Browse Topic: Timing belts

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Using a System Reliability Model to Optimize Maintenance Costs A Best Practices GuideJA6097_201905 (Current)5/26/2026
SAE JA6097 (“Using a System Reliability Model to Optimize Maintenance”) shows how to determine which maintenance to perform on a system when that system requires corrective maintenance to achieve the lowest long-term operating cost. While this document may focus on applications to Jet Engines and Aircraft, this methodology could be applied to nearly any type of system. However, it would be most effective for systems that are tightly integrated, where a failure in any part of the system causes the entire system to go off-line, and the process of accessing a failed component can require additional maintenance on other unrelated components.
HM-1 Integrated Vehicle Health Management Committee
AI Model Creation and System Verification of “Telemotion” Infrastructure-Cooperative Autonomous Driving System Using Digital Twin2026-01-02554/7/2026
The concept of the vehicle has changed as a result of many innovations over the last decade in the fields of connected, autonomous/automated, shared, and electric (CASE) technologies. At the same time, labor shortages in Japan are becoming more serious due to a decline in the working population. To help resolve these issues, a remote-controlled autonomous vehicle driving system called Telemotion has been developed that automates the movement of vehicles in production plants. This system is an autonomous driving and transportation system in which the recognition, judgment, and operation functions of driving are handled by a control system outside the vehicle that communicates wirelessly with the vehicle. This system utilizes artificial intelligence (AI) and other advanced technologies to realize safe unmanned autonomous driving, and is already in operation in production plants. Currently, efforts are under way to build a digital twin environment and conduct AI learning using computer graphics (CG) to configure the system and improve the accuracy of the AI models with the aim of expanding its use to other factories. Within this digital twin environment, it is possible to examine previous tasks by reproducing the vehicles, processes, cameras, and vehicle movements present at a production site. Utilizing this digital twin enabled a significant reduction in the labor required to implement the system.
Hatano, Yasuyoshi, Iwazaki, Noritsugu, Nagafuchi, Yuhei, Iwahori, Kento, Tanaka, Atsushi, Uezu, Satoru, Kanou, Takeshi, Inoue, Go, Okamoto, Yuki, Oka, Yuhei, Kakuma, Daisuke, Chiba, Hiroya, Egashira, Kazuki, Ishikuro, Megumi, Sawano, Takuro
Experimental Modal Analysis Study on Graphene Filled SBR2021-28-022510/1/2021
Rubbers are widely used in many engineering applications such as tubes, timing belt, tires etc. Apart from its functional use, it can also be used as damping material in many applications in order to dampen the vibrations transmitted from one structure to another. The present research work focuses on the development of Graphene filled (CB) Styrene-Butadiene Rubber (SBR) and its performances are compared with Carbon Black (CB) filled SBR. Both of these rubber samples were investigated for its mechanical properties such as hardness and tensile strength. Experimental modal analysis (EMA) was also carried out to examine the dynamic characteristics such as damping and natural frequency along with its mode shapes for the prepared samples and compared. It is observed from the results that the inclusion of graphene in SBR improved its vibrational characteristics in addition to the improvement of mechanical properties.
Natarajan, Ravikumar, S, Rizwan Asif, C, Sivakumar, Manohar, D Murali
Electric-Drive Battery Pack System: Functional GuidelinesJ2289_202108 (Current)8/3/2021
This SAE Information Report describes common practices for design of battery systems for vehicles that utilize a rechargeable battery to provide or recover all or some traction energy for an electric drive system. It includes product description, physical requirements, electrical requirements, environmental requirements, safety requirements, storage and shipment characteristics, and labeling requirements. It also covers termination, retention, venting system, thermal management, and other features. This document does describe guidelines in proper packaging of the battery to meet the crash performance criteria detailed in SAE J1766. Also described are the normal and abnormal conditions that may be encountered in operation of a battery pack system
Battery Standards Testing Committee
Report on Unmanned Ground Vehicle ReliabilityJ2958_202002 (Current)2/24/2020
This information report is applicable to the reliability characteristics of unmanned ground vehicles.
G-41 Reliability
Performance Engine Building Recommended PracticesJ2379_201910 (Current)10/3/2019
This SAE Recommended Practice applies to the function of building reciprocating spark-ignition engines which are used in conjunction with standard and high-performance ancillary components in applications intended to achieve a minimum of 1 hp/in3. This document does not apply to rebuilt engines which may only be partially repaired with little or no machining, nor does it apply to second-hand or used engines.
Motor Vehicle Council
Noise Problem Resolution and Sound Quality Improvement of Valve Timing Belt in 4 Cylinders PFI Gasoline Engine2019-01-07834/2/2019
IC Engine Timing belt is a major noise prone area and it takes time during development to achieve acceptable NVH characteristics. In an existing engine under series production noise problem observed due to excitation of timing belt span by crank timing sprocket tooth. From vehicle perspective noise was heard in vehicle cabin at around idling RPM and a second peak observed around twice the initial RPM. This paper includes a methodology for use of computer based analytical simulation methods to predict timing belt dynamic behavior and NVH characteristics. Along with development of computer based multi body dynamic model for timing belt, validation of simulation model with actual testing was done and after correlation of testing and simulated results countermeasure were finalized based on iterations in multi body simulation model. Multi body dynamics model of timing drive indicated resonance in one belt span when belt transverse vibration amplitude was converted from time domain to frequency domain using FFT. In an existing engine layout change to modify belt span length was not feasible to avoid resonance, other alternatives like reduction of belt natural frequency (by increasing belt mass density, tension reduction etc.) were explored using parametric simulation model. Final solution to avoid belt resonance in engine working RPM range was proposed as reduction of belt natural frequency by modifying the belt tension. Above proposal was checked on engine bench and anechoic vehicle test showed noise reduction of 5 and 11 dB at first and second harmonic respectively due to avoidance of resonance in engine working RPM range. Multi body dynamic simulation model helped to drastically reducing the number of testing trials/combination used to resolve the NVH issue of timing belt.
