Too Low: Causes tooth jumping, inaccurate positioning, excessive wear on tooth tips, and abnormal noise (flapping). Correct Tension: Ensures smooth power transmission, precise synchronization, optimal belt life, and minimal noise. Too High: Increases bearing loads (potentially causing premature bearing failure), reduces belt life due to high cord stress, increases energy consumption, and can lead to excessive noise and heat generation.
Installation & Setup: Correct tension, proper alignment, and appropriate pulley selection are fundamental. Operational Loads: Operating near or above the belt's rated capacity, frequent shock loads, or severe start/stop cycles. Environmental Conditions: Exposure to excessive heat (85°C for standard neoprene), oils, chemicals, ozone, UV light, or abrasive dust. Drive Design: Inadequate pulley diameter (causing excessive bending stress), insufficient wrap angle, or improper center distance. Maintenance: Lack of regular inspection, failure to clean debris, and ignoring early signs of wear (cracking, fraying).
Precise Tension Control: Use a tension meter to set and maintain tension within the specified range. Consider automatic tensioners. Select High-Speed Belts: Use belts designed for high-speed operation, typically with smaller pitches (e.g., 3M, 5M) and low-mass, high-strength cord materials (e.g., aramid). Ensure Perfect Alignment: Use alignment tools (laser, straight edge) to achieve near-perfect pulley alignment, minimizing dynamic forces. Specify High-Quality Pulleys: Use pulleys with tight tolerances, proper tooth form, and high-quality finishes. Dynamic balancing is often necessary. Eliminate Vibration: Secure the motor and driven unit, check bearings, and ensure a rigid frame to reduce system vibration. Avoid Inertial Loads: Gradually accelerate/decelerate the system where possible to reduce inertial shock.
Insufficient Tension: The most common cause. Low tension allows the belt to ride out of the pulley grooves under load. Excessive Load/Shock Loads: Operating beyond the belt's designed power capacity or sudden impact loads can force teeth to skip. Worn or Damaged Pulleys: Pulleys with worn, chipped, or deformed teeth cannot provide proper engagement. Mismatched Belt/Pulley: Using a belt with an incorrect pitch or profile for the pulley. Loss of Tensile Member Integrity: Internal cord damage from excessive heat, contamination, or fatigue reduces belt stiffness, leading to poor tooth engagement. Severe Misalignment: Angular or parallel misalignment can cause the belt to enter the pulley at an incorrect angle, promoting jump-out.