Wa0053.

DESIGN AND FABRICATION OF GEARLESS POWER TRANSMISSION
A PROJECT REPORT ON
Submitted in partial fulfillment of the requirements for
Award of the degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
By
K.PRAVEEN KUMAR 213J5A0313
P.HEMANTH KUMAR 203J1A0332
V.DHANARAJU 203J1A0308
R.SATYA NARAYANA 203J1A0335
L.CHANDRA SEKHAR 203J1A0324
CH.SRIBABU 213J5A0303
Under the guidance of

Mr. G VENUMADHAV, MTech,(PhD)
Assistant professor
DEPARTMENT OF MECHANICAL ENGINEERING

RAGHU INSTITUTE OF TECHNOLOGY
(Affiliated to JNTUGV , VIZIANAGARAM) Dakamarri
Bhemmunipatnam mandal , Visakhapatnam
2020-2024
1
DEPARTMENT OF MECHANICAL ENGINEERING (RIT)
RAGHU INSTITUTE OF TECHNOLOGY

( Affiliated to JNTUGV, VIZIANAGARAM )
Visakhapatnam - 531162
CERTIFICATE
This is to certify that the main project entitled “ DESIGN AND FABRICATION OF GEARLESS
POWER TRANSMISSION ” has been submitted by
K.PRAVEEN KUMAR 213J5A0313

P.HEMANTH KUMAR 203J1A0332
V.DHANARAJU 203J1A0308
R.SATYA NARAYANA 203J1A0335
L.CHANDRA SEKHAR 203J1A0324
CH.SRIBABU 213J5A0303
Of Mechanical Engineering Department , Raghu Institute of Technology (Affiliated to JNTUGV
VIZIANAGARAM) Visakhapatnam during the period of 2023-2024 in the partial fulfillment of the
requirement for ENGINEERING under the guidance .
PROJECT GUIDE HEAD OF THE DEPARTMENT
Mr.G.Venumadhav ,M.tech,(Ph.D) Dr.P. Vijaya Kumar , M.E ,Ph.D.
Assistant professor Professor & Head
Dept. of mechanical engineering. Dept. of mechanical engineering
Raghu Institute of Technology. Raghu Institute of Technology
Visakhapatnam Visakhapatnam
2
EVALUATION SHEET
Name of candidates : K.PRAVEEN KUMAR

P.HEMANTH KUMAR
V.DHANRAJU
R.SATYA NARAYANA
L.CHANDRA SEKHAR
C.H.SRIBABU
TITLE OF THE PROJECT : DESIGN AND FABRICATION OF GEARLESS POWER