Poonia, Sanjay, Singh, Amandeep, Singh, Jaspreet, Sharma, Shailender, Kumar, Narinder
Study of a Turbocharged Engine for Motorbike Application2018-32-007910/30/2018
Nowadays, the engine charging practice is widely adopted in the automotive field in relation to the “downsizing” technology: the reduction of the displacement and the adoption of a higher boost pressure, through a charging system, allow shifting the engine operating point in a zone of higher efficiency for a given engine torque. On the other hand, given a certain displacement, a supercharger can be adopted to increase the performance of the engine. The objective of this work is to provide a detailed analysis about the feasibility of the implementation of a charged engine to a motorbike, with main focus on the possibility to achieve a challenging performance target: in a first stage, several engine architectures (In-line, V-configuration, Boxer) together with different charging concepts (centrifugal or volumetric compressor, with mechanical or fluid-dynamic connection to the engine) have been analyzed from the point of view of packaging. In a second part, a V4 engine architecture has been selected for a patrol motorcycle application: the conceptual investigation of the base engine design has been carried out with the development target of lowest possible weight and size. Several concepts of crankcase, lubrication system and clutch, type and position of gearbox and timing belt have been analyzed. Once the best configuration has been selected, the specific performance requirements of the engine have been analyzed via 1D gas-exchange simulations and a charging strategy together with optimized valve timing, intake manifold and exhaust manifold have been found out. In a last step, the mechanical analysis of the crankshaft has been performed. The calculation of the cranktrain dynamics as well as the stress distribution under the most critical load conditions allowed to define the main web parameters with the aim of preventing fatigue failure of the crankshaft.
Bevilacqua, Vincenzo, Corvaglia, Giovanni, Fuoss, Klaus, Penzel, Matthias
Energy Management Through Direct Drive Servo TechnologyTBMG-272688/1/2017
Direct drive servo motor and drive technology has many advantages. It reduces an axis’ parts count, mechanical losses, and often its objectionable noise. What’s more, it also increases the machine’s efficiency, lowering operation cost for the user due to its inertia ratio as compared to the more common mechanically advantaged multi-body axis designs. Reducing the mechanical transmission components (gearboxes, timing belts, pulleys, cams, lead screws, etc.) between the motor and its load is only part of the savings.
New 1.0L I3 Turbocharged Gasoline Direct Injection Engine2017-01-10293/28/2017
To comply with the environmental demands for CO2 reduction without compromising driving performance, a new 1.0 liter I3 turbocharged gasoline direct injection engine has been developed. This engine is the smallest product in the new Honda VTEC TURBO engine series (1), and it is intended to be used in small to medium-sized passenger car category vehicles, enhancing both fuel economy through downsizing, state-of-the-art friction reduction technologies such as electrically controlled variable displacement oil pump and timing belt in oil system, and also driving performance through turbocharging with an electrically controlled waste gate. This developed engine has many features in common with other VTEC TURBO engines such as the 1.5 liter I4 turbocharged engine (2) (3), which has been introduced already into the market. Some of these are the rapid combustion concept realized by high tumble intake port design and the optimized combustion chamber configuration combined with a side mounted multi-hole direct injection system. In addition to VTC (valve timing control system), the VTEC (Variable valve timing and lift electronic control system) has been used in the intake valve system in order to realize an Atkinson cycle to reduce fuel consumption in low valve lift mode. Investigation results show that side-mounted direct injection has potential comparable to that of central-mounted direct injection in terms of mixture homogeneity and combustion chamber wall wetting, while no disadvantage in combustion performance was observed. Through such technologies, this developed engine achieved top level of fuel consumption characteristics in this class, contributing to improve the fuel economy by 26% from the previous engine in NEDC (new European driving cycle) mode.
Shibata, Mitsuhiro, kawamata, Masashi, Komatsu, Hirotaka, Maeyama, Kazuki, Asari, Masaru, Hotta, Naoki, Nakada, Kazutaka, Daicho, Hisashi
NEW ENGINES 201616MEIP03_033/1/2016
Highlighting the design, engineering, and technologies inside some of the most competitive new gasoline and light-duty diesel ICEs. Engine history bonus question for 100 points: What technology has been shared by the P-47 Thunderbolt fighter plane, Oldsmobile's 1962 Jetfire V8, the Saab 99 Turbo, and the 2016 BMW M4 GTS? Answer: Water injection, a proven technique for raising the knock threshold, enabling a higher compression ratio for more power output over a wide operating range. Water injection is particularly effective in highly boosted engines, hence BMW's adoption of it in a limited-production run of M TwinPower 3.0-L Turbo inline six units powering the track-day-focused M4 GTS.
Brooke, Lindsay, Birch, Stuart, Buchholz, Kami, Weissler, Paul
NEW ENGINES 201616AUTP02_022/1/2016
Highlighting the design, engineering, and technologies inside some of the most competitive new gasoline and light-duty diesel ICEs. Engine history bonus question for 100 points: What technology has been shared by the P-47 Thunderbolt fighter plane, Oldsmobile's 1962 Jetfire V8, the Saab 99 Turbo, and the 2016 BMW M4 GTS? Answer: Water injection, a proven technique for raising the knock threshold, enabling a higher compression ratio for more power output over a wide operating range. Water injection is particularly effective in highly boosted engines, hence BMW's adoption of it in a limited-production run of M TwinPower 3.0-L Turbo inline six units powering the track-day-focused M4 GTS.
