GEARLESS POWER TRANSMISSION

A PROJECT REPORT
SUBMITTED IN PARTIAL FULFILLMENT OF THE

REQUIREMENT FOR THE AWARD OF

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING/

MANUFACTURING ENGINEERING

CODE:- ME-7270

Under the guidance of Submitted by:-

MR. ANUJ BANSAL GURPREET SINGH (GME/122923)
(Assistant Prof. Mech. Deptt.) VARINDER MALIK (GME/101112)
RAVJOT BAWA (GME/122922)

SANT LONGOWAL INSTITUTE OF ENGINEERING AND

TECHNOLOGY LONGOWAL - 148106
DISTRICT- SANGRUR, PUNJAB, INDIA
 CERTIFICATE
Certified that this project report “GEARLESS POWER TRANSMISSION” Submitted by
GURPREET SINGH (GME/122923), VARINDER MALIK (GME/101112), RAVJOT BAWA
(GME/122922) in the partial fulfillment of the requirement for the award of Bachelors of
Technology.

This report has not been submitted to any other university or institution for the award of any
degree.

Signature of the student

GURPREET SINGH (GME/122923)
VARINDER MALIK (GME/101112)
RAVJOT BAWA (GME/122922)

Signature of the Supervisor

Mr. ANUJ BANSAL
(Assistant Prof. Mech. Deptt.)
 PREFACE

Project work is an investment & should be able to get due returns in terms of better quality of
workmen & engineers for the future .This report contains the work done by our team to complete
the project on Gearless Power Transmission. This project work turns out to be a very educative
& is sure sharpen the hidden finesse in me. We realized the essence of the designing, fabrication
& manufacturing process while doing this project work. We have also understood the need of
practical knowledge for a fresh engineer along with the theoretical knowledge.
Most of the Fresh Graduates in Organizations find it difficult to cope up with the
working culture in industries. Project work makes students familiar with the working
environment, which them a lot during their induction in industries. Students develop some
practical approach to problems along with validation of their theoretical knowledge.
Students acquire the most advance technical knowledge and get acquainted with
sophisticated instruments. In this liberalized and global market, it is necessary for an engineer to
have sound field knowledge in order to grow in a technical field.
We promise to give in our best to come up to the expectations of the college
authorities & all those who have instilled hope on me. I am very thankful to the faculty of our
college for the cooperation & guidance. We have tried our best to cover as much as possible in
the report.
 ACKNOWLEDGEMENT

We take this opportunity to express our deepest gratitude to those who generously helped me in
providing the valuable knowledge & expertise knowledge during the project work. It was indeed
a great experience & pleasure to do a project on Gearless Power Transmission.

We express my sincere gratitude to Mr. ANUJ BANSAL (Assistant Prof.) our project
guide who has helped and guided us for completing our final year mechanical project (Gearless
Power Transmission).

In the first instance, we owe a deep sense of indebtedness and gratitude to Mr.
M.A.AKHTAR (Associate Professor) who permitted us & give the opportunity to do project like
Gearless Power Transmission.

Words elude us in expressing our profound gratitude to all workshops in charges for
their painstaking and close guidance, constant encouragement, and constructive suggestion,
thought provoking discussion, allowing us to work in their respective workshops & allow us to
use various tools.
 ABSTRACT

POWER TRANSMISSION FOR PERPENDICULAR SHAFTS IS WITH THE HELP OF

EITHER CROSSED HELICAL GEAR OR WORM GEAR OR HYPOID GEARS IN A
MACHINE, BUT THE MANUFACTURING OF THESE GEARS IS VERY COMPLEX,
POWER LOSS IN GEARS DUE TO SLIDING MOTION AND THE SHAFT
ORIENTATIONS ARE VERY LIMITED MEANS NOT FOR EVERY SHAFT
ORIENTATION BECAUSE OF STANDARDIZATION OF GEARS, SO NEED ARISES FOR
A BETTER SYSTEM.

SO HERE WE WILL WANT TO INTRODUCE A GEARLESS POWER TRANSMISSION

SYSTEM FOR PERPENDICULAR SHAFTS WHICH REDUCE THE LOSSES, COST AND
SAVE THE TIME & COST.