TRANSMISSION
This dissertation is approved by the board of Examiners
External Examiner : ____________________
Internal Examiner : ____________________
3
ACKNOWLEDGEMENT
We are happy to present this report “ DESIGN AND FABRICATION OF GEARLESS POWER
TRANSMISSION ” in partial fulfillment of requirements for the completion of Bachelor of engineering in
Mechanical Engineering
We would like to express our deep sense of gratitude to our esteemed institute “ Raghu Institute of
Technology ” which has provided us an opportunity to fulfill our cherished desire .
Our whole hearted thanks to assistant professor Mr.G.Venumadhav , M.tech (Ph.D). our project guide for his
untiring guidance and valuable suggestions without which we could not have made our efforts a success .
We thank Dr. P. Vijaya Kumar, M.E,PhD, Professor&Head of the Department, Department of Mechanical
Engineering, for his constant encouragement and for sharing time for us from his schedule.
We would like to thank all the Teaching and non – Teaching staff members of Mechanical Engineering
Department for all their support in completion of our project.
We also show our gratitude to all other relevant staff of various departments for their cooperation, help and
guidance from providing us all the required equipment’s to the full internet access.
4
ABSTRACT
Designing and Fabrication of a Gear less Power Transmission . Today’s world require speed on each and
every field . In current scenario , Industries are in need to eliminate the gear transmission which requires
high level of maintenance and cost , so in order to over come these liabilities , effective gear less power
transmission arrangement is used for shafts to transmit power . In gear less transmission system power is
transmitted to odd number of pins or links . Increase in number of links and pins will give you a smooth
motion but it will not be cost effective.
In modern machineries, the motion and power need to be transferred from one shaft to other for various and
complex activities. Also, it is essential to achieve such objectives with maximum efficiency and minimum
cost. For transmitting power between different orientations of shaft, various medium like belt, chain and
especially Gears are used. But due to cost of manufacture of gear, interchangeability in parts and very
limited shaft Orientations, need arises for an alternative system. In this project a Gearless power
transmission system has been Studied, a possible gearless power transmission layout is designed and
developed where it can transmit power from One shaft to other without any gear being used. This project
deals with transmission of power from one shaft to other at right angle by means of sliding links that form
revolute pair with the hub.
5
CONTENTS Page No
CERTIFICATE 2
EVALUATION SHEET 3
ACKNOWLEDGEMENT 4
ABSTRACT 5
CONTENTS 6-7
LIST OF FIGURES 8
Chapter -1 INTRODUCTION 9
1.1 Background 10
1.2 Need of gear less transmission 11
Chapter – 2 LITERATURE SURVEY 12-14
Chapter – 3 WORKING PRINCIPLE AND COMPONENTS 15-16
3.1 Components of the model 17
3.1.1 View of planes 18
3.1.2 View of shafts 19
3.1.3 Views of set up 20-21
3.1.4 Views of the pins 22
3.1.5 Analysis of mechanism 23-25
CHAPTER – 4 DESIGN CALCULATIONS 26
4.1 Designing of Shaft 28
4.2 Designing of Hub 29
4.3 Designing of Elbow rod 30
4.4 Design model of the project fabrication 31
CHAPTER – 5 PERFORMANCE TEST AND RESULT 32
5.1 Performance Test 33
5.2 Result and Discussion 34
5.3 Applications 34
5.4 Comparison With Existing Solutions 35
5.5 Advantages 35
5.6 Disadvantages 36
6
5.7 Method Of Improving Efficiency 36

CHAPTER – 6 CONCLUSION 37-38
REFERENCES 39
LIST OF FIGURES
7
SL NO FIGURE DESCRIPTION
1 3.1 Gear less power transmission
2 3.2 Concept drawing of machine and working
3 3.3 View of the planes
4 3.4 Front view of shaft
5 3.5 Side view of shaft
6 3.6 Top view of shaft
7 3.7 Front view of setup
8 3.8 Side view of setup
9 3.9 Top view of setup
10 3.10 Front , side & top view of pins
11 3.11 View of shafts with holes
12 3.12 Setup view
13 3.13 Movement of Link 2 of Link Type 1 in XZ plane
14 3.14 Movement of Link 2 of Link type 2 in YZ plane
15 4.1 Elbow link design in Fusion 360.
16 4.2 Shaft , hub design in Fusion 360
8
CHAPTER – 1
INTRODUCTION
9
1.1 Background
Today’s world requires speed on each and every field. Hence rapidness and Quick working is the most
important. Now days for achieving rapidness, various Machines and equipment’s are manufactured. Gears
are costly to manufacture. Its Need to increase the efficiency of transmission which cannot be done using
geared Transmission. Gearless transmission mechanism is capable of transmitting power at Any angle
without any gears being manufactured. So here I introduced a gearless Power transmission system for skew
shafts which reduce the losses, cost & save the Time and space. This system allows the changing in the
orientation of shafts during Motion which is very interesting and fascinating about this mechanism.
Also during analysis of mechanism and working it is seen that this gearless transmission can be used for
both intersecting shafts and skew shafts but here we Introduced a solution for skew shafts so main attention
is towards the skew shafts .
In today’s world, as limited quantity of the resources available, it is Necessity to utilize those resources in
such way that it gives maximum of them. The Major problem for the gear transmission is that the
manufacturing of gear is Complex process which consumes more time and takes very much precision and
Manufacturing cost is high.
The another major problem is that the transmission having gear cause the Jamming due to the backless error
and produces more noise compared to other Drives due to pitch mismatch. This elbow mechanism is also
known as Gearless Transmission system, L-pin mechanism or Orbital transmission mechanism. This Elbow
mechanism is simple in construction and can be easily made with minor Precision.
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.
10
1.2 NEED OF GEARLESS TRANSMISSION

