MACHINE USED IN V-BELT MANUFACTURING

Comparative Test Rig

Comparative Test Rigs are widely used for testing the durability of production belts. These have proven more efficient as compared to others for testing and are available with one side motor and other side generator torque load, which is increased by generator. Furthermore, these are available in different models along with various specifications to fulfill the requirements.

Features:

• Slippage percentage is adjusted in rotating belts.
• Belt will be broken within hours
• Take no time to calculate torque load, RPM of motor, RPM of generator, slippage percentage
• To obtain the result of durability of the belts is very easy Dead Load Test Rig

V- Belt Process Machinery

V- Belt Process Machinery, is used in various industries. These machines are widely appreciated due to their longer functional life, easy installation, less maintenance, sturdy construction and reliability. These machines can be customized as per the specifications required.

Profile Base Calendar

Profile Base Calendars that are widely used in several industries. Specifications
Size:

• L type calendar providing 4 nos. of rollers 10” x 30”
• DC Motor 30 H.P. with Panel Box speed 0 to 200 RPM
• Cooling system with conveyer rollers
• Base winding system

Production capacity:

• 18” wide profile sheet approximately 500 meter long/hour
• For sanction SPZ belts 59 no. of base, 500 meter in length of each base/hour
• Section ‘A’ belts 49 nos. of base, 500 mtr in length of each base/hour
• Section ‘B’ belts 34 nos. of base, 500 mtr in length of each base/hour
• Section ‘C’ belts 27 nos. of base, 500 mtr in length of each base/ hour

Jacketing Machine

Jacketing Machines are specially fabricated for tight jacketing of fabric on application base. Using ideal rollers and pulley system, these machines generate the pressure at the top, side and bottom. Eliminating and throwing in line of machine, these machines are provided for rubberized fabric bobbin. In these machines, all systems are drawn by motorized system.
Specifications: Production capacity: 15 to 20 mtr. jacketing per minute

Stretching Machine

Stretching Machines that are widely used to get 100% accurate length for grading. These machines are available with 4 motors with panel box that are needed for heating the cord of the rotating belt. In addition to this, machine stops working automatically, when all the belts are being stretched at to the grading.

Finishing Machine

Finishing Machines automatically cut extra rubber cutting. In these machines, the belts are rotated automatically and the cutting process is being done itself. Used for the speed of cutting approximately 15 mtr./minute, these machines have both side extension for long size belts. Furthermore, the motor and gear boxes are provided in the closed box.

Slitting Machine

Slitting Machines that work on a special technology. With the help of this machine, 4 types of fabrics such as A,B,C & D section can be achieved easily by rotating one handle and without changing cutters. By changing the distance of the cutter holder, other different types of fabrics like S,P,Z & E can also be achieved. Moreover, for wrapping fabric strips, many bobbins are provided. For maintaining the speed of bobbins, the friction plates are provided for unwinding the fabrics.
Specifications:
a.) Size of the machine: 1.5 mtr. wide, 3.0 mtr. height and 3.0 mtr length
b.) Production capacity:

• Section SPZ fabric strip 40 no. of bobbin simultaneously
• Section ‘A’ fabric strip 35 no. of bobbin simultaneously
• Section ‘B’ fabric strip 27 no. of bobbin simultaneously
• Section ‘C’ fabric strip 22 no. of bobbin simultaneously
• Section ‘D’ fabric strip 16 no. of bobbin simultaneously
• The all strips of rubberized fabric cutting speed is 1000 mtr length/ hour simultaneously

RIGHT TIME TO REPLACE THE V-BELT

Though it is pretty difficult to predict life of a V-Belt like many other products. Since V-Belt life depends on three main factors. Manufacturing Factors Installations Factors and User Factors Manufacturing Process involves use of Quality raw material, Formulation and Process Control. Installation Factors involves Alignment, Tensioning. And User Factors involve the issue at the time of actual running times like temperature, dust, and presence of other external element. And if we can provide the best of above all, the life of and endless V-Belts can be endless too.

