Belt Tension and Shaft Load Calculator
Belt Tension and Shaft Load Calculator
How tight, measured the way you can actually measure it — deflect the span by a sixty-fourth of its length and read the force — and then the part every other belt-tension page leaves out: the resultant shaft load, in magnitude and direction, and what it does to the bearing’s rating life. The capstan relation with the groove angle done properly, the centrifugal term on both sides where it belongs, and ISO 281’s exponent to turn an over-tension into a number.
Belt tension and shaft load
7.5 kW at 1,450 rev/min, 140 mm to 280 mm pulleys on 600 mm centres, three B-section belts, a 1.2 service factor, tensioned 1.5 times the slip limit
From power to the bearing, in one line of vectors
- F_e
- effective tension — the difference between the two sides, and the only part of the tension that does any work. Everything else is there to stop the belt slipping
- T_c = m·v²
- centrifugal tension. It adds to both sides equally, so it does no work and reduces the ratio the friction can use. Negligible under about 5 m/s; at 25 m/s it is often the largest term in the belt
- γ
- the FULL included groove angle — 34, 36 or 38° on a V-pulley, and 180° for a flat belt. It is halved inside the relation, which is the step most retellings of the formula get wrong in one direction or the other
- 1/sin(γ/2)
- the wedge amplification: 3.42 at 34°, 3.24 at 36°, 3.07 at 38°. This is what a V-belt is FOR
- T_i
- installed static tension — what you set with the adjuster and measure with a deflection gauge. The only quantity on this page you actually control
- α
- the angle each span makes with the line of centres. Small on most drives, which is why the shaft load is usually quoted as simply T₁ + T₂ — and that IS the answer when the pulleys are equal
- T_i/16
- the deflection force at 1/64 inch of deflection per inch of span. The 16 is 4 × 64 / 16… more usefully: P = 4T_i·h/t, and h/t = 1/64 gives T_i/16
Worked example
7.5 kW at 1,450 rev/min, 140 mm to 280 mm pulleys on 600 mm centres, three B-section belts, a 1.2 service factor, tensioned 1.5 times the slip limit
Belt speed = π × 140 × 1450 / 60000 = 10.63 m/s, and the span is √(600² − 70²) = 595.9 mm, giving 166.6° of wrap on the small pulley
Design power = 7.5 × 1.2 = 9.0 kW, so the effective tension is 9000 / 10.63 = 847 N across three belts, or 282 N each
A 34° groove amplifies the friction by 1/sin 17° = 3.420, so μ of 0.30 behaves like 1.026 and the slip-limit ratio is e^(1.026 × 2.9077) = 19.8. A V-belt does not slip
Centrifugal tension = 0.185 × 10.63² = 20.9 N per belt. The minimum installed tension that will not slip is 282/2 × (19.8+1)/(19.8−1) = 156 N; at 1.5 times that, 234 N
Tight side = 234 + 20.9 + 141 = 396 N; slack side = 114 N. The spans lean 6.70° either side of the line of centres, so the vector sum per belt is √(396² + 114² + 2×396×114×cos 13.40°) = 508 N, and 1,524 N for three belts
So the bearing sees 1.8 times the tension that is doing the work. Tighten to twice the slip limit instead of 1.5 and the shaft load goes to 1,988 N and the ball bearing's rating life to 15% of what it was at the slip limit
To set it: deflect the span by 596/64 = 9.3 mm at mid-span with the drive stopped, and the force should be 234/16 = 14.6 N (1.49 kgf, 3.29 lbf) on one belt, or 44 N if you deflect all three together
Belt sections, and what the groove buys
| Section | Top width (mm) | Mass (kg/m) | Included groove angle (°) | Wedge amplification 1/sin(γ/2) | Effective μ at μ = 0.30 | Slip-limit ratio at 166.6° of wrap | Centrifugal tension at 10.63 m/s (N) |
|---|---|---|---|---|---|---|---|
| Z / 10 mm classical | 10 | 0.062 | 34 | 3.420 | 1.026 | 19.8 | 7.0 |
| A / 13 mm classical | 13 | 0.105 | 34 | 3.420 | 1.026 | 19.8 | 11.9 |
| B / 17 mm classical | 17 | 0.185 | 34 | 3.420 | 1.026 | 19.8 | 20.9 |
| C / 22 mm classical | 22 | 0.315 | 36 | 3.236 | 0.971 | 16.8 | 35.6 |
| D / 32 mm classical | 32 | 0.630 | 36 | 3.236 | 0.971 | 16.8 | 71.2 |
| SPZ narrow wedge | 9.7 | 0.074 | 34 | 3.420 | 1.026 | 19.8 | 8.4 |
| SPA narrow wedge | 12.7 | 0.120 | 34 | 3.420 | 1.026 | 19.8 | 13.6 |