1) Today’s world requires speed on each and every field. Hence rapidness and quick Working is the most
important
2) Now days for achieving rapidness, various machines and equipment’s are Manufactured.
3) Gears are costly to manufacture. Its need to increase the efficiency of transmission Which cannot be
done using geared transmission.
4) Gearless transmission mechanism is capable of transmitting power at any angle Without any gears being
manufactured.
In this transmission system Nos. of pins used are between 3, 4, 5, which were Inserted into the hole drilled
on the cylindrical disc. If we use less than 3 pins then It will not work and will cause jamming. The motion
is transmitted by sliding and Rotating movement of the L-pins simultaneously. This L-pin is inserted into
same Angular distance of 120⁰ on the cylindrical disc.
The Elbow mechanism consists of the following part:
1) L-pins
2) Cylindrical Discs
3) Shaft
4) Base Plates
5) Arm Supports (Bearing).
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° 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° Without any gear system to an output shaft without
gears .The transmission includes an input shaft.
11
CHAPTER – 2
LITERATURE SURVEY
LITERATURE SURVEY
12
R. Somraj et al. [1] Analyzed the Design and Fabrication of Gearless Transmission For Skew Shafts.
3Numbers of L-pin rods were used. Overall mechanism is Considered to be running on 0.25 HP motor with
140 R.P.M and Torque of 1238 N-mm. Design of Hub is done by Considering a hub of internal diameter is
32 mm and outer diameter is 92 mm, length is 82 mm. Design of shaft was done by taking maximum tensile
stress of 60 N/mm2 and maximum shear stress of 40 N/mm2 Diameter of elbow rods was 8 mm. It Was
Concluded that given arrangement can Be used for any set of diameters with any profile of shafts for skew
shafts of any Angle but the shaft’s must be having the rotational motion about his own axis, Transmission of
motion is very smooth and desirable and used only for the equal R.P.M. of driving shaft and driven shaft by
employing links or given type of links For appropriate joints for revolute pair. It was also found that
successful mechanical Devices function smoothly however poor fly they are made while other does this
Only by virtue of an accurate construction & fitting of their moving parts.
Neeraj Patil et al. [2] Researched on Gearless Transmission Mechanism and its Applications. Link of C-45
was used. Links bent at required angle slide inside the Holes in the hub Mechanism can transmit at any angle
0 to 180 degree. The Mechanism is studied and a possible go-kart transmission layout is fabricated and Few
future applications are suggested. Into This weight of model along with rider Assumed 1500 N. Kart was
loaded with 4 Numbers. Of tires each with 375 N of Load. Co-efficient of friction between road and tire was
Considered 0.7. Tire of Radius 0.1778 m Taken. Torque required moving Was 46.67 N-m with Torque on
Each link 15.55 N-m Tangential force of 311.15 N was acting on links. Diameter of Each link was 10 mm.
After study of the mechanism it was concluded that this mechanism is mainly Applicable to low cost
applications where torque is low to medium. With future Development in low friction materials (graphene
coating) and stronger composite Materials, the efficiency and capacity of this mechanism can be increased.
Also if Instead of bent links, bolted links or links held by universal joints are used then Transmission is
possible even when angle changes on the go.
Ashish Kumar et al. [3] performed study on Multi Angular Gearless Drive. The Mechanism was loaded
with 3 Numbers of L-pins. Parts of mechanism were Modeled on Solid Works and the analysis of the
mechanism was carried out on ANSYS. The study of mechanism was carried with0.63 Moment of Inertia
(Provided by Solid Works). Behavior of system is plotted on different charts i.e. Velocity v/s. Time,
Acceleration v/s. Time, Angular Acceleration v/s. Time, Separation Distance v/s. Time. From this it was
concluded that the final design thusObtained is capable of transmitting torque and power at varied angles
depending on The angular limitation of the hooks joint. With further research and advanced Analysis in the
design wide-ranging applications of the drive can be discovered.
Solanki Nehal et al. [4] studied Design and Analysis of Gearless Transmission Through Elbow Mechanism
which can be used into the replacement of the bevel Gears. 4 Numbers of L-pins was used into this
fabricated model. With input of 1HP Motor. Links of 10 mm diameter were used of S.S.M.S material. Shafts
are rotating With speed of 1440 R.P.M and 4947.066 N-mm of Torque. Stimulation is done by The ANSYS
16.2 and analysis of mechanism was done at 50,100,150,200 R.P.M for Both the material. It is been
concluded from that analysis that the mechanism with 6 Elbow rods made up of mild steel material is works
perfectly. The mechanism runs Smoothly when it is kept at 150 R.P.M Also it can be concluded that as the
no of Elbow rods increases smoother the operation would be.
Shiv Pratap Yadav et al. [5] performed Real time Study for Design, Analysis and Fabrication of Gearless
Power Transmission by using Elbow Mechanism. They Used 3 Numbers Of elbow rods inclined to the
90⁰.Modeling and rendering of Mechanism is done into the CATIA V5 and the analysis was carried on
13
ANSYS. The mechanism was working between 80 to 100 R.P.M after this it was concluded That It has a
high scope in future to replace the cumbersome usage of gears which Will be replaced simple, elegant usage
of the shafts that will change the overall cost Management of the industries using gear technology presently
