

Some equipment manufacturers will have a recommended frequency for the belt drive(s) in their system. As time goes on and components wear out, repairs/upgrades must be made to continue normal operation. Information like static belt pull is critical when calculating overhung/bearing loads especially when new components are introduced. To determine the static belt pull, the static tension must be known.

But how does one get there from Hertz?!

First we need to know a few characteristics about the belt drive.
• Mass constant of the belt (g/m/mm of width)
• Width of the belt (mm or #/ribs)
• Span of belt (mm)

Each can be determined if unknown.

Using the following equation, tension can be determined.













For additional information on this or any other topic please contact Gates Product Application Engineering by phone at 303-744-5800 or by email at ptpasupport@gates.com.

Fixed Tensioners Vs Spring Tensioners

It is common with industrial belt drive applications to implement a tensioning idler. This can either be in situations where there are multiple components being driven, space constraints, or if shaft locations are at fixed positions. Either method is acceptable but there are situations where one may be preferred over the other. When dealing with synchronous belt systems it is typically unnecessary to use a spring tensioner. A spring tensioner in certain situations can over-complicate the design and possibly cause more issues.  Once a synchronous drive is installed and tensioned correctly the system will not need re-tensioned.  For this reason a fixed idler bracket would be more than acceptable.

On systems where V-belts have been installed or space constraints are an issue then a spring tensioner may be the preferred option.  The physical properties of a V-belt will cause it to naturally stretch over time throughout its operating life. If the drive is also located in an area where it’s difficult to re-tension the system manually a spring tensioner could then be used. This will allow the system to continuously operate at the correct tension as the V-belt stretches, leading to reduced intervals for preventive maintenance. 

Gates Molded Notch V-belts can take the HEAT!

Whether you have a drive near an oven, around heating elements or just outside in the hot summer sun, the Gates Molded Notch V-belts have the capability of taking the heat.  Our Molded Notch V-belts have a high temperature limit of 250 degrees Fahrenheit* and come in the most popular sizes and cross sections including: AX, BX, CX, 3VX, 5VX, 8VX.  These belts are a drop-in replacement for the standard A, B, C, 3V, 5V, 8V belts in applications where the temperature exceeds 140 to 180 degrees Fahrenheit and the higher temperature rating is desired to improve drive performance and belt life. The notched nature of these belts allow them to bend around smaller sheaves as well, making them a great choice for drives that require smaller sheaves and tighter overall drive packages.

One thing to consider when contemplating the use of the Molded Notch construction is the fact that these belts will not slip and clutch as smoothly as the standard, wrapped belts will.  If this is desired then it is important to look at the most important features of the drive and select the best belt for your application needs.

For additional information on this or any other topic please contact Gates Product Application Engineering by phone at 303-744-5800 or by email at ptpasupport@gates.com.

*BX over 210" will have a temperature rating of -30 to 140 degrees Fahrenheit.

Learn the Terminology - Fluid Power

Lockout/Tagout:  The placement of a tagout device (LO/TO) on a power switch, in accordance with an established procedure, to indicate that the power switch and the equipment being  controlled may not be operated until the tagout is removed.

Fluid Power - Learn the Terminology

Velocity:   The time rate (speed) of linear motion in a given direction.

Viscosity:  A measure of the internal friction or the resistance of a fluid to flow.

Viscosity Index:  A measure of how viscosity changes in relation to temperature.

Installing Hose Assemblies III

Review the Safety Precautions found in previous blog posts about “Maintaining a Safe Work Environment” as well as your equipment’s operations manual before installing hydraulic hose assemblies. Installation varies depending on coupling configurations, use of adapters, and routing.

Coupling Configurations

Male fitting to port connections can be made using four types of configurations:

§  Solid male (MP, MB, MBSPT, etc.).

§  Male swivels (MPX, MBX, MIX).

§  Flanges (FL, FLH, FLC, FLK).
 

§  Block-style adapters with Lock- nuts.

Flanges

Flanges are installed using clamp halves/flange half sets. Use the following procedural steps for proper flange fitting installation:

1. Put a small amount of oil on the O-ring and place in the groove. Oil will prevent the O-ring from falling out.

2. Place fitting over port.

3. Install clamp halves over flange head and thread in bolts by hand.

4. Use torque wrench to tighten using crossing pattern.

5. Torque to manufacturer’s specifications.

Installing Hose Assemblies II

Review the Safety Precautions found in previous blog posts about “Maintaining a Safe Work Environment” as well as your equipment’s operations manual before installing hydraulic hose assemblies. Installation varies depending on coupling configurations, use of adapters, and routing.

Coupling Configurations

Male fitting to port connections can be made using four types of configurations:

§  Solid male (MP, MB, MBSPT, etc.).

§  Male swivels (MPX, MBX, MIX).