Brooke, Lindsay, Birch, Stuart, Buchholz, Kami, Weissler, Paul
Demands on Future Timing drives - Chain and Belt in Competition2015-01-12754/14/2015
When designing a new internal combustion engine, the choice of technology for the timing drive system is one of the key decisions that determines the overall characteristics of the engine with far reaching implications on the remaining architecture and overall packaging of the engine. For Passenger car engines there are two mainstream technologies: toothed belts and chains. Each of these offers several sub-variants, such as dry vs. wet belt, or toothed vs. roller chain. This paper examines the differences between these technologies in relation to the key engine attributes including package, cost, weight, durability, NVH and frictional losses. A quantitative evaluation is made where possible, based on data collected from recent engine development programs, backed up by literature study and data from the component supply industry. These differences are reviewed in the light of current and expected future engine development trends in order to give a basis for the engine designer to choose the appropriate technology for coming years.
Schoeffmann, Wolfgang Johann, Truffinet, Caroline, Howlett, Michael, Ausserhofer, Norbert, Zurk, Andreas
Development of Indigenous Methodology for Design and Dynamic Analysis of Engine Valve Train System with Timing Chain Drive for High Speed Applications2015-26-00221/14/2015
In the pursuit of design and development of efficient, reliable and durable system and components for modern engines, there is a need to understand complications involved in building mathematical models for simulation. Valve train and timing drive systems are having higher rankings for addressing these attributes. Hence, a new comprehensive multi body dynamics model is built and equations are solved by state-variable approach. Model developed is validated and in order to probe into details of Hydraulic Lash Adjuster (HLA) behavior and coupled analysis of timing chain drive systems for valve train system, simulation is carried out to freeze design options. Engine timing drives used in engines are one of the most critical systems. Timing chains are preferred widely in modern high speed engines as compared to timing belts and gear drives. In spite of advantages of chain drive systems, their complex dynamic behavior is not well researched. The major objective of the current work is to design & develop timing chain drive and valve train system for a high speed three cylinder diesel engine and investigate about its durability. In this research work, dynamic model of type-2 valve train with HLA and chain drive with hydraulically operated tensioners is built in GT valve train software. The final goal is to optimize the valve train and timing system performance by simulation. The results related to timing chain analysis are expressed in terms of parameters such as contact forces, normal forces between different components and link tension etc. The effectiveness of this model calibration technique was confirmed through comparison of unit dynamic characteristics in an excitation test and a calibrated simulation. The proposed simulation process is validated experimentally and has shown considerable reduction in development time with improved robustness.
Mulik, Rakesh, Ramdasi, Sushil S
Improvements in Fuel Efficiency through Improvements in Cord Reinforcements for Timing Belts2012-01-17509/10/2012
The overhead camshaft engine efficiency can be improved by control of the rotation and phase of the cam shaft rotation. The aim of this paper is to show the improvements that have been made to the cam shaft rotation through the improvements in the timing belt, and in particular the reinforcing cords within the timing belt. The current state of the art of timing belt reinforcement is presented, and an independent study of the fuel efficiency of a modern timing belt compared to the efficiency of a fully optimised gasoline engine with a timing chain. This considers the power losses due to friction as the timing belt (or chain) transmits power from crank to cam, the power losses expressed as vibrations and noise, the variations in speed of cam rotation for different designs of timing belt, and also consistency of cam rotation through the life of the timing belt (or chain). The improvements have been quantified from engine studies of engine efficiency, engine dynamics, engine friction measurements, accelerometer studies for NVH behaviour and from these the benefits in fuel economy and CO2 emissions were quantified. Novel systems that use a timing belt running within the engine immersed in oil are discussed. These have been adopted on two engines to date, with significant interest and development projects under way. Of concern to the motorist are not only fuel efficiency but also the cost and frequency of changing a timing belt. The historical mechanisms will be discussed of the changes in timing belts that control the belt durability. The improvements in reinforcing cord design and performance that contribute to life-of-engine belts will be presented, together with cord and belt developments that increase the durability and reliability of the timing belt even further.
Stevens, Chris A., Hayes, Craig H.
Automotive Synchronous Belt DrivesJ1313_201208 (Current)8/14/2012
The following information applies to automotive camshaft drives, distributor drives, or other underhood drives that may require synchronization. For other power transmission drives requiring synchronization, refer to Specifications for Drives using Synchronous Belts (MXL, XL, L, H, XH and XXH belt sections) (IP 24/1978), published jointly by the Rubber Manufacturers Association (RMA), the Mechanical Power Transmission Association (MPTA), and the Rubber Association of Canada (RAC).
Belt Drive (Automotive) Systems Committee
SI (Metric) Synchronous Belts and PulleysJ1278_201207 (Current)7/5/2012
Synchronous belt drives consist of a toothed belt which mates with grooved pulleys to provide a precise speed ratio between the driver and driven pulleys. This SAE Standard covers the synchronous belt and pulley sections currently in use in automotive applications such as camshaft, distributor, and other underhood drives that may require synchronization. It also provides for future sections to be added as usage develops.