to gain more profits.
Navneet Baradiya et al. [6] had done Analysis and Simulation of Gearless Transmission Mechanism. The
system is to be analyzed in Solid Works package Software to watch the response of the elbow rods and the
also the hub (coupled with Shaft). Motion analysis is performed by running the mechanism at 15 revolutions
Per minute and higher speeds, reaction forces and reaction moment are plotted Against clock run of 5
seconds by using post processor. Theoretical calculations are Made to obtain allowable stress by making use
of design data values. As a result,response of elbow rod and hub is Investigated to find the permissible speed
of Mechanism. Elbow rods of diameter 7.55 mm of stainless steel were used. It is Concluded that for smooth
and safe running of mechanism it should be kept below 140 rpm. With this study it is concluded that gearless
transmission mechanism is Capable of running up to 120 R.P.M under normal conditions. Further fatigue
Analysis is recommended for gearless transmission mechanism.
Amit kumar et al. [7] Introduced gearless power transmission arrangement used For skew shafts. 3
numbers of L-pins were used and the elbow mechanism was Compared with S-R-R-S links. During working
on experimental it is concluded that Proposed arrangement used for any set of diameters with any profile of
shafts for Skew shafts of any angle but the shaft’s must be having the rotational motion about His own axis,
transmission of motion is very smooth and desirable and used only for The equal R.P.M. of driving shaft and
driven shaft by employing pins or given type Of links for appropriate joints for revolute pair.
Jagushte G. S et al. [8] had done research about Design, Analysis and Fabrication Of Gearless
Transmission by Elbow Mechanism. This system was loaded with 3 L-Pins each at 1200 N of the cylindrical
disc. The L-pins are made up of the Stainless Steel (X6cr17). The rod diameter was taken 12.6 mm. part
modeling was done in Solid Works and Analysis is carried on Autodesk Inventor (2016).It Was Concluded
after analysis and Fabrication 140 rpm to 160 rpm is safe for gearless Transmission system. Thus simulation
results satisfy motion analysis results. Also The model works correctly as per the design. With the help of
this system, we can Efficiently reduce the cost in power transmission and further advancement in this
Technology can be made.
Mahantesh Tanodi et al. [9] Researched about Gearless Power Transmission-Offset Parallel Shaft
Coupling. 4 holes were drilled into the shafts and Z-links were Inserted into the each hole on shafts. This
paper was part of a study investigating The Gearless power transmission for parallel shafts. Gearless
Transmission which is Compact and portable equipment, which is skillful and is having something practice
In the transmitting power between parallel shafts without any gears being used. This Coupling for parallel
shaft gives variety of displacement and torque from a Minimum of 1 to 500 mm and from 5.4 to 80000 N-m
respectively. Analysis of Z-Pins done for the different angles and variation in length of pins is checked.
14
CHAPTER – 3
WORKING PRINCIPLE AND COMPONENTS
WORKING PRINCIPLE AND COMPONENTS
15
The Gearless transmission or El-bow mechanism is a device for transmitting Motion at any fixed angle
between the driving and driven shaft. The synthesis of This mechanism would reveal that it comprises of a
number of pins would be in Between 3 to 8, the more the pins the smoother the operation. These pins slide
Inside hollow cylinders thus formatting a sliding pair. Our mechanism has 3 such Sliding pairs. These
cylinders are placed in a Hollow pipe and are fastened at 120 Degree to each other. This whole assembly is
mounted on mild steel frame . Power is supplied by an electric motor. The working of the mechanism is
Understood by the diagram. An unused form of transmission of power on shaft Located at an angle. Motion
is transmitted from driving to the driven shaft through The rods which are bent to conform to the angles
between the shafts. These rods Are located at in the holes equally spaced around a circle and they are free to
slide in & out as the shafts revolve. This type of drive is especially suitable where quite Operation at high
speed is essential but only recommended for high duty.
Although this transmission is an old one many mechanics are skeptical About its operation, however it is not
only practicable but has proved satisfactory For various applications when the drive is for shafts which are
permanently located At given angle. Although this illustration shows a right angle transmission this drive
Can be applied also to shafts located at intermediate angle between (0 and 90 Degree) respectively. In
making this transmission, it is essential to have the holes For a given rod located accurately in the same
holes must be equally spaced in radial And circumferential directions, be parallel to each rod should be bent
to at angle at Which the shaft are to be located. If the holes drilled in the ends of the shafts have “blind” or
closed ends, there ought to be a small vent at the bottom of each rod hole For the escape of air compressed
by the pumping action of the rods.
After studying synthesis of mechanism it get revealed that this system consist of 3,to 8 pins and increasing
the Nos. of pins mechanism will work more smoothly. Power to this mechanism is supplied with motor.
Motion is transmitted from Driving to driven shaft with the help of L-pins. This L-pin starts TO and FREE
Motion when power is supplied.
Fig 3.1 Gear less power transmission