| SPB narrow wedge | 16.3 | 0.195 | 34 | 3.420 | 1.026 | 19.8 | 22.0 |
| SPC narrow wedge | 22 | 0.375 | 36 | 3.236 | 0.971 | 16.8 | 42.4 |
| Flat belt (no groove) | — | 0.150 | 180 | 1.000 | 0.300 | 2.4 | 16.9 |
The force-deflection method, and the makers’ own rules
| Step | What to do | Who says so |
|---|---|---|
| Span | t = √(C² − ((D − d)/2)²). Not the centre distance — the tangent length between the pulleys. | TB Wood’s Tensioning Drives prints the formula in exactly this form. |
| Deflection | 1/64 inch of deflection per inch of span. In metric that is 15.625 mm per metre; European makers generally round it to 16 mm per metre, which is 2.4% more deflection. | TB Wood’s: “the deflection height (h) is always 1/64″ per inch of span length (t)”. Gates give the same figure. |
| Where | Perpendicular to ONE belt, at the mid point of the span, with the drive stopped. | TB Wood’s. That the drive is stopped matters: the centrifugal tension is absent, so the force measures the installed static tension and nothing else. |
| Multiple belts | Multiply the FORCE by the number of belts you are deflecting. Do not multiply the deflection distance. | Gates: “you must multiply the deflection force by the number of strands that you will be deflecting”, and for a PowerBand the distance is “not multiplied by the number of ribs”. |
| A new belt | Goes on tighter, and drops fast. Recheck within the first 24 hours. | TB Wood’s: initial tension at twice the tabulated minimum, falling “rapidly during the first few hours”, with retensioning between the minimum and 1.5 times it. Gates: “any belt that has not been run more than about 24 hours is considered a new belt”. |
| Which force | A maker’s tabulated force for your section, sheave diameter and speed beats the one on this page. | TB Wood’s table is indexed by section, small sheave diameter, speed range AND drive ratio. It is also sized for the belt’s RATED power, not for the power you happen to be transmitting, which is why a tabulated figure is usually higher than the one computed here for a lightly loaded drive. |
What each extra turn on the adjuster costs — the default drive, tension by tension
| Tension margin over the slip limit | Installed tension (N) | Tight side (N) | Slack side (N) | Total shaft load (N) | Shaft load (%) | Ball-bearing life (%) | Roller-bearing life (%) | Deflection force per belt (N) |
|---|---|---|---|---|---|---|---|---|
| 1.00 | 156.2 | 318.2 | 35.9 | 1,060 | 100.0 | 100.0 | 100.0 | 9.76 |
| 1.10 | 171.8 | 333.8 | 51.6 | 1,152 | 108.7 | 77.8 | 75.6 | 10.74 |
| 1.25 | 195.2 | 357.2 | 75.0 | 1,292 | 121.9 | 55.2 | 51.7 | 12.20 |
| 1.50 | 234.3 | 396.3 | 114.0 | 1,524 | 143.8 | 33.6 | 29.8 | 14.64 |
| 1.75 | 273.3 | 435.3 | 153.1 | 1,756 | 165.7 | 22.0 | 18.6 | 17.08 |
| 2.00 | 312.3 | 474.4 | 192.1 | 1,988 | 187.6 | 15.1 | 12.3 | 19.52 |
| 2.50 | 390.4 | 552.4 | 270.2 | 2,453 | 231.5 | 8.1 | 6.1 | 24.40 |
| 3.00 | 468.5 | 630.5 | 348.3 | 2,918 | 275.3 | 4.8 | 3.4 | 29.28 |
Every relation this page uses, and where it comes from
| Quantity | Expression | Source |
|---|---|---|
| Belt speed | v = π·d·n / 60000 m/s (d in mm) | Definition. |
| Span | t = √(C² − ((D − d)/2)²) | TB Wood’s, printed in this form. Identical to the chain drive’s tangent length — see the chain length calculator. |
| Arc of contact | θ_small = π − 2·asin((D − d)/2C) | Plain geometry, and the same expression as the chain wrap angle. |
| Effective tension | F_e = P_design / v | Definition. P_design is the power times the service factor. |
| Centrifugal tension | T_c = m·v² | Khurmi. The Cambridge DANotes call ρv² “often conveniently if erroneously referred to as the centrifugal tension” — it is a tension that does no work and must be taken off BOTH sides before the friction relation is applied. |
| Tension ratio | (T₁ − T_c)/(T₂ − T_c) = e^(μθ/sin(γ/2)) | Khurmi writes it as 2.3 log(T₁/T₂) = μθ·cosec β with β the groove HALF angle; Cambridge as f ≡ μ∗cosec β. γ here is the FULL included groove angle, so γ/2 is Khurmi’s β. A flat belt is γ = 180°, where sin(90°) = 1 and the expression becomes the plain capstan relation. |
