Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

CHAPTER 1

Introduction
1.1 Introduction to Chainless Bicycle

This project was created to allow users to replace rear wheel using a propeller shaft. Chain drives are
the most traditional and common way to transmit power when using a bicycle. In order to solve the
numerous drawbacks of chain drive, we developed the chainless transmission to the bicycle in this
work. Shaft drives were invented more than a century ago, but chain-driven bicycles largely replaced
them due to the wide range of gears that could be used with sprockets and derailleurs.

A few new, shaft-driven bicycles have recently been released as a result of developments in internal
gear technology. The back wheel is often driven by the chain and sprocket system in two-wheelers.
The shaft drive just requires occasional grease gun lubrication to maintain the gears operating quietly
and smoothly. A bicycle that employs a shaft drive rather than a chain and has two sets of roller
bearings at either end is known as a shaft-driven bicycle. This new type of transmission system for
bicycles results in a system that is higher performing and safer. In place of the chain ring on a
standard bicycle, shaft-driven bikes use a pinion-style drive shaft mechanism additional roller
bearing positioned on the pinion forms a mesh. A second roller bearing positioned on the driving
shaft is meshing with the pinion. The axis of the drive torque from the pedals can be rotated through
90 degrees due to the usage of roller bearings.

The drive shaft then includes a second roller bearing next to the rear wheel hub that meshes with a
pinion on the hub in place of the rear sprocket on a standard bike, cancelling out the first shift in axis
of the drive torque. The pedal's motion will determine whether the wheel moves forward or
backward. By doing this, the chain and sprocket approach is avoided. The energy is smoothly,
quietly, and effectively transferred from the pedals to the rear wheel by this "chainless" drive
mechanism. In contrast to chain-driven bicycles, it has a more appealing appearance. It displaces the
conventional approach.

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1.2 Purpose of drive shaft

The torque that is produced from the engine and transmission must be transferred to the rear wheels
to push the vehicle forward and reverse. The drive shaft must provide a smooth, uninterrupted flow
of power to the axles. The drive shaft and differential are used to transfer this torque.

1.3 Functions of the Drive Shaft

a) Initially the torque must be transferred from the transmission to the foot pedal.
b) During the operation, it is necessary to transmit maximum low-gear torque
developed by the engine.
c) The drive shafts must also be capable of rotating at the very fast speeds required
by the vehicle.
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Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

CHAPTER 2

Literature Survey

A traditional derailleur system has 8 points of sliding 39 friction while their new system has two
points of rolling friction which leads to a 49% reduction in friction. A weight reduction of 10-15% is
also expected. An innovative drive train design that eliminates the need for chains and derailleurs
while also setting new efficiency objectives. Driven uses 21 Ceramic Speed hybrid bearings for
maximum efficiency. Each bearing contains unique ceramic balls that are 58% lighter and 2.3 times
harder than traditional steel, increasing the speed of the bearing by 30-50%. Each bearing works in
harmony to deliver greater power, playing a pivotal role in performance and speed. Driven sets a new
benchmark in drive train technology, increasing optimal efficiency to 99% and creating 49% less
friction than market leaders.Due to its unique pinion drive shaft design, Driven, unlike conventional
drive train systems, completely eliminates friction brought on by the articulation of a chain.
The gearing mechanism was then used to overcome the problems of chain-drive, such as low load
capacity, noisy operation that can cause vibrations, and the need for frequent lubrication, followed by
chain adjustments due to slackness. The ability of the gearing system to turn or change torque load
direction 90 degrees provided smooth and noiseless transmission. so in this project we conclude that
we can use bearings rather than chain or bevel gears for so many advantages mentioned
[1] Prof. Amit Kumar Kundu et.al., conducted experiment on “Design & Fabrication of Shaft Driven
Bicycle”, draws to the conclusion that The presented work was aimed to reduce the wastage of
human power on bicycle riding. The presented work also deals with optimization i.e. converting
rotary motion into the linear motion with aid of two bevel gears. Instead of chain drive one piece
drive shaft for rear wheel drive bicycle have been optimally designed and manufactured for easily
power transmission. Thereby we took the use of bearing-operated mechanism in place of gearing-
setup on the bicycle.

[2] Khan Hassan Zakariya et.al, conducted experiment on “Design & Fabrication of Shaft Driven
Bicycle”, draws to the conclusion that the focus was on the operations of shaft which was required of
low weight and less maintenances. These requirements could have filled with use of composite
elements like kevlar or epoxy fibers because of facts like now the conversion would occur from two
piece shaft into a single piece shaft and also now the shaft would have the high tensile strength, high
damping capacity, high torque capacity, long fatigue life and also absorb vibrations. Now the major
outcome would be the reduction in weight of shafts but here our problems wouldn’t be almost end.