The motion is transmitted through the S-R-R-S Pair made by L-pins and cylindrical disc.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
16
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.
3.1 COMPONENTS OF THE MODEL

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.
Fig 3.2 Concept drawing of machine and working
3.1.1 VIEW OF PLANES

Here in the below diagram, planes are shown in the 3D, which helps us in The understanding of the
mechanism and movement of shafts and link used, the Figure shown in below is views of the planes.
This can be shows the x- axis y-axis And the z-axis and also very clearly viewed by the XY-plane ZY-plane
and the XZ-Plane.
17
Fig 3.3 View of the planes
3.1.2 VIEW OF SHAFTS

Below diagram shows a different view of the shaft arrangements 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.
18
Fig 3.4 Front view of shaft
Fig 3.5 Side view of shaft
Fig 3.6 Top view of shaft
19
3.1.3 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, in the front view As show in the below diagram fig
3.7 by using the software called CATIA V5 as Shows the front side and the top views, here using the two
shafts and the three bent Links or pins are shown in the below, here shows the shaft 1 is x-axis and the shaft
2 Is y- axis. And the three bent links are also shown.
Fig 3.7 Front view of setup
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.
20
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.
Fig 3.8 Side view of setup
Fig 3.9 Top view of setup
21
3.1.4 VIEWS OF THE PINS

