Conti Synchroflex AT5 GEN III 455

Conti Synchroflex AT5 GEN III 455 – durable PU timing belt with stable tooth pitch

With 91 teeth distributed over a pitch length of 455 mm, the Conti Synchroflex AT5 GEN III 455 is designed for precise transmission of rotation, stroke and position. The belt is cast endlessly in PU and has integrated steel cord tension elements that stabilize the length during normal operation. The nominal tooth pitch is 5 mm and the tooth profile must match the profile of the pulleys precisely. It is not sufficient for another belt to have approximately the same length or width. The GEN III version is the reinforced high-performance construction with red high-performance polyurethane and denser, two-filament steel cord. It should therefore be treated as a separate product series and not as the usual standard version.

Product data and fixed targets

• Pitch length: 455 mm
• Number of teeth: 91
• Tooth profile: AT5 GEN III
• Tooth pitch: 5 mm
• Material: cast polyurethane with steel cord
• Brand: Conti Synchroflex

The technical data below describes the part of the product that does not change when a different belt width is selected. Pitch length, tooth pitch and number of teeth remain identical for all width choices. However, the width affects the available belt cross-section width and the price calculated on the product page. Correct sizing must always take into account torque, speed, number of teeth in mesh, pulley diameters, service factor and any counter-bending.

Function of the tooth profile

The metric AT geometry has trapezoidal teeth with a larger tooth volume than the standard T profile. The purpose is to distribute the load advantageously in the tooth mesh and achieve higher tooth strength without making the drive unnecessarily large. The profile requires suitable AT timing belt pulleys with the same pitch; a visual similarity to other profiles is not evidence of compatibility.

Materials and endless manufacturing

With the cast manufacturing method, the finished belt becomes an exact copy of a precision-machined shape. This is a major reason for the uniform tooth pitch and reproducible length. The steel cord is integrated into the polyurethane and contributes to position and angular precision. The design is suitable for synchronous drives, where a conventional elastic friction belt does not provide the desired repeatability.

What does the version designation mean?

GEN III is the reinforced high-performance version of the Conti Synchroflex series. The construction uses red high-performance polyurethane, more densely packed steel cord tension elements and a two-filament construction with balanced S and Z cords. Continental states up to 25% higher power transmission than the corresponding AT or ATP standard series. GEN III can use the standard profile timing belt pulleys, but the belt still needs to be dimensioned for the specific drive.

Areas of application

The profile series is used in practice for tasks such as machine tools, pu , textile machines and positioning and conveying systems. Common to these machines is the need for a fixed transmission ratio and controlled tooth engagement. A timing belt can transmit both force and position, but the capacity cannot be assessed based on length alone. Width, profile version, wrap angle and load cycle are among the data that must be included in the selection.

How the width variants work

The belt width is not written in the product name because the same pitch length is collected on one product page. The starting pu is 6 mm. Integer widths from 6 to 50 mm can be selected on this product page. The original supplier widths for this length are 6, 8, 10, 12, 16, 20, 25, 32 and 50 mm. Other intermediate sizes are offered as cut-to-size versions of the same type of timing belt sleeve when they are within the selection shown. The number of teeth, pitch length and profile do not change when the width is changed.

Timing belt pulleys and transmission ratios

The pulleys and belt should be considered as a single tooth engagement. Proper AT5 GEN III geometry ensures that the load is distributed across the tooth flanks rather than concentrated on tooth tips or edges. The drive ratio is selected by the number of teeth on the pulleys, while the 91 teeth and 455 mm pitch length of the belt determine the required combination of pulleys and center distance. When changing the drive, the geometry should be calculated.

Pre-tensioning and disc alignment

Proper installation begins with clean, undamaged pulleys with the correct profile. Teeth and grooves should be checked for deposits, bars and wear before the new belt is fitted. The pretension should be based on the drive's calculation and should not be selected based on a random hand feel. After the initial run-in, it is a good idea to check grooveing, noise, temperature and whether the belt runs centrally.