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Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

Actually we faced unavailability of these kinds of composite elements in the market and if we
somehow accessed them they could be available with high purchasing costs ultimately add on the
production of bicycles to us. Thereby we used the mild steel as the material for shafts as it provides
perfect pros to our shafts like resistance to breakage, high tensile strength followed by the low
weight with load carrying capacities.

[3] R.P. Kumar et.al., conducted experiment on “Design and Optimization of Drive Shaft with
Composite Materials,”, draws to the conclusion that Actually we could have faced with cons of using
composite materials like their high UV-resistance (so that they may degrade under sunlight) and
ability to absorb moisture (becoming sensitive to environment), so now we were satisfied with the
suitability of mild steel over these kinds of materials.

[4] Anup B. Patel et.al, conducted experiment on “Design Optimization & Analysis of Drive Shaft”,
draws to the conclusion that main aim in concentrated towards reducing overall weight of shaft
with same strength, which ultimately results in less human power consumption. More over by
using composite drive shaft we can avoid using two piece drive shaft, since composite
materials are providing much better natural frequency compared to the steel material.

[5] Parashar A et.al, conducted experiment on “Design and fabrication of shaft driven bicycle”,
draws to the conclusion that The presented work also deals with optimization i.e. converting rotary
motion into the linear motion with aid of two bevel gears. Instead of chain drive one piece drive shaft
for rear wheel drive bicycle have been optimally designed and manufactured for easily power
transmission. The result obtained from this work is a useful approximation to help in the earlier stage
of the development, saving development time and helping in the decision making process to optimize
a design.

[6] Prasad G. H et.al, conducted experiment on,“Design & fabrication of shaft drive for bicycle”,
draws to the conclusion that This bicycle can be used for racing purpose and off-road riding. As the
speed of the shaft driven bicycle is more enough, it can be utilized for generating pedal work. The
result obtained from this work is a useful approximation to help in the earlier stages of the
development, saving development time and helping the decision-making process to optimize the
design.

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Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

2.1 Conclusion drawn from literature review

A thorough review of several journals and articles were carried out and came to the conclusion that
bearing-oriented mechanisms should be used as a replacement for both chained-driven and gearing-
operated mechanisms.
Bearings with the advantages of reducing friction and having high load carrying capacity.
As a result of that it was used in conjunction with a lighter shaft (capable of encompassing smooth
transmissions).
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Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

CHAPTER 3
Objectives of dynamic bicycle

1. Increase durability of bicycle with the help of shaft drive.

2. Drive system is less likely to become jammed, a common problem with chain-driven bicycles
3. Reduce maintenance cost of bicycle.
4. Increase power transmission efficiency of the bicycle and makes system more reliable.
5. Reduce frictional power compared to chain bicycle.
6. Reduces weight of bicycle.
7. Improved consistency of performance. According to Dynamic Bicycles, a drive shaft bicycle
can give 94% efficiency, and a chain powered bike may deliver 75-97% efficiency depending
on condition.
8. Greater ground clearance: without a derailleur as well as other low-hanging machinery, the
bicycle provides roughly double the ground clearance.
9. The rider pulls the pedal, which turns the shaft rod at the front end through  pinion. This
rotating shaft also contains a ball bearing pinion at the back end, which meshes with another
pinion on the rear hub, as well as the rear wheel, to drive the bicycle's rear wheel. CBS is
completely enclosed and requires minimal care other than regular lubrication using a grease
gun.
10. The Chainless Bicycle System is extremely comfortable and provides effective power
transmission from the rider's foot to the rear wheel. The rider's shoes and pants  don't
get damaged by accident. So chain bite is not present in this system, cyclists of this chainless
bicycle system are not affected.
11. The drive shaft then has another pinion at the rear wheel hub that meshes with a ball bearing
on the hub where the rear sprocket would be on a typical bike, cancelling out the initial axis
shift of driving torque.
12. The smallest misalignment will result in chain failure. As a result, the shaft drive system may
be used to solve this problem.

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Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

CHAPTER 4

Bearing

A rolling-element bearing, also known as a rolling bearing, is a bearing which carries a load by
placing rolling elements between two bearing rings called races. The relative motion of the races
causes the rolling elements to roll with very little rolling resistance and with little sliding Roller
Bearing Types and Applications There are lot of different types of roller bearings available to meet
specific application requirements. A variety of rollers are available from Emerson Bearing including
the following popular types:

4.1 Cylindrical roller bearings

These bearings which differ from ball bearings in having rollers that are longer than their diameter,
can support heavier loads. Our cylindrical roller bearings are suitable for high-speed applications and
can handle significant radial stresses.