Belt Drive (Automotive) Systems Committee
Development of Design and Engineering Recommendations for In-Vehicle Alphanumeric MessagesJ2831_201204 (Historical)4/26/2012
This Information Report provides recommendations for alphanumeric messages that are supplied to the vehicle by external (e.g., RDS, satellite radio) or internal (e.g., infotainment system) sources while the vehicle is in-motion. Information/design recommendations contained in this report apply to OEM (embedded) and aftermarket systems. Ergonomic issues with regard to display characteristics (e.g., viewing angle, brightness, contrast, font design, etc.) should review ISO 15008.
Driver Vehicle Interface (DVI) Committee
A Method to Calculate the Natural Frequency of the Timing Belt Drive2011-28-014010/6/2011
A method to calculate the Natural frequency of the Timing belt drive is developed and validated. Timing belt drives are widely used in the automotive engines for valve actuation drives where accurate motion and force transmission is utmost necessary. Natural frequency is an important parameter to understand the vibration behavior of a system. Previous studies have found the Natural frequency and frequency response of the timing belt with experimental method and with FEA/ MBD software. In this study attempt has been made to develop a tool which will require basic material properties to calculate the natural frequency. Complete timing belt drive system is divided into set of standard components/elements. The belt tooth is divided in four layers and stiffness calculation is based on apparent modulus of elasticity derived from form factor. For belt pulley tooth analogy with cantilever beam is used. The model can be used for trapezoidal shaped timing belt as well as for other forms of the tooth. The belt drive level mathematical model is developed by calculating the equivalent system properties from the individual element properties. In order to reduce computational efforts a MATLAB based tool is developed. The validation is done by comparing the mathematical model with the experimental data. The predicted value from the mathematical model and experimental values are in close agreement.
Kulkarni, Chaitanya, Aher, V. S.
Vibration Test Machine and Operation ProcedureJ577_201106 (Historical)6/1/2011
This SAE Recommended Practice provides procedures, and information to conduct vibration (impact) tests on lighting devices and their components as well as other safety equipment used on vehicles.
Test Methods and Equipment Stds Committee
Time Belt Dynamics and Noise Study2010-01-09024/12/2010
This paper studies the dynamics and noise of timing belt. A comprehensive theoretical contact dynamics model for belt tooth-sprocket tooth pair is developed. The general belt dynamics model in conjunction with the contact model is used to quantify the impact-sliding process of belt tooth. The effect of tooth meshing process is illustrated which results in the vibrations of belt span and tooth vibrations. The structural borne noise consists of structural impact portion and friction-induced portion. The relationship between system parameters and noise is quantified. The air borne noise due to air-pumping is investigated based on Lighthill's equation. A comprehensive model is developed and the spectrum signatures of the air-pumping noise are illustrated.
Sheng, Gang, Qatu, Mohamad, Dukkipati, Rao V., Zheng, Hui
Analytical Life Prediction Modelling of an Automotive Timing Belt2008-01-12074/14/2008
This paper presents a methodology that makes use of computer based analytical simulation methods combined with statistical tools to predict timing belt life. This allows timing belt life to be estimated with no requirement for running test engines and associated test equipment, which is both very time and expense exhaustive. A case study on a belt driven primary drive for a V6 Diesel engine was used to illustrate the methodology. A computer based dynamic model for the belt drive system was developed and validated, and a belt life prediction model was developed, which uses tooth load predictions from the analytical model. Statistical modeling of predicted damage accumulated to failure was used to estimate the model parameters given a limited set of belt life results from a motored rig test. The practical use of the model is illustrated by predicting belt life under customer usage.
Hamilton, Andy, Fattah, Muhammad, Campean, Felician, Day, Andrew
Finite Element Analysis of a Three-Point Belt Tension Tester2005-01-31377/1/2005
A device developed for use in measuring the belt tension of a power transmission was designed and tested with two types of automotive engine belts, - the timing belt and the V-belt. An elastic finite element analysis using geometric non-linearity properly predicts a measure of the belt tension using the three-point deflection principle. A good agreement was found to exist between the F.E. analysis and the experiments, and it was shown that the accuracy of the measured belt tension depends on the device span. This apparatus is highly reliable with respect to the repeatability and accuracy of the measured belt tension.
Champliaud, Henri, Lajmi, Abdelmajid, Van Lê, Ngan
Mechanism for Varying the Diameter of Rotors Using Compound Differential Rotary TransmissionsVFS-F61-0002796/1/2005
Existing VDR mechanisms have not progressed beyond the ground test experimental stage partially due to their inability to achieve the weight, reliability and maintainability requirements for practical aircraft application. Recent advancements in digital flight control systems and Health Usage Monitoring however can be applied to make a Variable Diameter Rotor (VDR) mechanism practical. Current published VDR design concepts do not integrate with existing rotor hub designs since their mechanisms occupy the space normally used by the rotor hub's structure and constant velocity joint. Many of these designs require a rigid hub configuration to maintain alignment of their VDR mechanism gearing. By using separate differential planetary rotary transmissions at each blade and interconnecting them with flexible timing belts, the mechanism described in this paper integrates with most existing rotor hub design configurations. This paper studies the application of system control and mechanical power transmission technologies to create a practical VDR mechanism for the BA609 three bladed rotor. A historical review of VDR studies and experimentation performed by Bell between 1962 and 1971 provides an introduction to the technical issues facing the development of a practical VDR mechanism design.
Fenny, Carlos A.