HERE IS A WONDERFUL MECHANISM THAT CARRIES FORCE THROUGH A 90

DEGREE BENT ROD. TRANSMITTING ROTATIONAL MOTION AROUND AN AXIS
USUALLY INVOLVE GEARS, WHICH CAN QUICKLY BECOME COMPLICATED AND
INFLEXIBLE. SO, INSTEAD OF USING GEARS, THIS TECHNOLOGY ELEGANTLY
CONVERTS ROTATIONAL MOTION USING A SET OF CYLINDRICAL BARS,BENT TO
90 DEGREE, IN A CLEVER,SIMPLE AND SMOOTH PROCESS THAT TRANSLATES
STRONG ROTATIONAL FORCE EVEN IN RESTRICTED SPACES.
 Table of Contents

1. Introduction
2. Working
3. Components of the model and operation
4. Applications
5. Comparison with Geared drive
6. Selection of materials
7. Bill of materials and Cost
8. Feasibility study
9. Cost estimation
10. Possible Improvements
11.Merits and Demerits
12.Bibliography
1. INTRODUCTION
Today’s world requires speed on each and every field. Hence rapidness and quick
working is the most important. Now a days for achieving rapidness, various
machines and equipments are manufactured by man. Engineer is constantly
conformed to the challenges of bringing ideas and design in to reality. New
machine and techniques are being developed continuously to manufacture various
products at cheaper rates and high quality. The project “GEARLESS POWER
TRANSMISSION” being compact and portable equipment, which is skilful and is
having something practice in the transmitting power at right angle without any
gears being manufactured. Most of the material is made available by our college.
The parts can be easily made in our college-shop its price is also less. This project
gives us knowledge, experience, skill and new ideas of the manufacturing. It is a
working project and having guarantee of the success. This project is the equipment
useful to improve the quality of the gear being manufactured and can be made in
less time, hence we have selected this project el-bow mechanism is an ingenious
link mechanism of slider and kinematic chain principle. This is also called as
“gearless transmission mechanism” this mechanism is very useful for transmitting
motion at right angles. However in certain industrial application “gearless
transmission at right angle” can also work at obtuse or accurate angle plane can be
compared to worm and worm gear or bevel and pinion gear which are invariably
used in the industry for numerous application. The main feature for mechanism
comparatively high efficiency between the input and the output power shafts with
regards to the gear efficiencies. It has elaborately discussed in detail in the entire
books o engineering that the gear drives have very low mechanical efficiencies.
Since Factor relating to under frictional Forces between the mating gear teeth, the erratic
hunting of the gears, the back lash between the teeth can not be overcome and hence
the efficiency can not be more than 55% Of recent gears of warm bevel type are being
manufactured in poly propylene and epoxy material where the Frictional Forces are
comparatively eliminated. Even though such gears are used for relatively small
applications because the efficiencies are not more than 42%. The El-bow Mechanism
transmits the I/P power towards the O/P side such away that the angular Forces
produced in the slacks are simply transmitted with the help of pins which takes up
the I/P power and the right angle drive is transferred towards the O/P slack and pin
assembly. Hence very little friction plays while the power is being transmitted; the
Hunting and backlash one absent. Therefore, it is appreciated that efficiency as
high as 90-92% are possible in gear less transmission mechanism. Here we are going to
show two applications of El-bow mechanism. How it will become work, which we
are showing by cutting the wood by attaching the wood cutter at the output shaft as
well as we are also making it as compressor. It will such the air from atmosphere,
compressor it & delivers it at high pressure. As we were calculate the result
obtained is we can get the compressed air at pressure2 bar. The first application of
this mechanism was made use of the “Big Ben Clock” having four dials on the tower
of London. This clock was installed some Time between 1630 to 1635 AD. And
still it is functioning in good condition.

