Calculate Timing Belt Drives
To calculate a timing belt drive, you need the power, speed, gear ratio, center distance, and operating conditions. Based on this data, the appropriate timing belt profile, pulley dimensions, belt length, and required belt width are determined. For a safe and economical design, torque, service life, belt tension, and environmental conditions must also be taken into account. With the Walther Flender Belt Drive Navigator 2.0, the complete drive design—including documentation and CAD data—can be generated automatically.
With Walther Flender’s Belt Drive Navigator 2.0, timing belt drives can be designed online. The tool calculates a suitable timing belt drive based on the drive parameters and also supports multi-pulley applications.
Yes. The Belt Drive Navigator 2.0 can calculate the appropriate timing belt drive based on the entered drive parameters, even if no specific belt system has been selected beforehand.
Yes. The Belt Drive Navigator 2.0 also supports the recalculation of existing drives if the timing belt has already been preselected.
Tensioning the Timing Belt
Proper belt tension extends the service life of the timing belt and ensures trouble-free operation of the entire drive system. If the tension is too low or too high, it can increase wear and impair the function of the drive system.
Ideally, you should use the WF-TC 1.0 belt tension meter. After tapping the belt, an acoustic sensor detects the belt’s natural frequency and displays the measurement directly on the screen.
The WF-TC 1.0 is suitable for all standard timing belts, V-belts, and ribbed V-belts.
The measurement accuracy is ±1% in the range of 10 to 400 Hz and ±2% in the range of 400 to 600 Hz.
Yes. The flexible gooseneck with a small sensor head allows for measurements even on hard-to-reach belt drives.
No. The WF-TC 1.0 is shipped factory-calibrated and is ready for immediate use.
Storing Timing Belts
Timing belts should be stored in a dry place, protected from light, and at temperatures below 30 °C. Direct sunlight, moisture, heat, chemicals, and proximity to electric motors or transformers should be avoided. The recommended relative humidity is below 70%. To prevent damage to the material, timing belts must not be kinked, crushed, or bent too sharply.
Key storage conditions at a glance:
• Temperature: below 30 °C
• Humidity: below 70%
• Protect from sunlight
• Avoid contact with chemicals
• Do not store near sources of ozone
• Do not kink or crush
Inappropriate storage conditions can compromise a timing belt’s service life, dimensional stability, and performance. Proper storage helps preserve the belt’s original properties over the long term and ensures operational reliability.
During extended periods of inactivity, timing belts should be slackened. If this is not possible, it is recommended to remove them and store them separately under suitable conditions. This helps prevent deformation and loss of tension.
Synchronous belts should ideally be stored flat on a smooth surface and can be nested inside one another to save space. Larger belts may be rolled up, but care must be taken to ensure that the bending radius is not too small. This could cause permanent damage to the belt.
When stored properly, timing belts retain their properties for up to eight years. This requires suitable storage conditions in terms of temperature, humidity, and protection from direct sunlight.
Coating timing belts
For FDA applications, we recommend white PVC, white studded, and white Supergrip as suitable timing belt coatings.
White PVC, white Supergrip, herringbone profile, white studs, and sawtooth profile are particularly suitable for applications in the food industry. The best coating depends on the product weight, hygiene requirements, and conveyor speed.
For the glass industry, we recommend Novoflies, various Sylomer variants, PU films, herringbone profiles, Supergrip variants, RP400, or Viton.
Numerous coatings are available for filling and packaging systems, such as Celloflex, Sylomer, Supergrip, Teflon, EPDM, and studded coatings. The optimal solution depends on the packaging material, cycle rate, and required grip.
For the wood industry, we recommend, among other options, polyamide fabric, PU films, Supergrip coatings, Linatex, or RP400. The key factors in making this selection are abrasion load, dust generation, and the nature of the wood.
Celloflex, Sylomer, PU Yellow, Polythan, and PVC coatings are suitable for the paper industry. The appropriate solution should be tailored to the type of paper, surface sensitivity, and production speed.
For the film industry, we recommend Celloflex and PU Yellow coatings. The choice should be based on film thickness, surface texture, and the desired conveying accuracy.
Various Supergrip coatings are suitable for cardboard boxes. The optimal coefficient of friction depends on the weight, the surface of the cardboard box, and the conveyor angle.
Sylomer, yellow PU, Porol, Teflon, and sponge rubber are used for labeling machines. Precise label guidance requires coordination of the coating, speed, and product geometry.
Celloflex, Sylomer, PU Yellow, and PU Gray are used for pressure belts. The optimal coating depends on the contact pressure, material sensitivity, and process speed.
