Belt Test Rigs

Test Rig for Endurance Study of Belt Transmissions

Belt Test Rig

Performance testing of power transmitting belts demands that they be studied under conditions of rated belt speeds and rated tension values continuously over a period long enough to stabilize their aging characteristics. A test bench needed to validate the design limits of performance therefore should be capable of running the belts under adjustable power transmitting conditions and adjustable wrap angles around tensioning and idling pulleys of specified diameters.

The high-end Test rig is designed and manufactured to perform endurance testing of poly-V belts, at elevated temperature fewer than 3 or 4-pulley configurations. The test rig is based on the concept of DC regeneration of braking energy. The objective of this test rig is to perform endurance testing of poly-V belts under following conditions:

  • Elevated temperature of 125°C±1oC under 3 or 4-pulley configurations
  • Belt pre-tensioned up to a maximum of 100 kg
  • Maintain the prescribed included angles of 90 degrees around the tensioning and idler pulleys and maintain wrap angles
  • 180 degrees around the driving and loading pulleys
  • Drive the belts at adjustable speeds up to 5000 rpm
  • Load the belt under dynamic conditions at adjustable loads to transmit belt power up to 16kW on continuous duty basis
  • Percentage belt slip to be within the desired limits

Test Set-up

Heating chamber: The heating chamber surrounds the belt under test. The temperature-controlled heating chamber has an air-circulating blower mounted on top of this chamber. An inspection window in front of the heating chamber serves the purpose of periodic visual inspection of belts under test.

Drive Arrangement: An AC motor working in conjunction with digital AC motor controller drives the driving pulley at adjustable speeds.

Loading Arrangement: DC motor controlled by a regenerative digital DC drive exerts load on the loading pulley and the braking energy is regenerated back to the mains. Thus power only to the extent of frictional losses is consumed from the mains.

Spindles: The spindles supporting the driving, driven and tension pulleys are engineered for high-speed operation and overhang loads. The spindles are continuously cooled and lubricated by a carefully designed oil circulating and lubrication system. An oil reservoir, oil pump and other hydraulic components forms this hydraulic circuit, which is electrically interlocked so to protect the bearings against dry running.

Belt tensioning: The specified belt tension is ensured by a motorized tensioning arrangement based on tension feedback from a load cell attached to the tensioning roller. “The auto tension corrector” automatically corrects any loss in the tension during running. The slide mechanism ensures that the included angle as well as belt length is automatically maintained without the need of any external measuring scale.

Belt Slip measurement: Set of two pulse resolvers monitoring the speeds of driving and driven pulleys serve to monitor and annunciate belt slip conditions.

Control System: PLC based control system serves all the control needs of the Test Bench. The system automates all cyclic sequencing with dynamic control of load on the driven pulley, speed of the driving pulley, belt tension, belt temperature and chamber temperature. All fault conditions are displayed on the Man-machine Interface unit (MMI) located on the face of the panel.