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A geometrical set of closed form trigonometric equations are developed as a simplified alternative to the complex numerical computations required for determining lateral belt tracking locus due to pulley misalignment tolerances. Solutions are validated by a comprehensive statistically designed database. Further, analytical verification is obtained from ABAQUS/Explicit results based on a nonlinear hyperelastic Ogden finite element model. Three-dimensional geometric equations form the basis of a computer tool developed to predict belt displacement across a flat backside pulley, as well as angles of entering and exiting spans. Predictions are performed for the critical combination of a grooved-flat-grooved pulley arrangement typically found in automatically tensioned front-end automotive serpentine accessory drives. Excellent correlation is found between the three-dimensional finite element analysis, experimental data, and the simplified geometrical model.

This paper reviews a test procedure and some empirical and theoretical insights related to V-ribbed belt accessory drive system belt alignment. The paper focuses on the effects of backside pulleys, or the smooth pulleys, which can generate significant belt misalignment. The test procedure has been recently introduced to determine the belt alignment sensitivities of accessory drive belt system variables such as belt tension, belt wrap, belt span length, belt backside surface, and backside pulley crown. The test procedure is described in detail, and some examples of results are provided. The advantages of generating real-time data are also discussed.