Compare with the existing belt

When replacing a spare part, the marking on the existing belt should be compared with the product name. Check the profile designation, pitch length, number of teeth, design and width. If the text on the belt has worn away, the number of teeth can be counted and the pitch can be assessed by measuring over several teeth. A single external length measurement is less reliable because the nominal length of the timing belt is indicated in the pitch line.

What does belt wear indicate?

Troubleshooting should start with pu location of the damage. Edge wear is typically associated with grooveing and alignment, while tooth skipping can be associated with too low tension, load peaks or too few teeth in mesh. Ctiming bars on the back can be caused by too small rollers, back bending or environmental influences. Do not simply replace the belt without also finding the mechanical cause.

Operating environment and maintenance

Continental specifies a temperature range of up to +100 °C for the GEN III series. When operating close to the temperature limits, the drive must still be dimensioned according to the specific load and environmental conditions. The timing belt operates without lubrication, and oil or grease should therefore not be added to dampen noise. The polyurethane is described as resistant to aging as well as simple oils, grease and petrol and to certain acids and bases. In the case of permanent contact, cleaning chemicals or unknown media, material compatibility should be specifically clarified.

Questions and answers about this timing belt

Conti Synchroflex AT5 GEN III 455: can an old V-belt be directly replaced by this timing belt?

No. A timing belt requires timing belt pulleys with the correct profile and pitch, while a V-belt works by friction in V-grooves. A conversion therefore requires new pulleys and a dimensioning of the entire transmission. The product is intended as a timing belt, not as a universal replacement.

Conti Synchroflex AT5 GEN III 455: can the belt be installed by pressing it over the flange of the pulley?

This should be avoided. The belt should be installed by adjusting the center distance or following the correct installation procedure for the machine. Forcing it over a flange can damage the cord pullers, teeth or belt edge. After installation, the pulleys must be parallel and the pretension must be correct.

Conti Synchroflex AT5 GEN III 455: can the belt run with counter-bending?

The possibility depends on the profile, cord design, the diameter of the rollers and the specific belt routing. Counter-bending increases the bending load and must be included in the dimensioning. A roller on the belt back must have sufficient diameter and be positioned so that tooth engagement and grooveing are not impaired.

Conti Synchroflex AT5 GEN III 455: can AT5 GEN III be used on a different tooth profile with the same pitch?

No, not without documented compatibility. The 5 mm tooth pitch describes the distance between the teeth, but the shape and clearance of the tooth flanks may differ. The belt must be used with pulleys manufactured for AT5 profile. Visual similarity is not sufficient documentation.

Conti Synchroflex AT5 GEN III 455: how does preload affect operation?

Correct pretension keeps the teeth in stable engagement and reduces the risk of tooth jump. Too low a tension can cause impact and jump under load, while too high a tension increases the load on the cord, pulleys and bearings. The correct value must be determined based on the drive's dimensioning.

Conti Synchroflex AT5 GEN III 455: are the standard widths the only possible widths?

The documented supplier widths for this size include 6, 8, 10, 12, 16, 20, 25, 32 and 50 mm. The product page may also show intermediate sizes as cut widths when they are within the allowed range. This does not change the tooth profile or length, but the price is calculated based on the base width.

Conti Synchroflex AT5 GEN III 455: why is the number of teeth important for spare parts?

The number of teeth links the pitch of the profile to the nominal length of the belt. For this size, 91 teeth at 5 mm pitch gives a length of 455 mm. It is a simple check that often reveals faults that are not visible by a quick comparison of two loose belts.

The product in brief

In summary, this is a Conti Synchroflex PU timing belt with a fixed geometry of 5 mm pitch, 91 teeth and 455 mm pitch length. The width is selected separately, but does not change the length or number of teeth. A safe replacement requires that the entire designation and the specific version match the machine documentation.