Fig 4.1 Cylindrical roller bearings

…...

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Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

…
4.2 Spherical roller bearings
Even with shaft deflection and misalignment, these can support enormous loads. They can be made
to mount with or without a sleeve adapter and can have cylindrical or tapered bores. Spherical
roller bearings can withstand strong shock loads as well as axial loading in either direction and are
available with a variety of internal clearances and retainer configurations. These bearings come in a
variety of bore sizes, from 20 mm to 900 mm.

Fig 4.2 Spherical roller bearings

4.3 Needle roller bearings

This type of bearing can be made with or without an inner ring and is thinner than typical roller
bearings. When dealing with radial space restrictions in heavy-load, high-speed applications, needle
roller bearings are the best option. Drawn cup designs give a thin cross-section while still allowing
for high load capacities and huge grease reservoirs. These bearings are available with metric or inch
seals.…

Fig 4.3 Needle roller bearings

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4.4 Taper roller bearings

Radial and thrust loads can be supported by these bearings. They are only capable of supporting
unidirectional axial loads, hence the counter stay requires a second lateral reversed bearing. There
are metric and inch sizes of taper roller bearings. Roller bearings are utilised in a variety of
applications, including those for manufacturing, aerospace, and heavy machinery and equipment.

Fig 4.4 Taper roller bearing

4.5 Ceramics Bearing

4.5.1. Hybrid ball bearings using ceramic balls
Depending on size and substance, ceramic bearing balls can weigh up to 40% less than steel ones.
Hybrid ceramic bearings can function 20% to 40% more quickly than conventional bearings as a
result of the decreased centrifugal loading and skidding. This indicates that as the bearing rotates, the
outer race groove applies less pressure to the ball from the inside. Friction and rolling resistance are
reduced as a result of the force reduction.
The bearing can spin more quickly and with less energy consumption thanks to the lighter balls.
Usually, the ceramic balls are tougher than the competition. They will eventually develop a groove in
the racing due to wear. This is preferable to the balls being worn, which could result in flat patches
that would seriously impair performance. Although ceramic hybrid bearings use ceramic balls
instead of steel ones, their steel inner and outer rings are what give them their hybrid moniker.

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Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

Despite being stiffer than steel and having a higher strength than steel, ceramic material has a lower
load capacity due to the greater strains it places on the rings. Electrically insulated ceramic balls can
prevent arcing failures if electricity is allowed to flow through the bearing. Additionally, ceramic
balls can be useful in situations where lubrication might not be available (such as in space
applications).

4.5.2. Fully ceramic bearings

These bearings use ceramic balls as well as races. These bearings rarely, if ever, need to be
lubricated since they are resistant to corrosion. These bearings are noisy at high speeds because the
balls and race are stiff and hard. These bearings are fragile and prone to cracking under load or
impact due to the stiffness of the ceramic. Due to the same hardness of the ball and the race, wear
can result in chipping at high speeds of both the ball and the race, which can result in sparking.
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Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

.CHAPTER 5

Drive Mechanism
5.1 Working principle

The Driven idea converts a cyclist's pedal stroke into motion for the rear wheel by engaging teeth on
a flat cassette with ceramic ball bearings. As a result of the bearings rolling through the teeth, there is
no sliding friction. The method gains efficiency by substituting 2 rolling friction points for the 8
sliding friction points found in a typical derailleur system. According to them, the system is about
49% more effective than a typical derailleur system.

Fig. 5.1 Bearings Enclosure with Sprocket

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Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

Fig. 5.2 Bearing-Shaft Joint

5.3 Different Parts of Bicycle:
5.3.1 Transmission Shaft: It served to transfer power from the pinion to the rear cog. It's
constructed from composite materials. It is a mechanical shaft made up of the following components.
5.3.2 Pinion: The transmission shaft is connected to the pinion. The paddles are rotated while the
pinion, which is in the form of a roller bearing, receives the rotation.
5.3.3 Bearings : Ball bearings are used to withstand radial and axial loads as well as to reduce
rotational friction when clamping with the sprocket-wheel (so that the system does not jam). By
using bearings, we can benefit from a quiet and squeaky-free transmission as well as less effort,
which ultimately conserves human energy.