Here different views of the pins according to the setup are shown (a) Front View (b) Side view (c) Top view.
These pins are used for transmitting the power When there is no change in orientation of shafts during
motion as shows the below Figure as well as front view side view and the top views of the pins. By using the
Here only three pins based on base metal, and using hub diameter that’s why in my Experimental setup
using the three pins.
(a) (b) (c)
Fig 3.10 Front, Side & Top view of pins
22
Fig 3.11 View of shafts with holes
3.1.5 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.
23
Fig 3.12 Set up view

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.
The various views and setup is clearly established, the front view is used to explain And analyze setup
mechanism. Initially the instant shaft 1 starts rotation with 6 links 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 60 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 similarly the Total 6links replaces the same point periodically by
sliding in shaft.
Fig 3.13 Movement of Link 2 of Link Type 1 in XZ plane
24
Working with pins – pins are used with the arrangement when there is no need of Change in positions of
pins during motion and very high speed required. Working with links- links are used in the arrangement at
the place of pins if we Required flexible motion or orientation on pins are changes during motion or during
Intermittent motion. Working with link type 1 permits that during motion shaft 2 can move in the plane XZ
from initial position to final position (initial and final position is indicated in Section E and also in upper
Figure 3.12 ). Working with link type 2 permits that during motion shaft 2 can move in the Plane YZ from
the initial position to final position as indicated in section E and also In below Figure 3.13
Fig 3.14 Movement of Link 2 of Link type 2 in YZ plane

More arrangement can be possible for the shafts with such type of links which can Be easily understandable
during working. As the name is introduced is SRRS Mechanism that is
1) S -sliding pair made between link 1 and shaft 1.

2) R -revolute pair made between link 1 and link 3.
3)R -revolute pair made between link 3 and link 2.
4)S -sliding pair made between link 2 and shaft 2.
Working with link type 1 during motion initial position is skew shafts at 90 degrees And this arrangement is
similar to working with pins as discussed previous so first Position is working. After 90 degrees rotation of
link 2 of link type 1 system is Transformed as gearless transmission for offset shaft and it is well established
Arrangement for pins which can be seen with the help of reference [2], so this Position is also working.1St
position is easy to understand with setup and also by imagination as similar to Working with pins. 2 nd
position, After 45 degrees rotation of link 2 position is Similar to the initial position of for working with link
25
type 1, so this position is Working well. After 135 degrees rotation setup is changed as gearless power
Transmission for intersecting shafts at 90 degree.
CHAPTER – 4
DESIGN CALCULATIONS
26
DESIGN CALCULATIONS
Testing of the machine and for functioning
Power of motor = ¼ H.P = 746 x 0.25 = 186.5 N- m /s
Rpm of motor N= 1440 rpm
Power of motor P =186.5 watt.
P = 2 πN TP /60 --------- (Eq.1)
Where, N = Rpm of motor = 1440 T = Torque transmitted
From eq.1 we get
186.5 = 2π×1440×T/60
T = 1.238 N-m
T = 1238 N-mm.
27
4.1 DESIGNING OF SHAFT
Following stresses are normally adopted in shaft design
Max tensile stress = 60 N/mm^2
Allowable shear stress = 70 N/mm^2
Considering 25 % overload
T max= 1238 x 1.25= 1.525 x 10^3 N-mm
The shaft is subject to pure torsional stress
We know T = 3. 14/16 x allowable stress x d^3
15250 = 3. 14/ 16 x 70x d^3
D=10.20 mm
Taking Factor of safety = 2.5
D = 10 x 2.5 = 25 mm
28
4.2 DESIGNING OF HUB
Considering a hub of internal diameter is 32 mm and outer diameter is 92 mm,Length is 82 mm. The mass of
the system is 28 kg
Force F = mg = 28 x 9.81 = 275 N
The bending stress of the hub was evaluated using Equation below
Bending stress = FDî2/( Dô2-Dî2)
= 275 x 32^2 / ( 92^2-32^2)
= 37.84 x 10^ 3 N/m
29
4.3 DESIGNING OF ELBOW ROD
We know that,
Same torque is transmitted to bent link shaft
So torque on each shaft = T /3 = 15250 /3 = 5083 N mm T= 3.14/16 x allowable shear stress x d³
5083 = 3. 14/ 16 x 70x d³
D = 7.17 mm.
Take approximately D=8mm.
Diameter of rod is 8mm and length is 300mm