| Minimum installed tension | T_i,min = (F_e/2)·(R + 1)/(R − 1), R = e^(μ_eff·θ) | Follows from T₁ − T₂ = F_e and the ratio above, with T₁ + T₂ = 2(T_i + T_c). This is the tension at which the belt is exactly on the point of slipping. |
| Tight and slack sides | T₁ = T_i + T_c + F_e/2, T₂ = T_i + T_c − F_e/2 | The belt’s length is fixed, so T₁ + T₂ is set by the installed tension and the speed, and the difference by the power. |
| Resultant shaft load | R = √(T₁² + T₂² + 2·T₁·T₂·cos 2α), sin α = (D − d)/2C | DERIVED HERE. No source consulted in this batch printed it. The two spans are tangent to both pulleys and symmetric about the line of centres, each inclined to it by α, so the pulley feels the vector sum. It collapses to T₁ + T₂ when the pulleys are equal. Confirmed three ways over 500 random geometries: the closed form, a component sum, and an explicit tangent-point construction. |
| Direction of the shaft load | atan2((T₁ − T₂)·sin α, (T₁ + T₂)·cos α), off the line of centres | Same derivation. It leans toward the tight side, and the lean is small — a few degrees on a normal drive — which is why the load is usually taken as acting along the line of centres. |
| Deflection distance | h = t / 64 | TB Wood’s and Gates. |
| Deflection force | P = 4·T_i·h/t = T_i/16 at h/t = 1/64 | DERIVED HERE by string statics, and shown to be 0.049% below the exact 2T_i·sin(arctan 2h/t). |
| Bearing life | L₁₀ ∝ (C/P)³ for a ball bearing, (C/P)^(10/3) for a roller bearing | ISO 281. Only the exponent is used. |
The tension is the easy half. The bearing is the other half
Every belt-tensioning page stops at the tension. The bearing does not. Tensioning a belt correctly is the easy half: measure the span, deflect it by a sixty-fourth of its length at mid-point with the drive stopped, and read the force. The hard half is that the tension you set does not go into the belt and stay there. It goes into the shaft, and from the shaft into two bearings, as a resultant that is the vector sum of the tight and slack side tensions — on the default drive here, 1.8 times the tension that is actually doing the work. And bearing life does not go with load; it goes with load cubed. That is why over-tensioning is the commonest cause of premature bearing failure on a belt drive, and why this page does not end at the tension.
The number nobody prints. The two belt spans are tangent to both pulleys, so they are symmetric about the line of centres and each leans away from it by α, where sin α = (D − d)/2C. The pulley therefore feels T₁ along one span and T₂ along the other, and the resultant is √(T₁² + T₂² + 2T₁T₂·cos 2α) — which collapses neatly to T₁ + T₂ when the pulleys are the same size, which is the form everybody quotes. It also has a direction, a few degrees off the line of centres toward the tight side, and that direction is what tells you which way to orient a self-aligning housing. None of the belt-drive material consulted in this batch printed either the magnitude or the direction. It is elementary statics; it is also the whole reason for this page, so it was derived here and then checked three independent ways over 500 random geometries — the closed form, a component sum, and an explicit construction that finds the tangent points on the two circles numerically and adds the vectors.
Why a V-belt essentially never slips, and why that is a problem. The capstan relation for a flat belt is (T₁ − T_c)/(T₂ − T_c) = e^(μθ). Put the belt in a groove and the wedging action multiplies the effective friction by 1/sin(γ/2), γ being the full included groove angle: 3.42 at 34°, 3.24 at 36°, 3.07 at 38°. So a modest μ of 0.30 behaves like 1.03, and over 166° of wrap the belt can hold a tension ratio of about 20 — against about 2.4 for the same belt running flat. The consequence is that slip is almost never the binding constraint on a V-belt drive, which is exactly why makers publish a deflection-force table rather than asking you to compute a slip limit, and exactly why over-tensioning is so easy to do: there is no audible feedback. A belt that is 60% too tight sounds better than one that is 10% too loose.