Dynamic Modeling of Timing Belt Frictional Contact using an Explicit Finite Element Formulation2005-01-05034/11/2005
In this study, an efficient dynamic finite element model is developed for timing (also known as synchronous) belt drive systems capable of determining the transient and steady-state response of systems consisting of any number of driver and driven sprockets. For validation purposes, a two-sprocket drive is studied in detail and a comparison is made between tooth loads predicted by the finite element model and experimental data available from the literature. The drive belt is modeled using truss or beam finite elements, while the sprockets are modeled using rigid constraints. Two types of belt contact nodes are identified: tooth nodes and groove nodes. Tooth nodes experience frictionless penalty contact forces associated with radial sprocket penetration, as well as penalty contact forces associated with trapezoidal sprocket tooth interaction. Groove nodes interact frictionally with the sprocket pitch circles in regions away from the trapezoidal teeth. The resulting contact algorithms are a natural extension of previously published and validated algorithms developed for non-toothed belt-pulley contact (Leamy and Wasfy, 2002) and therefore inherit much of the previous models' accuracy and efficiency. A complete simulation tool is achieved by incorporating the model into an in-house explicit finite element code, which can maintain time-accuracy for large rotations and for long simulation times. Simulation results of the validation drive's tooth loads are shown to compare favorably with available experimental data.
Leamy, Michael J., Wasfy, Tamer M.
Estimation of Field Life Distribution of Automotive Components and Aggregates2005-26-0681/19/2005
In this paper a procedure has been established to estimate the field life of a component using the data of accelerated life tests on old and new designs of the component, and the field failure data on the old design of the component. For this, the correlation factors have been established between the accelerated life data and the field life data of the old design and these correlation factors have been applied to the accelerated life data of the new design to estimate the life distribution of the new design in the field. The formula for the correlation factor is based on the assumption that all the life data distributions under investigation have increasing failure rates (IFR). A case study on engine timing belt has been presented as an example at the end to validate this work. Such a procedure has been found to be useful to introduce the component in the field without any field trials.
Dharmadhikari, A. D., Panse, S. M.
Air/Oil Separation in Cylinder Head Covers2004-01-293310/25/2004
Plastic cylinder head covers are an important component in modern engines. Their design is governed not just by space, economy and functionality considerations, but also by the growing number of functions that have to be accomplished by the cover, such as: provide a leak proof seal to the cylinder head and timing belts, isolate the vibrations transmitted from the engine through the cover to the environment, control the crankcase pressure and house the device(s) to separate oil from the blow-by gas. Additionally, the use of plastic affords the development of lighter, more elaborate and cost effective solutions. The present work describes analytical and experimental efforts aimed at understanding and, thus, improving the air/oil separation (AOS) in a given type of cylinder head covers.
Bastías, Pedro, Grafl, Dieter, Wagner, Jürgen, Caloghero, Dimitrius, Puckett, Michael, Nash, David
TURBINE BLADE MACHININGAEROMAY02_045/1/2002
To ensure more efficient grinding of its turbine blades, Rolls-Royce installed Midwest Engineered Products' CentraSep centrifuge for automatic filtering of cutting oil. Aircraft engine manufacturer Rolls-Royce has employed a new ac-powered centrifuge developed by Midwest Engineered Products to ensure cleaner cutting oil for its remanufactured grinders. The grinders are used at the company's Indianapolis facility to machine turbine blades for Rolls-Royce engines powering the C-130, P3 Orion, and other aircraft. “The machining is critical,” said Pat Huser, Manufacturing Engineer at Rolls-Royce. “Blade parts are ground to a tolerance of 0.0006 in. and used in a section of the engine that reaches nearly 2000°F, so the oil is used under high pressure and must be clean and cool to avoid any burning of the parts as they are machined.”
A Method for Identifying the Natural Frequency of the Timing Belt2002-01-11883/4/2002
A method to identify the natural frequency of a timing belt is developed. The method is simple and based on applying a lateral load at the middle point between the camshaft wheel and the crankshaft wheel. The tension measurements together with the belt density and length provide necessary information in order to identifying the natural frequency. The analytical method is also validated by experimental measurements of natural frequency. Results were found to be in a good agreement.
Melas, D. A., Esat, I. I., Craighead, I. A.
Automotive V-Belt DrivesJ637_200112 (Historical)12/10/2001
The following information is intended as a guide to be used for evaluating belt construction, source approval, and quality audit. This recommendation has been prepared from existing literature, including standards, specifications, and data supplied by both producers and users. These recommendations cover drive layout details and V-belt testing methods, including test layout, pulley diameters, torque loads, and guidance for interpreting test data. The application of these automotive V-belts is to power engine or vehicle accessories that are physically attached to the engine.