Polar section modulus (Z) =0.78*r3
=0.78×4^3
=49.92 kg/mm²
Here P = power = 186.5 watts
Bending stress =
PL/4Z =186.5×300/4×49.92 =280.19 N/mm²
30
4.4 DESIGN MODEL OF THE PROJECT IN FUSION 360
Fig 4.1 Elbow link Design in Fusion 360
31
Fig 4.2 Shaft , hub Design in Fusion 360
32
Item Qty Parts number Part list

1 1 Frame Steel
2 1 Bearing v4
3 1 Bearing v4(1)
4 1 Bearing v4(2)
5 1 Bearing v4(3)
6 1 Hub v1 Steel, mild
7 1 Hub v1(1) Steel , mild
8 1 Link v2 Steel, mild
9 1 Link v2 (1) Steel ,mild
10 1 Link v2 (2) Steel , mild
11 1 Electric motor v1 Generic O
33
CHAPTER – 5
PERFORMANCE TEST AND RESULT
34
5.1 PERFORMANCE TEST

The gearless power transmission system consists of three number of pins. Performance test of this
gearless power transmission system depends on input motor speed, input shaft speed and output shaft
speed. Efficiency is calculated from this input shaft speed and output shaft speed. Below Table shows
the data collection for this system.
Motor speed Output speed Efficiency

(RPM) (RPM) (%)
129 105 81.3
154 123 79.8
173 146 84.4
178 156 87.6
186 136 73.1
229 162 70.7
237 216 91.1
246 192 78.0
302 275 91.0
308 253 82.1
314 281 89.5
328 296 90.2
335 287 85.7
328 296 90.2
335 287 85.7
342 308 90.1
346 305 88.1
348 322 92.5
356 302 84.8
360 308 84.8
35
5.2 RESULT AND DISCUSSION
The final design thus obtained is capable of transmitting torque and power At varied angles depending on
the angular limitation of the hooks joint. With further Research and advanced analysis in the design wide-
ranging applications of the drive Can be discovered.
The model works correctly as per the design. With the help of this system, We can efficiently reduce the cost
in power transmission and further advancement In this technology can be made.
There is clear in design and Fabrication of our project is safe at 140 rpm to 260 rpm for gearless
transmission system.
5.3 APPLICATIONS
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, Toy sand 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 made use of the “Big Ben
Clock” having four dials on the tower of London. This clock was Installed on 1630 AD and still it is
functioning in good condition.
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) Gearless transmission mechanism is capable of transmitting power at
any angle Without any gears being manufactured.
10) Its need to increase the efficiency of transmission which cannot be done
36
using Geared transmission.
5.4 COMPARISON WITH EXISTING SOLUTIONS

