Design of a Test Stand for Lifetime Assessment of Flat Belts in Power Transmission

Abstract

Flat belts are machine elements used for the power transmission between rotating elements. Compared to chain or gear drives, belt drives express advantages such as low-noise, and shock- and vibration-damping characteristics. Additionally, the simple, low maintenance and cost effective setup as well as high energy efficiency up to 98 % make them an attractive choice. Since they transfer power based on friction, they are subject to wear and consequently are expendable parts. Hence, there is a demand to increase the service lifetime of power transmission flat belts to decrease cost and downtime due to belt failure. This requires a deeper understanding on the fundamental transmission mechanics of flat belts as well as the failure mechanism limiting their lifetime. Experimental investigation is key in achieving both goals. Existing test stands are not able to replicate high performance applications and accelerating the lifetime assessment of flat belts due to limited capabilities in belt force and speed. Therefore, in this work an innovative test stand was designed and build, with a maximum belt tension of 1500 N and a maximum belt speed of 50 m/s, enabling the transfer of 75 kW. The design of the test stand was governed by modularity regarding multiple aspects. First, a variety and range of reproducible adjustable parameters were required. Second, the test stand had to be flexible regarding the emulation of possible drive configurations. Lastly, auxiliary instrumentation had to be accommodated by the test stand and its data acquisition system. The solution concepts for specific components were evaluated using morphological analysis.