Belt Drive (Automotive) Systems Committee
Electric Driver Battery Pack System Functional GuidelinesJ2289_200011 (Historical)11/15/2000
This SAE Information Report describes common practices for design of battery systems for vehicles that utilize a rechargeable battery to provide or recover all or some traction energy for an electric drive system. It includes product description, physical requirements, electrical requirements, environmental requirements, safety requirements, storage and shipment characteristics, and labeling requirements. It also covers termination, retention, venting system, thermal management, and other features. This document does describe guidelines in proper packaging of the battery to meet the crash performance criteria detailed in SAE J1766. Also described are the normal and abnormal conditions that may be encountered in operation of a battery pack system
Electric Vehicle Forum Committee
Analytical Studies on Influence of Crankshaft Vibrations on Engine Noise Using Integrated Parametric Finite Element Model: Quick Assessment Tool1999-01-17695/17/1999
Torsional and lateral bending vibrations of cylinder block have a large effect on engine noise. Cylinder block vibration not only causes noise to radiate from the cylinder block itself but it is also the major exciting force to the oil pan and timing belt cover. In order to reduce engine noise, it is important to completely understand the mechanism of cylinder block vibrations. An analysis is conducted using FEM and BEM to compute the influence of crankshaft torsional vibrations on cylinder block vibrations. A crankshaft system for a four cylinder automobile engine was used for analysis. Finite Element model of crankshaft is created using parametric modelling software developed based on ANSYS FEA software. Finite Element model of cylinder block, bearing cap, oil sump is also created using another parametric software developed based on ANSYS FEA software. Both the models are assembled and oil film is simulated at the journal bearings using spring-damper elements with appropriate values for stiffness and damping. Dynamic analysis presented here focuses on the influence of crankshaft mode shapes on the excitation behaviour in the engine structure under crankshaft resonance conditions. The influence of the mass and moments of inertia of the front pulley on crankshaft vibrations is studied. Results obtained so far match with the published data available on the subject experimentally. The paper focuses on the parametric tool developed for quick assessment of noise character of the combination of engine block, crankcase, oil sump and crankcase.
Athavale, Swati M., Sajanpawar, P. R.
Generalized Predictive Kinetic Energy Controller for Vibration Suppression in Turning1999-01-18734/14/1999
A Generalized Predictive Kinetic Energy Controller (GPKEC), which has been previously developed, is implemented to control the machine tool vibration in a lathe turning process. The control variable, tool feed, is computed using acceleration feedback through the GPKEC algorithm. The feed is controlled by attaching a high torque/low inertia permanent magnet DC servomotor to the main feed rod through a high performance timing belt. Experiments are carried out for a number of cases. The system identification of the overall machining process is done on-line and precedes the control action. Accelerometers have been used to sense the vibration signal in the feed direction. The experimental results show that GPKEC can effectively suppress the chatter vibration in a single point turning process, even in presence of an appreciable change in the dynamics of the process. GPKEC has also been observed to be robust against step disturbances.
Anwar, Sohel, Chandra, Abhijit
Ford Zetec-E, I4 Engine Timing Belt Drive1999-01-06413/1/1999
The Ford Zetec-E engine primary drive system generation will be presented. The Zetec-E engine has been developed for a high volume production. The engines are produced in three engine plants with an installation capacity of 1.2 Mill. engines p.a. This paper describes the design features for the timing belt drive concept of the Ford Zetec-E engine family. The first engine was launched in January 1992 at Bridgend Wales (UK) and other plants are located in Cologne, Germany and Chihuahua, Mexico. The continuous improvement of the timing belt drives as well as the vehicle installation and packaging requirements for the world wide Ford power trains led us to the latest upgrade generation for MY 1999. In depth a technical view is taken into the different timing belt concepts, with idlers and various tensioning systems. The influence of a valve train with variable camshaft timing and none VCT applications will be evaluated. The experience during the development of the Zetec-E inline engine family shows the real lifetime robustness and capability for timing belt drive systems, as well as its potential for 150 K miles durability.
Thomanek, Ralf, Steinberg, Rainer, Krauser, Beate, Morawitz, Urban, Querengaesser, Joerg, Weiss, Juergen, Graf, Herbert
AUTOMOTIVE V-BELT DRIVESJ637_199708 (Historical)8/1/1997
The following information is intended as a guide to be used for evaluating belt construction, source approval, and quality audit. This recommendation has been prepared from existing literature, including standards, specifications, and data supplied by both producers and users. These recommendations cover drive layout details and V-belt testing methods, including test layout, pulley diameters, torque loads, and guidance for interpreting test data. The application of these automotive V-belts is to power engine or vehicle accessories that are physically attached to the engine.
Belt Drive (Automotive) Systems Committee
Performance Engine Building Recommended PracticesJ2379_199708 (Historical)8/1/1997
This SAE Recommended Practice applies to the function of building reciprocating spark-ignition engines which are used in conjunction with standard and high-performance ancillary components in applications intended to achieve a minimum of 1 hp/in3. This document does not apply to rebuilt engines which may only be partially repaired with little or no machining, nor does it apply to second-hand or used engines.
Motor Vehicle Council
Reliability Predictions Using Probabilistic Methods and Key Life Testing9725875/1/1997
A Key Life Test is an accelerated test designed to detect a major component failure mode. The Key Life Test process will be outlined, as applied to predicting the life and reliability of an automotive synchronous timing belt. The main objective of this type of testing is the development of a model to improve quality by designing reliability into the product. A math model will be described to assess severe customer usage, determine the test conditions and acceleration factor and is used to find the timing belt life and reliability. The application of Probabilistic Methods will be explained to predict the belt life and reliability, after the model has been correlated against the test results obtained. It will be shown that the design can be optimized to improve the timing belt reliability using the model.
Salzman, Ronald H., Ciemniecki, Scott L.
Analysis of Stress Distribution of Timing Belts by FEM9709192/24/1997
A model of a timing belt analyzed by FEM (a general non-linear finite element program:ABAQUS) successfully confirmed the mechanism that generates belt cord stress. Analysis revealed a good correlation between the experimental and computed results of stress distribution of the belt cord. Through calculation, it was discovered that belts broke near the tooth root, which is the point of maximum stress of the cord.
Furukawa, Yoshihisa, Tomono, Kiyohisa, Takahashi, Hideaki, Uchida, Takanao
SAE ELECTRIC VEHICLE CONDUCTIVE CHARGE COUPLERJ1772_199610 (Historical)10/1/1996
This SAE Recommended Practice covers the general physical, electrical, and performance requirements for the electric vehicle conductive charging system and coupler for use in North America. The intent of the document is to define a common electric vehicle conductive charging system architecture and the functional requirements of the vehicle inlet and mating connector. Application and compatability requirements for the connector and vehicle inlet are stated herein.