5.3.4 Shaft-driven: To satisfy the demands of torque transmission capabilities, the support was a
revolution instead of a chained support, making it practical for obtaining required wheel speeds more
easily. In our project, we substituted mild-steel shafts for composite and other materials like
aluminium due to their superior similar mechanical qualities. Shaft: 450 mm; Steel Type: Mild (in
length).

5.3.5 Sprocket-wheels: Maintain tooth orientation along the wheels, but in our instance, the bearing
enclosure requires that all of the teeth be perpendicular to the wheel axes. The front wheel's outer
sprocket measures 210mm in diameter, while the rear wheel's inner sprocket measures 112mm. In
comparison to the rear sprocket, which has 16, the front sprocket has 32 teeth. 223 mm for the axle
(in length).

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Fig 5.1 Assembly of Transmision of shaft

Mass gains have been made by removing parts like the chain and derailleur and replacing them with
pinion and shafts. they estimate that this might be 15-20% lighter than a typical arrangement.
They envision a rapid release technique of replacing the entire carbon fibre axle (electronics and
everything) with a different ratio between the front and rear bearing pinions in order to modify the
total gear ratio (typically done by replacing the front chainring with a different number of teeth). To
achieve a mechanical advantage, the present design includes 8 bearings up front and 11 bearings
behind.

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Fig 5.2 Catia model of crank

Fig 5.3 Catia model of frame

Fig 5.4 Catia model of front pinion

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Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

Fig 5.5 Catia model of rear pinion

Fig 5.6 Catia model of rear hub

The principle of the bearing pinion sliding it should be possible to slide the bearing pinion up and
down the gears without damaging the gear teeth, but in practice , this is very challenging. According
to them, it employs shift channels that allow the bearing pinion to change gears numerous times
during rotation. It would be intriguing to observe how it wears while shifting gears under torque. The
system must index itself and be aware of the location of the shift channels with respect to the bearing
for this to function.
5.4 Outcomes from the Project
The removal of the chain and derailleurs, Driven is lighter than a traditional drivetrain. Aerodynamic
benefits have a lot of potential. The reduction of all friction, including chain link stiction and chain
sliding friction. There are countless choices for a 1x gear's gear range. The overall final drive ratios
can be changed by using front and rear pinions of various diameters. Drive system jamming is less
common, which is a major issue with chain-driven bicycles. The friction produced by the Ceramic
Speed Driven is 32% lower than that of the enhanced Ceramic Speed drivetrain and 49% lower than
that of the base Dura-Ace drivetrain. After realising the drawbacks of bevel gears, which were also
left with the impression of replacements, this method was modified. The gearing system also had

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several limitations, such as the loss of flexibility caused by increased speeds, which allowed
vibrations to escape, and the deterioration of gear teeth, which made periodic removal of the gears
necessary.

CHAPTER 6

Future Scope

1. The Driven system continues to lead the efficiency curve and retains its excellent efficiency values
at these racing power outputs. This powertrain is ideal for a variety of uses, including commuting
bikes, track bikes, triathlon bikes, and time trial bikes.
2. The creation of a tricycle designed specifically for people with special needs that transmits power

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more smoothly. Options for Driven can include a double row of ball bearings (improving efficiency
levels even more), a more optimal tooth shape that may be asymmetrical, and material testing
(advanced lighter and durable materials for the rear cog and front ring).
3. It offers the potential for an internal power, and a small shroud can cover the entire drivetrain to
shield it from mud, water, and debris.
4.This Chainless Bicycle System generates efficient and reliable output as compared to the
traditional system.
5.. In the future, this technique might be implemented on bicycles and become a superior
transmission system.
6. This may also be used on vehicles driven by engines, such as trucks and other high-powered
vehicles.
7. The technique may also be used in motorbikes with high-powered motors such as 1kW.
8. The bicycles can be introduced as a start up in countries like China, Malaysia, and Japan etc.
where the number of people using cycles are very high.
9. These kind of bicycles would be a perfect alternative for motor bikes.
10 These kind of bicycles are gaining popularity among young mountain bikers.

REFERENCES

[1] Prof. Amit Kumar Kundu, “Design & Fabrication of Shaft Driven Bicycle,” IJSTE - International
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Bicycle,” IRJET -International Research Journal of Engineering & Technology, Volume 5, Issue 03,
Page No.-2836-2837, March-2018, www.irjet.net.

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Design of Chainless bicycle with the help of propeller shaft and ball bearing 2022-23

[3] R.P. Kumar, “Design and Optimization of Drive Shaft with Composite Materials,” International
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[16] Aakash Patel, Hitesh Prajapati, Vivek Patel, Amit Patel, “ Design and modelling of
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