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A general three-dimensional finite element model was built to simulate the tracking conditions inherent in automotive front-end accessory drives, specifically, serpentine V-ribbed belt drives. Commercial finite element code ABAQUS was used for the simulation. The analysis is based on a hyper-elastic material model for the belt, and includes the effect of the reinforced cords and fibers in the rubber compound. The model can be used to study different parameters of the belt drive system such as rib number, pulley misalignment, drive wrap angle and drive speed. Experiments were used to validate the finite element model. Belt misalignment force of two, four and six ribbed belts under different misalignment conditions was obtained from experiment and compared with the results from the finite element model. Good correlation between these results brings confidence to the finite element model. Finally, typical FEA simulation results for a six-ribbed belt are presented.

Two instrumented pulleys were developed to empirically measure the dynamic lateral forces of V-Ribbed belts used in automotive accessory drives. The first test pulley utilizes two cantilever beams cut into the pulley with strain gauges attached to measure the lateral dynamic forces in each individual belt rib caused by misalignment. A test stand which simulates multiple accessory drive configurations at low-end drive speeds typical in automotive engines was implemented to create the dynamic response necessary. This test stand allows variations in lateral offset, toe, camber, tension, and span length, as well as in the speed of the system through a variable speed AC motor. The second test pulley utilizes a unidirectional load cell oriented to measure the total lateral force on the test pulley. After conducting static calibration tests of the two experimental systems, dynamic results were obtained using real time data acquisition.