PU films, Sylomer, Correx, Linatex, and RP400 are used for pull-off belts. For best results, tensile strength, material properties, and process parameters should be taken into account.
For inclined conveying, profiled coatings with exceptional grip—such as herringbone, sawtooth, or Supergrip—are available. The steeper the incline, the more important it is to select a suitable surface texture.
Novoflies, Teflon, and Viton are used for elevated temperatures. The selection should always be based on the actual operating temperature.
For wet conveying, the Sawtooth profile, Supergrip Green, and RP400 are recommended. In addition to traction, water resistance and ease of cleaning play an important role.
Novoflies and polyamide fabrics are used for applications in dusty operating conditions. The right coating helps reduce wear and increase process reliability.
For high abrasion resistance, we recommend PU film 85°, PU film 60°, and EPDM. The optimal choice depends on the material being conveyed, contact load, and mileage.
Chrome leather, herringbone profile, and Linatrile are suitable for applications involving oil and grease. The key factors here are chemical resistance and the desired level of adhesion.
Sylomer M, Sylomer P, Correx, and Linatex are used in the cable industry.
Chrome leather is recommended for transporting pipes.
Causes of Malfunctions
Excessive noise is often caused by misaligned pulleys, excessive belt tension, overloading of the drive system, or worn pulleys. Therefore, check the alignment of the pulleys, set the recommended belt tension—for example, using the WF-TC 1.0 belt tension gauge—and replace worn components to restore smooth drive operation.
A timing belt that appears to be longer is usually the result of a changed center distance, loose fasteners, or worn pulleys. Check the center distance and all fasteners, and replace any worn components so that the drive system functions properly again.
If a timing belt drifts off-center, the timing pulleys are often not properly aligned. Carefully align the timing pulleys and shafts and check that they are parallel so that the timing belt runs centered again.
This is often caused by high axial forces resulting from misalignment or unsuitable flanges. Check the alignment of the toothed discs, use suitable flanges, and verify the stability of the bearings and shafts.
Excessive or insufficient tension, worn pulleys, or foreign objects can significantly accelerate tooth wear. Set the correct tension—for example, using the WF-TC 1.0 belt tension gauge—replace worn components, and protect the drive system from contaminants.
Tooth breakage is often caused by overload, insufficient belt tension, or too few teeth in mesh. Check the drive configuration—for example, using the Belt Drive Navigator 2.0—adjust the belt tension—for example, using the WF-TC 1.0 belt tension gauge—and, if necessary, use a wider timing belt.
A timing belt failure is often caused by overloading, pulley diameters that are too small, foreign objects, or installation errors. Be sure to follow the recommended minimum diameters, avoid overloading, and install the belt according to our recommendations.
Excessive belt tension, overloading, or foreign objects between the timing belt and the timing pulley can accelerate wear. Check the tension—for example, using the WF-TC 1.0 belt tension gauge—remove any debris, and make sure the components you’re using are compatible.
Extreme temperatures, corrosive substances, or improper tension can cause cracks in the timing belt. Use a timing belt suitable for the application and ensure that the permissible temperature and environmental conditions are observed. Walther Flender’s Application Engineering team will be happy to assist you in selecting the right belt.
Vibrations are often caused by incorrect belt tension or improper alignment of the components. Set the recommended belt tension—for example, using the WF-TC 1.0 belt tension gauge—align the pulleys precisely, and use a tensioner pulley for vibration damping if necessary.
Signs of overload include unusual noises, excessive wear, broken teeth, or vibrations. Reduce the load or select a more powerful timing belt drive to prevent further damage. For drive design, use, for example, the Belt Drive Navigator 2.0 timing belt calculation program.
Insufficient tension can cause tooth slippage and vibrations, while excessive tension puts strain on bearings, timing pulleys, and the timing belt. Check the tension regularly and adjust it according to the manufacturer’s specifications. The WF-TC 1.0 belt tension meter, for example, can help with this.
Selecting a Timing Belt
When selecting the right timing belt, the application is always the deciding factor. Whether for material handling, linear drives, or power transmission: A timing belt will only function reliably if it is consistently matched to its specific task and operating environment.
Many problems—such as excessive wear, noise, or unstable processes—are not caused by the timing belt itself, but rather by a selection that is not tailored to the specific application. What exactly is the timing belt’s function? Which requirements are most important—service life, smooth operation, positioning accuracy, or power transmission? And what factors does it face, such as chemicals, dust, or regulatory requirements like FDA or EU guidelines? In material handling applications in particular, the protection of the cargo, abrasion resistance, and the appropriate coating also play a central role. For power and lifting drives, on the other hand, both service life and cost-effectiveness are key considerations.
