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Conveyor Belt Tension Calculation: T1, T2 & Take-Up Design

In any friction-driven conveyor system, the most fundamental concept is the relationship between the Tight Side Tension (T 1 ) and the Slack Side Tension (T 2 ) . If you get this ratio wrong, your drive pulley will slip, your belt will wear out prematurely, or your take-up counterweight will be too light to maintain traction. In this guide, we will use CEMA standard calculations to determine the correct tensions and take-up weight. Table of Contents 1. The Basics: T1 vs T2 2. Euler’s Equation (The Grip Formula) 3. Worked Example: Calculating Tensions 4. Take-Up Units: Gravity vs Screw 5. Common Failure Modes Advertisement 1. The Basics: T1 vs T2 Imagine a conveyor belt running over a drive pulley. The motor pulls the belt, creating a tension differential: T 1 (Tight Side): The tension pulling the loaded belt toward the drive pulley. This is the highest tension point in the system. ...
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Chain Sprockets Guide: ANSI Hub Styles & Selection

Chain Sprockets are the gears of the chain drive world. While they look simple, selecting the right profile and hub style is critical for preventing downtime in conveyor systems.

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Assortment of industrial chain sprockets showing different hub styles
Figure 1: Selecting the correct sprocket hub style is critical for shaft mounting and load distribution.

Sprockets are fabricated from a variety of materials depending on the application. Large fabricated steel sprockets are often manufactured with lightening holes to reduce the rotating mass and stress on the motor bearings.

Standard Sprocket Hub Styles

The American National Standards Institute (ANSI) defines four primary hub styles. Choosing the wrong one can lead to shaft bending or installation nightmares.

  • 1. Type A (Plate Sprocket)
    These are flat plates with no hub at all. They are typically welded onto a separate hub or bolted to a flange. They are the most economical choice but require custom fabrication to mount.
  • 2. Type B (Hub on One Side)
    The industry standard. The hub extends on one side to allow for a keyway and set screw. This design allows the sprocket to be mounted close to the bearing, eliminating large overhung loads that could bend the shaft.
  • 3. Type C (Hub on Both Sides)
    Used for heavy-duty applications. The hub extends on both sides of the plate, providing maximum surface area contact with the shaft. They are usually used on the driven sprocket where the pitch diameter is larger and the torque load is higher.
  • 4. Type D (Bolted/Detachable)
    This uses a Type A sprocket bolted to a split hub. It allows the speed ratio to be changed easily by unbolting the sprocket rim without removing the hub or bearings from the shaft.
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Advanced Features: Hardening and Bushings

Beyond the basic shape, two factors determine the price and lifespan of a sprocket:

1. Induction Hardened Teeth

For high-speed or high-load drives, standard steel teeth wear down quickly, forming a "hook" shape. Hardened teeth (typically Rockwell C 35-50) resist this wear. While they cost more upfront, they significantly reduce maintenance costs by extending the life of both the sprocket and the chain.

2. Taper-Lock and QD Bushings

Modern industrial drives rarely use simple "bored-to-size" holes with set screws anymore. Instead, they use Taper-Lock or QD (Quick Disconnect) Bushings.

The Advantage: These are split, tapered hubs that squeeze the shaft like a clamp when tightened. They provide a vastly tighter grip than a set screw, eliminate shaft wobble, and are much easier to remove when rusted, saving hours of labor during repairs.
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