Electric Vehicle Forum Committee
Pitch Difference and Belt Tooth Configuration Effect on Load Distribution of Timing Belt Using FEM Analysis9602992/1/1996
A timing belt used for an automotive engine's camshaft consists of a facing fabric, elastoeric body and glass fibre cords. These materials show significant non-linear characteristics. Therefore, a model of the timing belt was analyzed using ABAQUS (: a general non-linear finite element program). As a result, the mechanism that generates the belt load distribution was successfully confirmed by calculation. It was found that the pitch difference existing between the timing belt and pulley, and belt tooth configuration both have a large affect on load distribution of toothed belts. This paper reports the development of an analytical model which shows the effects of pitch difference and pulley tooth configuration on belt contact pressure.
Uchida, Takanao, Furukawa, Yoshihisa, Tomono, Kiyohisa, Takahashi, Hideaki
The Development of an Electric Car9519038/1/1995
This paper presents the development of Wright State's electric racecar. The car utilizes two AC induction motors and controllers and is propelled by a timing belt/pulley assembly on the rear axle. Conventional lead-acid batteries are adopted due to low installation cost. Differential equations that describe traction and propulsion capabilities as well as power consumption were formulated. Instead of using section-to-section estimation, “closed-form” solutions for the traction, propulsion and power requirement were derived. The simulation results for vehicle traction and propulsion are presented. The car was tested on tracks and successfully raced in various events.
Lieh, Junghsen
Structural Design and Evaluation of Composite Closure Systems for Under-the-Hood Applications9504862/1/1995
The opportunity for composites in engine closure systems such as valve covers, oil pans, and timing belt covers is expanding rapidly. The primary driving forces are lighter weight finished components, integrated designs, improved isolation of engine noise, improved materials systems, and matured manufacturing processes for composite materials. Thermoset-based composite materials, particularly those based on high-temperature resistant epoxy vinyl ester matrices, offer improved performance with respect to thermoplastic and thermoset polyester-based composites and can be manufactured using different processing methods. This paper presents the current state-of-the-art design, engineering and optimization techniques for engine closure systems. The performance requirements of different systems such as valve covers and oil pans are explained in detail. Techniques for long-term structural stiffness evaluation, vibration performance assessment and noise transmission estimation are described. The paper also shows the material characterization required to develop design allowables for long-term, high-temperature composite applications. Definitions of design allowables and examples for thermoset-based composites are also included. COMPOSITE ENGINE CLOSURE SYSTEMS such as valve covers, oil pans and timing chain covers offer several advantages over systems based on traditional materials, including cast aluminum and stamped steel. Composite systems can provide the same design flexibility as cast aluminum at a lower total cost. Unlike stamped steel systems, features such as brackets, bosses, tubes, grooves and lettering may be integrated into the part without additional fabrication or machining. This design flexibility also allows noise emission reduction and parts consolidation opportunities such as providing structural support for other engine compartment components. Since composites typically have half the strength and one-fifth the stiffness of aluminum, the composite closure systems require detailed global and local engineering analyses during the design process to provide acceptable deflections and stresses upon static and dynamic loadings during long-term exposure to under-the-hood conditions. This paper presents techniques and recommendations for designing and optimizing composite engine closure systems.
Tarnowski, Tom, Lorenzo, Luis, Winkler, Marie
Torsional Vibration Analysis of Belt-Driven Camshafts in a High Speed IC Engine94250312/1/1994
An experimental method was developed to dynamically measure rigid-body camshaft torsional vibrations in a high speed internal combustion engine. A mathematical model of the system was also created which required an accurate dynamic model of the entire valvetrain to predict the forcing function. Techniques for limiting the vibration were also implemented and tested. While attempting to correlate the experimental and theoretical results, it was discovered that the rubber timing belt exhibits viscoelastic behavior. The system stiffness and damping coefficients are frequency dependent. A system identification was required to accurately determine these parameters. No distinct relation between camshaft torsional vibrations and valve response was determined for the system studied. However, significant vibration reduction was achieved with a camshaft damper and an inertia addition to the camshaft.
Mitchell, Brian E., David, Joseph W., Covey, James A.
High Strength HNBR - The New Benchmark Elastomer for Automotive Synchronous and Serpentine Belts9405513/1/1994
Global competition in the automotive industry, specifically new trends in engine design, involve the replacement of traditional engines with high performance overhead cam engines and multi valve designs. This has created a unique challenge to the engineering of timing belts with increasing underhood temperatures due to hotter running engines and compact engine compartments. These factors along with increased load bearing requirements has pushed traditional synchronous belt materials beyond their limits. Materials suppliers and belt manufacturers have combined efforts to develop new designs and materials which address these performance needs. This paper evaluates the performance of past, present and future belt compounds including polychloroprene (CR), alkylated chlorosulfonated polyethylene (ACSM), hydrogenated nitrile butadiene rubber (HNBR), and high strength HNBR utilizing static and dynamic testing equipment. These findings illustrate that high strength HNBR will provide improved heat and ozone resistance, higher abrasion resistance and improved dynamic performance. Its higher load bearing capabilities will help establish this material as the new benchmark for extended warranties and dynamic performance in synchronous and serpentine belts.
Bradford, William G., Wood, Michael E.