Selecting a timing belt that is consistently tailored to the specific application increases operational reliability, reduces the effort required for fine-tuning, and prevents the need for subsequent modifications to the drive system.
You can find the right timing belt for your application using, for example, the Belt Drive Navigator 2.0 belt calculation program. With this multi-pulley calculation program, you can not only design the optimal timing belt drive in no time, but you can also configure timing belt pulleys at the same time. Walther Flender’s Application Engineering team is also happy to assist you in selecting the optimal belt. Our team of experts has many years of experience across more than 25 industries.
In the printing and paper industry, high standards for cleanliness, low abrasion rates, precise positioning, and smooth operation are crucial. Hybrid LL timing belts and polyurethane LL timing belts are particularly well-suited for lifting and linear applications. For power transmission, Hybrid, GT3, GT4, Twinpower, and Poly Chain Carbon Volt timing belts are the preferred choices. For transport tasks involving continuous operation or vacuum technology, polyurethane LL, Flex, and molded timing belts are the optimal solution.
For woodworking machines, Hybrid, GT3/GT4, and Poly Chain Carbon Volt timing belts are suitable for power transmission; PU molded and Flex timing belts are suitable for workpiece transport; and Hybrid LL, HTD-LL, and PU-LL timing belts are suitable for lifting and positioning tasks. They enable precise positioning, low wear, and gentle material transport.
Hybrid and molded PU timing belts, Flex belts, or polyurethane belts sold by the meter—such as the Hybrid LL timing belt—are frequently used in medical technology. They enable clean, low-wear, and precise operation in sensitive applications.
Hybrid timing belts are particularly suitable for textile machines. GT3/GT4, Twinpower, and Poly Chain Carbon Volt timing belts, as well as finite polyurethane timing belts, are also frequently used. They ensure clean processes, low abrasion rates, and smooth operation.
For machine tools, Hybrid LL and HTD-LL timing belts are suitable for precise linear motion, while Hybrid, GT3/GT4, and Poly Chain Volt timing belts are suitable for power transmission. In addition, the Machine Tool timing belt was developed specifically for use in machine tools. It enables high positioning accuracy, a compact drive system, and quiet operation—even in demanding industrial environments, such as those involving coolants and lubricants.
The HYBRID LL timing belt from Walther Flender is ideal for applications with high demands on smooth operation, cost-effectiveness, and compact installation space. The HYBRID LL timing belt features a special nylon fabric that helps reduce noise, making it particularly suitable for use in noise-sensitive environments. The HYBRID LL timing belt is available in 3M and 5M pitches, enabling compact and efficient drive designs.
The PolyChain Carbon Volt timing belt is particularly well-suited for applications at very low temperatures and in deep-freeze environments. It is temperature-resistant in a range from +85°C to -54°C. In addition, Powergrip GT timing belts are available in a special LowTemp rubber compound, allowing even the neoprene belts to be used at very low temperatures.
As a high-performance belt, the PowerGrip GTX synchronous belt is ideally suited for applications involving high torque at low speeds. Thanks to its high-strength, low-elongation cord, the GTX synchronous belt is particularly resistant to shock loads.
Which timing belt lasts the longest depends heavily on the application and operating conditions. In general, however, the PolyChain timing belt is known for its long service life. Compared to traditional drive systems, the PolyChain Carbon™ Volt timing belt delivers up to 8 times more power. The carbon-fiber core ensures high strength and dimensional stability, with improved impact and fatigue resistance, lower elongation, and greater flexibility.
The extremely high-performance Poly Chain Carbon™ Volt timing belt is particularly well-suited for high speeds. Compared to conventional drive systems, it delivers up to 8 times more power. The carbon fiber core ensures high strength and dimensional stability, with improved impact and fatigue resistance, lower elongation, and greater flexibility.
PowerGrip® GT4 / GT3 ADVANCED timing belts are particularly well-suited for precise positioning tasks. They offer high positioning accuracy thanks to optimized tooth geometries, low elongation, and consistent motion transmission. This makes them ideal for automation, handling, and positioning applications.
The PowerGrip® GT4 / GT3 ADVANCED timing belts are among Walther Flender’s timing belt systems that require particularly little maintenance. They require no lubrication and no retensioning. For automatic door and gate drives, the HYBRID LL timing belts also offer maintenance-free operation thanks to their exceptionally low voltage drop.