2.WORKING

Fig.1 Gearless transmission model

Here is a wonderful mechanism that carries force through a 90º bend.Translating

rotational motion around an axis usually involves gears, which can quickly become
complicated, inflexible and clumsy-looking, often ugly. So, instead of using gears,
this technology elegantly converts rotational motion using a set of cylindrical bars,
bent to 90º, in a clever, simple and smooth process that translates strong rotational
force even in restricted spaces. A gearless transmission is provided for transmitting
rotational velocity from an input connected to three bent links. Both the input shaft and the
housing have rotational axes. The rotational axis of the input shaft is disposed at an
angle of 90 degree with respect to the rotational axis of the housing. As a result,
rotation of the input shaft results in a processional motion of the axis of the bent
link. The rotary and reciprocating motion of bent link transmit rotation of prime
mover to 90 degree without any gear system to an output shaft without gears. The
transmission includes an input shaft.

3.Components of the Model and Operation

In this section different views of the arrangement and the components used for
arrangement are shown, which is necessary for understanding the proper working
and setup of the arrangement.

A. View of the Shafts

Below diagram shows a different view of the shaft arrangement which are skew
and angle between them is 90 degrees, which helps us in the understanding of the
arrangement of shafts. In below figure (a) front view (b) side view (c) top view.

a (front view) b (side view)

 c (top view)

Fig. 2 views of shafts

B. Views of Setup
Different views of the setups are shown in Figure (a) Front view. (b) Side view (c) Top view.
These views show the arrangement of links and shafts.

a (front view) b (side view)

C (top view)

Fig. 3 views of setup

C. Views of the Pins

These pins are used for transmitting the power when there is no change in
orientation of shafts during motion.
D. Arrangement of Pins in Shaft

In the below diagram for basic arrangement of pins in the shaft holes are shown.
The diagram clearly shows that pins used are in odd number 3,5,7,9… and centers
of any two pin holes must not be on that line which represent the diameter of the
shaft and angle between all consecutive holes should be equal for smoother power
transmission. Value of angle such that the its multiple with any integral not equal
to 180 degrees.
Let the Value of angle = x degree
Then n*x ≠ 180 degree. Where n is an integral value.
As mentioned, Angle between the centers of any two pin holes must not be on that
line which represent the diameter of the shaft because if this happen angle between
them is 180 degrees and during motion pins or links use are trying to overlap each
other because of this motion interrupted.
Also, as we mentioned that pins no. should be odd and angle between consecutive
holes are equal.

Fig. 5 Arrangement of pins in shaft

E. Analysis of Mechanism

From the above diagrams and views the setup is clearly established in the mind,
but as for convenience here we use the front view of the setup for analyzing the
mechanism of setup.

Fig. 6 front view of model

Let at the starting instant shaft 1 starts rotation with 3 pins in anticlockwise
direction and a reaction force developed at the pin surface which in contact with
the shaft and this force transferred to the other end of the pin which is in the shaft
and applying on the shaft 2 due to which shaft 2 starts rotating in the same
direction as shaft 1, after 120 degree rotation pin 1 comes at the place of pin 2 &
pin 2 comes at the place of pin 3 & pin 3 comes at the place of pin 1 by sliding in
shaft and self adjusting. This motion repeated for next 120 degrees and further for
next 120 degrees and pins are exchanging the position in successive order as
discussed before.

4. APPLICATION
The featured product has its widest application as an extension for a socket
wrench. Here the design makes it easy to reach fasteners in the automotive and other
mechanical industries, where direct access to bolts and screws is often limited.
However, the possible applications for this technology extend into numerous
fields. Just think of the possibilities for power transmission in push bikes, toys
and hand-cranked equipment, or for movement transmission in store and outdoor
signage.
1. Driving for all kinds four faced tower clocks. The elbow mechanism was
first use in the year 1685 for the famous London tower clock named bigben.

2. The mechanism is invariable used for multiple spindle drilling operation

called the gang drilling

3. Used for angular drilling between 0 to 90 degree position.

4. Lubrication pump for C.N.C. lathe machines.

5. The mechanism is very useful for a reaching a drive at a clumsy location.

6. Air blower for electronic and computer machine.

7. The mechanism has found a very usefully use in electronic and computer

technology for multiple.