Tension Behavior of an OHC Drive Timing Bell System for Fixed and Automatic Tensioner93187111/1/1993
The belt tension behavior in OHC drive timing belt system was investigated analytically and experimentally for (1)fixed and (2)automatic tensioner. From the numerical results it was found that the automatic tensioner makes the belt tension larger than those of the fixed tensioner. When the initial belt tension decreased due to the belt elongation, the slack side belt tension of the fixed tensioner could decrease to near zero while the belt tension for the automatic tensioner maintained above zero by the tensioner spring. The mean value and the difference between the maximum and the minimum belt tension for the automatic tensioner increased compared with those of the fixed tensioner. Also, the numerical results for a hydraulic tensioner showed that the hydraulic tensioner has the good parts of both tensioners; i.e., the smaller amplitude in belt tension and the higher mean tension. Experimental results for the automatic and fixed tensioner of the OHC timing belt system were in agreement with the theoretical results.
Lee, In-hwan, Kin, Hyunsoo, Yeo, Chang-gi
Special Noise Problems in Automotive Timing Belts9313165/1/1993
During the development of an automotive engine with timing belt usually problems with timing belt noise occur. This paper describes the solution of two different noise problems excited by the timing belt. These problems were mainly sound quality issues and required dedicated analysis methods such as listening studies or time domain analysis in defined frequency bands. First a short overview to the theory of belt noise is given. The first problem was caused by torsional vibrations of a belt span which forces the balls of the bearing of an idler to move through their clearance. This leads to a high frequency noise (rattle). The detailed analysis of that problem leads to a V-shaped idler with greater diameter. The second problem was caused by a natural frequency of an idler which was excited by belt span vibrations (warble). An idler with a small add on ring, a shift of natural frequency and a modified sprocket profile gives the solution for that concern. In addition to the problem solutions the influence of pretensioning procedure on timing belt noise will be described.
Kaiser, H.-J., Querengässer, J., Bündgens, G. M.
SI (METRIC) SYNCHRONOUS BELTS AND PULLEYSJ1278_199303 (Historical)3/29/1993
Synchronous belt drives consist of a toothed belt which mates with grooved pulleys to provide a precise Speed ratio between the driver and driven pulleys. This SAE Standard covers the synchronous belt and pulley sections currently in use in automotive applications such as camshaft, distributor, and other underhood drives that may require synchronization. It also provides for future sections to be added as usage develops. Table 1 lists the sections currently in use.
Belt Drive (Automotive) Systems Committee
A Self-Energizing Dual-Phase-Shift Camshaft Timing Pulley9308193/1/1993
A novel concept from FORD is described which exploits the internal torque fluctuations inherent in the cam-shaft drive train and directs them by way of a mechanical one-way clutch to cause phase change of the camshaft automatically between two locked positions. No external power is necessary for actuation and a light weight trigger is used to initiate the phase change. The Dual-Phase-Shift (DPS) pulley was designed by INA and developed at FEV. First prototypes are currently being tested on live engines. The key features of the pulley are explained in this paper and test data on the performance of the phase shift is presented. The design is unique in its simplicity and is sufficiently compact to fit inside the dimensions of a conventional timing belt pulley. The DPS pulley can therefore be installed on current production engines requiring only minor modifications and replacing the normal timing belt pulley. For engines with dual camshafts, by installing one DPS pulley on each camshaft, dual independent phase control can be achieved. The described concept was designed and tested as part of joint investigations by FORD Powertrain Research and INA into alternative systems for camshaft phasing. Whilst the main activities were concentrated on systems with hydraulic actuation, this smart mechanical system was investigated since it offers 2-step operation with only small engine changes for adaptation.
Ma, Tom, Golovatai-Schmidt, E., Scheidt, M., Tenberge, P., Saupe, T.
Multi-Disc Viscous Auto-Tensioner for Timing Belts9306233/1/1993
This paper describes the construction, characteristics and capabilities of a compact automatic tensioner for timing belts that was recently developed by NSK. This auto-tensioner differs from conventional ones having separate actuators. By incorporating the damping mechanism inside the bearing, a compact size nearly equal to that of fixed type tensioners was achieved. The damper is a multi-disc viscous type that uses high viscosity silicone oil.
Watanabe, Toshiki, Suzuki, Hiroshi, Grace, William
Development of Toyota JZ Type Engine Series9308813/1/1993
The newly-developed 2JZ engine series is available in two types; a naturally aspirated 2JZ-GE and a turbo charged 2JZ-GTE. Both have in-Line-6 cylinder arrangement and displacement volume of 2.997 liters and have attained many features expected for the engines of new era by utilizing new technologies, such as DOHC 4 valve, high compression ratio, a highly rigid structural design which is realized by extensive use of the CAE, a serpentine accessory drive belt, and auto tensioners for timing belt and accessory belt systems. These engines are stroke up versions of the 1JZ engines. The 2JZ-GE engine, which has been developed for the SC300, delivers high performance of 169 KW/6000rpm and 284 Nm/4800rpm by adopting a variable induction system, a knock-control system with two sensors, etc. The other type, the 2JZ-GTE engine which has been developed for the Aristo in japan includes a TWO-WAY-TWIN-TURBO’ system equipped with ceramic turbine wheels. With this system, the engine is allowed to selectively use a suitable turbo unit depending on the low/high speed range, thus providing excellent transient response and delivering easy-to-use torque characteristics in wide speed range. This engine delivers high performance of 206 KW/5600rpm and 431 Nm/3600rpm.
Tanke, Akihito, Sugiyama, Toshihisa, Kotani, Akira
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