·         Flanges (FL, FLH, FLC, FLK).

·         Block-style adapters with Lock- nuts.

Male Swivel

Male swivel installation does not require hose rotation.  Install the male thread into the port and use a wrench to torque properly.  Orient the hose curvature to assist in routing, since the hose does not rotate.  Male swivels (except MIX) have internal O-rings that must be compatible with the fluid used.

Installing Hose Assemblies I

Review the safety precautions found in previous blog posts about “Maintaining a Safe Work Environment” as well as your equipment’s operations manual before installing hydraulic hose assemblies. Installation varies depending on coupling configurations, use of adapters, and routing.

Coupling Configurations

Male fitting to port connections can be made using four types of configurations:

§  Solid male (MP, MB, MBSPT, etc.).

§  Male swivels (MPX, MBX, MIX).

      ·         Flanges (FL, FLH, FLC, FLK).

·         Block-style adapters with Lock- nuts.

Solid Male

Solid male fittings are installed by rotating the entire hose assembly when the male thread is threaded into a port. For ease of installation and improved seal, Teflon® tape can be used on tapered threads.

If an O-ring is used, lubricate it with oil before installation. A poor seal can be the result of a dry O-ring sticking and pulling away from the sealing area.

Once hand-tight, use a wrench on the hex to properly torque the fitting. Since hose rotation is necessary, never use two solid males on the same hose assembly.

 

  

Maintaining a Safe Work Environment - Electrical V

Establishing a safe working environment in and around your hydraulic equipment requires a few things you must be aware of.  These include:

·         Pressure

·         Temperature

·         Flammability

·         Mechanical

·         Electrical

Electrical

Hydraulic equipment should always be turn off before starting to do work on the equipment.   Prior to working on any plant equipment, lock the control box, and tag it with a warning sign that states “DOWN FOR MAINTENANCE. DO NOT TURN ON POWER.”   If the equipment is mobile, take the key and/or disconnect the battery cables from the battery so the equipment can’t be started.

During normal equipment operation, you may be exposed to electrical hazards such as high-voltage power lines and underground power sources. Always identify these potential hazards before running the equipment. Most hydraulic hose is wire-reinforced, making it conductive to electricity. Even non-wire reinforced hose may be conductive through the rubber compound itself or moisture that penetrates a pin-pricked hose cover. Some equipment requires the use of non-conductive hose if there’s a chance of contacting power sources.

OSHA standards require that all hydraulic tools used on or near energized power lines or equipment be supplied with non-conducting hose having adequate strength for normal operating pressures [29 CFR 1926.951(f)(3)].

Faulty wiring can also be an electrical hazard. A regular preventive maintenance program should always include a wiring check.

Maintaining a Safe Work Environment - Pressure IV

Establishing a safe working environment in and around your hydraulic equipment requires a few things you must be aware of.  These include:

·         Pressure

·         Temperature

·         Flammability

·         Mechanical

·         Electricity

Flammability

All hydraulic fluids (including fire resistant hydraulic fluids) are flammable when exposed to the proper conditions.  Exceptions are those fluids comprised primarily of water.

Systems leaking pressurized hydraulic fluids that develop a mist or fine spray that come in contact with a source of ignition can flash or explode. These very severe explosions can cause serious injury or death.

Precautions should be taken to eliminate all ignition sources from contact with escaping fluids, sprays or mists resulting from hydraulic failures.  Sources of ignition could include electrical discharges (sparks), open flames, extremely high temperatures, hot manifolds, engine blocks, and sparks caused by metal-to-metal contact.

Mechanical

Unexpected mechanical motion can be dangerous. Watch out for swinging arms, booms, rollers, or presses.  Anything that moves can be dangerous if a hose fails. For example, when a hose bursts, objects supported by fluid pressure may fall and vehicles or machines could lose their brakes because of pressure loss.

Maintaining a Safe Work Environment - Pressure III

Establishing a safe working environment in and around your hydraulic equipment requires a few things you must be aware.  These include:

·         Pressure

·         Temperature

·         Flammability

·         Mechanical

·         Electricity

Pressure

Operating pressures of hydraulic systems can be up to 10,000 psi.

The dangers that could be encountered with hydraulic fluid under pressure include:

Whipping Hose:  If the hose end or end fitting comes apart under pressure, the loose hose can whip around with great force. This has the potential to cause serious injury. Restrain or shield the hose using clamps or protective shielding if this hazard exists.

Stored Energy: Hydraulic systems sometimes use accumulators to store potential energy or absorb shock. This energy can create pressure that keeps the system’s components moving.

Temperature

Hydraulic systems typically operate at 150° to 180°F, but hydraulic systems can go as high as 300°F. Liquid at these temperatures may burn skin. Metal parts (such as fittings and adapters) are also hot and may cause burns. Hoses can also become hot.