8. The elbow mechanism is used for movement of periscope in submarines,

9. The year 1685 for the famous London tower clock.

5. COMPRATION

COMPARISON OF GEARED DRIVE WITH GEARLESS DRIVE

The gearless drive is capable of transmitting motion at any fixed angle between 0
to 90 degree. This desired effect is also possible with help of bevel gearless differ
to a great extent not only in their manufacturing method or working principle but
also in other aspects etc. the aspects have been discussed below:
I) MANUFACTURING METHODS
Bevel gears, which are straight teeth or spiral teeth are manufactured on special
purposes machines like Gearless machines´. These required large amount of
calculation and every pair or set of gear are made together and there is no
interchangeability. The gearless drive has this advantage that it can be machined and
manufactured on conventional machines and it provide complete freedom of
interchangeability.

II) WORKING PRINCIPLE:-

A gear comprises of a frustum of a cone with teeth out on its periphery. The driving gear
mounted on the input shaft meshes with the driven gear and thus provides motion at right angle
to the input shaft.

III) CAUSE OF FAILURE:-

Starting with the principle that failure is the result of the stress i.e. condition more
severe than the material can with stand. The various type of failures such as pitting,
corrosion, erosion, fatigue etc. Cause the wearing of the gear tooth resulting in the
tooth leads to the replacement of the entire gear set, which is very expensive. The effect
of pitting, erosion, corrosion etc. will be present in the gearless drive also but the
effect of these will be not be as severe as in the case of geared drive, failure will
take place in the pi s ton e.g. Either bending or crack. Of the pins, but the main
advantage is that only particular pin will have to be replaced instead of case of
failure.

IV) MATERIAL:-
The material chosen for any component must
(a) be easily available
(b) be capable of being processed in the desired conditions and
(c) have the necessary physical properties. The gears generally fail due to
bending, fatigue and impact and the gears are also responsible for the failure
of the components in the gears have to very careful determined since it may lead to
pitting.

V) LUBRICATION AND COOLING:- A few open gears drives are lubricated by

grease but gear units are usually totally enclosed and oil lubricated. The arrangement
for lubrication is simple and easy, since it requires only a leak proof housing in
which the gears are placed and oil is filled. This lubricating also acts as cooling medium. The
heat generated and it then spreads to other areas. In the gearless drive lubrication and
cooling plays a very major role. The efficiency of the mechanism is affected by
lubrication. Although the system of lubrication and cooling complex gives good
result. Due to sliding contract, between pins and cylinders, heat generated is more
and thus effective cooling is a must.

VI) TORQUE TRANSMITTING CAPACITY:-

The gear drive is capable of transmitting very high torque as compared to the gearless drive
which is meant only for low torque applications.

VII) LIFE AND EFFICIENCY:-

Designed life represents the total period of operation, regardless of any variations
of torque or speed, which may occur during that the time industrial. The geared
drive is capable of giving an efficiency of about 40% and certain errors like
backlash, hunting etc. can not be eliminated. In the gearless drive, although the life has
not been calculated but it is assumed that its life will be in comparison to that of geared drive but
its efficiency could be as high as 85 % to 92%with proper lubrication and cooling.

VIII) Comparison of this drive with gear drive infinite no of speed can be
available which can not to easily possible in gearbox.

IX) Optimum machining is important which require exact machining speed

for particular operation which is very difficult to gain for gear drive but can easily
available by this drives increase the following.
1)Tool life
2)Productivity
3)Energy saving

X) The different speed at eight angle (0 to 90) is possible which is not

easily possible in gear drive
XI) Efficiency can be increased by increasing no of pins, by precise
machining, selecting suitable material and proper lubrication.

6. SELECTION OF MATERIAL:-

The proper selection of material for the different part of a machine is the main
objective in the fabrication of machine. For a design engineer it is must that he be familiar
with the effect, which the manufacturing process and heat treatment have on the
properties of materials. The Choice of material for engineering purposes depends
upon the following factors:
1.Availability of the materials.
2.Suitability of materials for the working condition in service.
3.The cost of materials.
4.Physical and chemical properties of material.
5.Mechanical properties of material.