The centrifugal tension belongs on both sides, and it does no work. T_c = m·v², and it adds equally to the tight and the slack side, so it must be subtracted from both before the friction relation is applied — the Cambridge engineering notes go so far as to call ρv² “often conveniently if erroneously referred to as the centrifugal tension”, because it is a tension in the belt that transmits nothing. Below about 5 m/s you can ignore it. At 25 m/s it is often the largest single term, and Khurmi’s condition for maximum power transmission says the useful limit is reached when it hits one third of the total: past that, running faster transmits LESS power. The page prints its share of the tight-side tension so you can see where you are.
What a new belt needs, and what this page will not do. A new belt is set tighter and loses it fast: TB Wood’s put the initial tension at twice their tabulated minimum, say it falls “rapidly during the first few hours”, and ask for a recheck inside 24 hours, with retensioning between the minimum and 1.5 times it — Gates define a new belt as one that has run less than about 24 hours. Where your maker publishes a deflection force for your section, sheave diameter and speed, use theirs: their table is indexed by four things this page does not ask about, and it is sized for the belt’s RATED power rather than the power you are transmitting, which is why a tabulated figure is usually higher than the one computed here for a lightly loaded drive. And this page will not compute a belt length or a centre distance for a given belt — that is a different calculation and the site already answers it elsewhere. What it will do is take the span, which is what the deflection is measured over, and carry the tension all the way to the bearing. The service factor that starts it off comes from the drive service factor calculator; the same shaft-load question on a chain drive is a different shape, because a chain has no slack-side tension to speak of — see the roller chain selection calculator and the chain length and centre distance calculator.
Frequently asked questions
How tight should a V-belt be?
Tight enough not to slip and no tighter, and the two ends of that range are further apart than people expect. The slip limit on the default drive here is 156 N of installed tension per belt. Practice sits somewhere between about 1.3 and 2 times that: below about 1.3 the slack side is nearly dead and a shock load or a start will let the belt slip and glaze, and above about 2 you are paying for it in bearing life. The correct answer, when you can get it, is the deflection force your belt maker publishes for your section, your small sheave diameter and your speed — their table is indexed by four variables and supersedes this calculation.
How do I measure belt tension without a gauge?
With a rule and a spring balance, by the force-deflection method. Measure the span — the tangent length between the pulleys, which is √(C² − ((D − d)/2)²) and not the centre distance. Deflect it at mid-span by 1/64 inch per inch of span, which is 15.625 mm per metre; European makers usually round that to 16 mm per metre, 2.4% more. Push perpendicular to ONE belt with the drive stopped and read the force. On the default drive that is 9.3 mm of deflection and 14.6 N of force. If you deflect several belts at once, multiply the force by the number of belts — Gates’ rule — and do not multiply the distance.
Why is the shaft load so much bigger than the useful tension?
Because only the DIFFERENCE between the two side tensions does any work, and the bearing feels something close to the SUM. On the default drive the effective tension is 847 N and the resultant shaft load is 1,524 N, a factor of 1.8. Everything above the effective tension is there to stop the belt slipping, and all of it is carried by the bearings. That ratio is worst on a lightly loaded, heavily tensioned drive, which is the commonest way a belt drive is set up: three belts where two would do, tightened by feel.
Why does over-tensioning kill bearings?
Because of one exponent. ISO 281 makes a bearing’s basic rating life go as the load raised to the power 3 for a ball bearing and 10/3 for a roller bearing. So a 30% over-tension, which raises the shaft load by roughly 30%, leaves about 45% of the rating life; doubling the tension leaves about an eighth. Nothing about the drive sounds or looks different — a V-belt has so much friction reserve that it will not squeal to tell you — and the bearing fails eighteen months later, where nobody connects it to the adjuster. The table on this page prints the life against the tension so the trade is visible before the spanner goes on.
What is the groove angle for, and what happens with a flat belt?
The groove wedges the belt, so a given belt tension presses harder on the pulley faces than it would on a flat rim, and the effective friction coefficient becomes μ ÷ sin(γ/2) with γ the full included groove angle. At 34° that is a multiplier of 3.42. Over 166° of wrap it turns a tension ratio of about 2.4 into about 20. Select the flat-belt option on this page and the groove term collapses — sin(90°) is 1 — and you can see the whole difference in the results. Note that γ is the FULL angle: Khurmi’s relation is written with the HALF angle β, so μθ·cosec β there is μθ/sin(γ/2) here. Getting that factor of two wrong changes the tension ratio by a large factor in either direction.
Does the centrifugal tension matter?