One way to find out is to examine the belt. If a V-belt is full of tiny cracks, frayed, has pieces of rubber missing, is peeling or otherwise damaged, it needs to be replaced -- NOW. Also, if a belt is oil soaked or "glazed" (hard shiny appearance on the sides of the belt) it also needs to be replaced. Either of these two conditions can cause the belt to run hot, which can weaken it and increase the danger of it breaking.

Unfortunately, a visual inspection alone isn't a sure-fire method of determining the true condition of a belt because internal wear that you can't see is just as important as external wear that you can see. All belts are reinforced with cords. The cords are what give the belt its strength and keep it from stretching or breaking. But as a belt ages, the constant flexing, heat and strain weakens the cords. Eventually the cords reach a point where failure can happen suddenly and unexpectedly. The belt may still look good as new on the outside, but be on the verge of snapping internally because the cords have lost their strength.

So the other factors that need to be considered when judging the condition of a V-belt include the belt's mileage and age. A V-belt that's more than three or four years old and has more than 40,000 or 50,000 miles on it may be a belt that is nearing the end of its useful service life. For this reason, you might be well advised to replace a high mileage belt even if it still looks okay

Save Energy, Replace V-Belts with Cogged or Synchronous Belt Drives

About one-third of the electric motors in the industrial and commercial sectors use belt drives. Belt drives provide flexibility in the positioning of the motor relative to the load. Pulleys (sheaves) of varying diameters allow the speed of the driven equipment to be increased or decreased. A properly designed belt transmission system provides high efficiency, decreases noise, requires no lubrication, and presents low maintenance requirements. However, certain types of belts are more efficient than others, offering potential energy cost savings.
The majority of belt drives use V-belts. V-belts use a trapezoidal cross section to create a wedging action on the pulleys to increase friction and improve the belts power transfer capability. Joined or multiple belts are specified for heavy loads. V-belt drives can have a peak efficiency of 95% to 98% at the time of installation. Efficiency is also dependent on pulley size, driven torque, under or over-belting, and V-belt design and construction. Efficiency deteriorates by as much as 5% (to a nominal efficiency of 93%) over time if slippage occurs because the belt is not periodically re-tensioned.

Cogged belts have slots that run perpendicular to the belts length. The slots reduce the bending resistance of the belt. Cogged belts can be used with the same pulleys as equivalently rated V-belts. They run cooler, last longer, and have an efficiency that is about 2% higher than that of standard V-belts.

Synchronous belts (also called timing, positive-drive, or high-torque drive belts) are toothed and require the installation of mating toothed-drive sprockets. Synchronous belts offer an efficiency of about 98% and maintain that efficiency over a wide load range. In contrast, V-belts have a sharp reduction in efficiency at high torque due to increasing slippage. Synchronous belts require less maintenance and re-tensioning, operate in wet and oily environments, and run slip-free. But, synchronous belts are noisy, unsuitable for shock loads, and transfer vibrations.
Example A continuously operating, 100-hp, supply-air fan motor (93% efficient) operates at an average load of 75% while consuming 527,000 kWh annually. What are the annual energy and dollar savings if a 93% efficient (η1) V-belt is replaced with a 98% efficient (η2) synchronous belt? Electricity is priced at $0.05/kWh.

Energy Savings = Annual Energy Use x (1 – η1/η2 ) = 527,000 kWh/year x (1 – 93/98) = 26,888 kWh/year Annual Cost Savings = 26,888 kWh x $0.05/kWh = $1,345
Considerations For centrifugal fans and pumps, which exhibit a strong relationship between operating speed and power, synchronous belt sprockets must be selected that take into account the absence of slippage. Operating costs could actually increase if slippage is reduced and a centrifugal load is driven at a slightly higher speed. Synchronous belts are the most efficient choice. However, cogged belts may be a better choice when vibration damping is needed or shock loads cause abrupt torque changes that could shear a synchronous belt’s teeth. Synchronous belts also make a whirring noise that might be objectionable in some applications.

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