Materials selected in Project for

Shafts, Rods, Angles, Disc
Material used
Mild steel
Reasons:-
1.Mild steel is readily available in market
2.It is economical to use
3.It is available in standard sizes
4.It has good mechanical properties i.e. it is easily machinable.
5.It has moderate factor of safety, because factor of safety results in unnecessary
wastage of material and heavy selection. Low factor of safety results in
unnecessary risk of failure
6.It has high tensile strength
7.Low co-efficient of thermal expansion

Properties of Mild Steel:

M.S. has a carbon content from 0.15 % to 0.30%. They are easily wieldable thus
can be hardened only. They are similar to wrought iron in properties. Both ultimate
tensile and compressive strength of these steel increases With increasing carbon
content. They can be easily gas welded or electric or arc welded. With increase in
the carbon percentage weld ability decreases. Mild steel serve the purpose and was
hence was selected because of the above purpose.

7.BILL OF MATERIALS

Sr.No Part Specification Material Units Cost/unit

Name
1 Shafts OD=25mm,L=457mm MS 2 Rs 50/kg

2 Pins OD=3mm,L=400mm MS 3 Rs 20/pin

3 Bearing UCP 6205 CI 4 Rs170/piece

4 Frame 60mm×60mm×30mm MS 6 Rs 52/kg

meter
(5
kg)

5 Circular Dia.=152mm,Thickness=5mm MS 4 Rs 50/kg

Disk
6 Plate 228mm×150mm MS 1 Rs 48/kg

7 Nut & MS 8 Rs 40
Bolt
8.Feasibility Study

Component Specification Availability Availability

status

Shafts OD=25mm,L=457mm Iron and steel Easily available

shop

Pins OD=3mm,L=400mm Iron and steel Very easily

shop available

Bearing UCP 6205 Automobile Rarely

spare parts available
shop
Frame 60mm×60mm×30mm Iron and steel Easily available
shop

Circular Disk Dia.=152mm,Thickness=5mm Iron and steel Easily available

shop

Plate 228mm×150mm Scrap house Available

Nut & Iron and steel Very easily

Bolt shop available
9. Cost Estimation

Cost estimation may be defined as the process of forecasting the expenses that
must be incurred to manufacture a product. These expenses take into a
consideration all expenditure involved in a design and manufacturing with all
related services facilities such as pattern making, tool ,making as well as a portion
of the general administrative and selling costs.

PURPOSE OF COST ESTIMATING:

1.To determine the selling price of a product for a quotation or contract so as to

ensure a reasonable profit to the company.

2.Check the quotation supplied by vendors.

3.Determine the most economical process or material to manufacture the

product.

4.To determine standards of production performance that may be used to control

the cost.

BASICALLY

THE BUDGET ESTIMATION IS OF TWO TYPES:

1.Material cost

2.Machining cost
MATERIAL COST ESTIMATION:

Material cost estimation gives the total amount required to collect the raw material which has
to be processed or fabricated to desired size and functioning of the components.

These materials are divided into two categories.

1.Material for fabrication:

In this the material in obtained in raw condition and is manufactured

or processed to finished size for proper functioning of the component.

2.Standard purchased parts:

This includes the parts which was readily available in the market like

Allen screws etc. A list is forecast by the estimation stating the quality, size and

standard parts, the weight of raw material and cost per kg. For the fabricated

parts.

MACHINING COST ESTIMATION:

This cost estimation is an attempt to forecast the total expenses that may include to
manufacture apart from material cost. Cost estimation of manufactured parts can
be considered as judgment on and after careful consideration which includes
labour , material and factory services required to produce the required part.

PROCEDURE FOR CALCULATION OF MATERIAL COST:

The general procedure for calculation of material cost estimation is

1. After designing a project a bill of material is prepared which is divided into

two categories.

a. Fabricated components

b. Standard purchased components

2. The rates of all standard items are taken and added up.

3. Cost of raw material purchased taken and added up.

LABOUR COST:

It is the cost of remuneration (wages, salaries, commission, bonus etc.) of the

employees of a concern or enterprise.