Below about 5 m/s, no — it is well under a per cent of the tight-side tension. Above about 20 m/s it is one of the largest terms in the belt, and it is worse than useless: T_c = m·v² adds equally to both sides, so it raises the tension the belt has to carry without raising the difference that does the work. Khurmi’s condition for maximum power says the useful limit is where the centrifugal tension reaches a third of the total; beyond that, a faster belt transmits less power. The page prints T_c and its share of the tight side. It needs the belt’s mass per metre, which is a product property — the defaults per section are typical figures and your belt maker’s number is better.
Does this page give me the belt length?
No, deliberately. It computes the SPAN — the tangent length between the pulleys — because that is what the deflection is measured over, and a span is not a belt length. Belt length and centre distance are a separate calculation and this site already answers it on its own page, so duplicating it here would put two pages in competition for the same question. What you get here is the other half: what the tension you set does to the shaft and the bearings.
Where does the resultant shaft load formula come from?
It was derived for this page, because none of the sources consulted printed it. The two spans are tangent to both pulleys, so they are symmetric about the line of centres and each is inclined to it by α with sin α = (D − d)/2C. The pulley feels T₁ along one and T₂ along the other, so the resultant is √(T₁² + T₂² + 2T₁T₂·cos 2α) and its direction leans toward the tight side by atan2((T₁ − T₂)sin α, (T₁ + T₂)cos α). Three checks were run over 500 random geometries: the closed form against a component sum, and both against an explicit construction that locates the tangent points on the two circles numerically and adds the vectors. All three agree to twelve figures, and with equal pulleys all three give T₁ + T₂, which is the textbook special case.
Related calculators
References
- TB Wood’s (Altra Industrial Motion). Tensioning Drives, catalogue section BEV-1, P-1686-TBW. “The deflection height (h) is always 1/64″ per inch of span length (t)”, with the span itself “t = √(C² – ((D–d)/2)²)”; the force applied “perpendicular to any ONE of the belts at the mid point of the span”; initial tension at twice the tabulated minimum, falling “rapidly during the first few hours”, with retensioning between the minimum and 1.5 times it; and, on an older drive, excessive tension leading to “excessive bearing load or excessive shaft deflection”.
- Gates Corporation. Design Flex force/deflection tensioning (Gates Belts, Hoses and Applications). Confirms the same “1/64 of an inch per inch of span length”, and adds two rules this page uses: on a multiple-belt drive “you must multiply the deflection force by the number of strands that you will be deflecting”, and “any belt that has not been run more than about 24 hours is considered a new belt”.
- R.S. Khurmi and J.K. Gupta, A Textbook of Machine Design, chapter 21 Chain Drives and chapter 20 V-Belt and Rope Drives (the chapters as distributed by Al-Mustansiriyah University and Al-Mustaqbal University). Source for Table 21.2, factor of safety for bush roller chain against the smaller sprocket’s speed; for the service factor as K1 × K2 × K3 (load, lubrication, hours); for the recommended teeth on the smaller sprocket against velocity ratio; for the V-belt tension ratio 2.3 log(T1/T2) = μθ cosec β with β the groove HALF angle and a groove angle of 32° to 38°; for the centrifugal tension Tc = mv²; and for the maximum-power condition Tc = T/3.
- University of Cambridge, Department of Engineering. DANotes: V-belt drives — Kinetics and fatigue. Gives the tension ratio with the centrifugal term separated, “(Fmax − ρv²)/(Fmin − ρv²) ≤ e^(fθ)min”, and the effective friction coefficient “f ≡ μ∗cosec β” with β the groove half angle. It also calls ρv² “often conveniently if erroneously referred to as the centrifugal tension”, which is why this page subtracts it from both sides rather than adding it to the load.
- ISO 281:2007, Rolling bearings — Dynamic load ratings and rating life. Cited by number for the life exponent only: basic rating life goes as (C/P) raised to 3 for a ball bearing and 10/3 for a roller bearing. That exponent is what turns a 30% over-tension into a bearing-life figure on this page, and it is the only thing taken from the standard.
- BestORQ. V-Belt Quick Selection Guide. The V-belt service factor table used here: four driven-machine groups with their named examples, driving Group 1 (normal-torque AC, shunt-wound DC, multiple-cylinder engines) against Group 2 (high-torque and single-phase AC, series and compound-wound DC, single-cylinder engines), and three service bands — intermittent 3–5 hours, normal 6–16 hours, continuous 16–24 hours or a start above 200% of rated load. Also the idler additions: inside slack side 0.0, outside slack side 0.1, inside tight side 0.1, outside tight side 0.2.