Labour cost is classifies as:

1)Direct labour cost

2 )Indirect labour cost

DIRECT LABOUR COST:

The direct labour cost is the cost of labour that can be identified directly with the
manufacture of the product and allocated to cost centers or cost units. The direct
labour is one who counters the direct material into sale able product; the wages etc.
of such employees constitute direct labour cost. Direct labour cost may be
apportioned to the unit cost of job or either on the basis of time spend by a worker on
the job or as a price for some physical measurement of product.

INDIRECT LABOUR COST:

It is that labour cost which can not be allocated but which can be apportioned to or
absorbed by cost centers or cost units. This is the cost of labour that does not alters
the construction, confirmation, composition or condition of direct material but is
necessary for the progressive movement and handling of product to the point of
dispatch e.g. maintenance, men, helpers, machine setters, supervisors and foremen
etc.

The total labour cost is calculated on the basis of wages paid to the labour for 8

hours per day.

Cost estimation is done as under

Cost of project = (A) Material cost + (B) Machining cost + (C) Labour cost

(A) Material cost is calculated as under :-

i) Raw material cost

ii) Finished product cost

RAW MATERIAL COST:

It includes the material in the form of the Material supplied by the “Steel authority
of India limited” and “Indian aluminium co.” as the round bars ,angles , square
rods, plates along with the strip material form. We have to search for the suitable
available material as per the requirement of designed safe values.

Price of Shaft = 50 x 5.8 = Rs. 290

Price of Pins = 20 x 3 = Rs. 60

Price of Bearings = 170 x 4 = Rs. 680

Price of Circular Discs = 4.8 x 50 = Rs. 240

Price of Angle = 52 x 5 = Rs. 260

Price of Plate = Rs. 48

Price of Nut & Bolt = Rs. 40

Finished Product Cost :

The machining cost of the product is Rs. 450

Total cost of the finished product = raw material cost + machining cost

= Rs. 1618 + Rs. 450

= Rs. 2068

10.Possible Improvements

The project designed and manufactured by us although is only model and has not undergone
any extensive research or study but we are quite confident that it is possible to
improve it’s efficiency to a considerable extent by improving the manufacturing
techniques and also by corporative certain modifications. This device can also be
used for various other applications besides just transmitting motion at desired angle
those applications have discussed in detailing the following: -

METHOD OF IMPROVING EFFICIENCY: -

Manufacturing of improving efficiency: -

The main motion is transmitted with the help of a sliding pair which formed between pin & the
cylinder. These pins have to be lapped and cleaned and it should be capable of providing
complete interchangeability similarly with the cylinder, they too have to be hone or
lapped so as to provide smooth surface finish. This will result in less frictional loss and loss heat
generation.

LUBRICATION AND COOLING METHODS: -

Lubrication and cooling are a must in sliding members. One of the simple
techniques applied for lubrication can be to drill oil holes in the cylinder body for
fill than up with oil. But this technique will not be very effective since the weight and use of
cylinders will increase.

MODIFICATION: -

One of the methods by which efficiency or performance can be enhanced is by

increasing the number of pins. From the working of the mechanism we know that the pin at the
inner most position is the drawing pin the pins the mechanism. Thus if the number required for
the next pin to attain the inner most position is considerable reduced and thus the
performance of the mechanism &its life increases.

11. Merits and Demerits

Merits

• Complete freedom of interchangeability.

• More efficient than gear.
• Power could be transferred to any desired angle.
• Ease of manufacturing.
• Misalignment of shafts can be tolerated to some extent.
• Simpler cooling system
• Low cost of manufacturing
• Portability of parts.

Demerits

• Does not work at very low starting torque.

• Improper hole drilling could pose much problem.
• Sudden load would cause mechanism breakdown.
• Links are to be replaced after certain cycle time.
 • Speed ratio is always constant 1:1.

12. BIBLIOGRAPHY

We referred the following books,

BOOK NAME AUTHOR

Thermal Engineering R.S.Khurmi

Machine Design R.S.Khurmi

Work Shop Technology S.K.Hajra, Chaudhary

http://wikipedia.com/gearlesstransmission/
http://encylopedia.com/powertransmission /
http://sciencelearn.org.nz/Science-Stories/gearlesspowertransmission/