1) This arrangement gives the coverage of a wide range of shaft diameter, which may Be standard or non-
standard which is not possible in the existing gear arrangement Because the manufacturing of gears for skew
shafts very complex and because of Standardization its only use of shafts of standard diameter.
2) Proposed gear less transmission with pins can be used for very high speeds and for High loads which is
comparable to the worm gear and not possible for crossed Helical gears.
3) This system not having any possibility of like sliding and point contact as in Crossed helical gears so
power loss is very low in introduced arrangement and used For high loads with proper rigidity of shafts and
pins.
4) The main and very interesting advantage of this proposed system is that we can Changes the position of
shafts during motion or during intermittent position According to need by using given type of links at the
place of pins which is not Possible in any existing system till now.
5) Since any dimension of any component used is not out the shafts dimensions limit, A large reduction in
the size of the machines is possible .in short a large space Saving should be done.
6) Repairing cost on failure of any component is very low.
7) Very low setup cost.
8) Easy and time saving installation of setup.
9) Easy manufacturing of links and pins in comparison of crossed helical and worm Gear.
After complete study of the mechanism, we understood that this mechanism is Mainly applicable to low cost
applications where torque is low to medium. With Future development in low friction materials (graphene
coating) and stronger Composite materials, the efficiency and capacity of this mechanism can be Increased.
Also if instead of bent links, bolted links or links held by universal joints [2] are used then transmission is
possible even when angle changes on the go.
5.5 ADVANTAGES
1) Complete freedom of interchangeability.
2)More efficient than gear.
3)Low cost of manufacturing.
4)Power could be transferred to any desired angle.
5)Ease of manufacturing.
6)Simpler cooling system.
37
7)Portability of parts.
5.6 DISADVANTAGES
1) It is only used for small power generation.
2) Does not work at very low starting torque.
1) Speed ratio is always constant 1:1.
2) Sudden load would cause mechanism breakdown.
3) Improper whole drilling could pose much problem.
4) Inks are to be replaced after certain cycle time.
5.7 METHOD 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 a to provide smooth surface finish. This
will Result in less frictional loss and loss heat generation.
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 its 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 above.
38
CHAPTER – 6
CONCLUSION
39
CONCLUSION
During working on experimental setup and after a long discussion it is Observed that proposed arrangement
used for any set of diameters with any profile Of shafts for skew shafts of any angle but the shaft’s must be
having the rotational Motion about his own axis, transmission of motion is very smooth and desirable And
used only for the equal R.P.M. of driving shaft and driven shaft by employing Links or given type of links
for appropriate joints for revolute pair.
Some successful mechanical devices function smoothly however poor fly They are made while other does
this only by virtue of an accurate construction & Fitting of their moving parts.
This projects which looks very simple & easy to construct was actually very Difficult to conceive & imagine
without seeing an actual one in practice. Motions Demands to be studied first & we have done that very
thing. We find that while Acceptable analysis for existing mechanism can often be made quite easily we
Cannot without insight & imagination make effective synthesis of new mechanism Hence we are would to
present this our project gear less transmission at 90 degree (El-bow mechanism) which we have managed to
successfully device after long & Hard input in conceiving its working principle.
During working on experimental setup and after a long discussion it is observed That proposed arrangement
used for any set of diameters with any profile of shafts For skew shafts of any angle but the shaft’s must be
having the rotational motion About his own axis, transmission of motion is very smooth and desirable and
Used only for the equal R.P.M. of driving shaft and driven shaft by employing pins Or given type of links
for appropriate joints for revolute pair’s.
40
REFERENCES
[1] Prof R. Somraj, B. Sailesh, “DESIGN AND FABRICATION OF GEARLESS POWER
TRANSMISSION FOR SKEW SHAFTS”. International Research Journal Of Engineering and Technology
(IRJET), Volume: 04 Issue: 04 | Apr -2017’.
[2] Neeraj Patil , Jayesh Gaikwad , Mayur Patil , Chandrakant Sonawane , Shital Patel, “Gearless
Transmission Mechanism and its Applications” International Journal of Innovative Research in Science,
Engineering and Technology, Vol. 6, Issue 3, March 2017.
[3] Ashish Kumar, Puneet Pawar, Sagar Rana, Shishir Bist, “Multi-Angular Gearless Drive” International
Journal of Scientific & Engineering Research, Volume 6, Issue 7, July-2015.
[4] Solanki Nehal Pramesh, Patel Harshil K, Singh Montu, Rajwani Avesh, “DESIGN AND ANALYSIS OF
GEARLESS TRANSMISSION THROUGH ELBOW MECHANISM” International Journal of Scientific
Research in Engineering (IJSRE) Vol. 1 (3), March 2017.
[5] Shiv Pratap Singh Yadav, Sandeep G M, Rudra Naik, G C Keerthi Prakash, Gaurav Kulkarni, Hemanth
Kumar S, Thalanki G Vamsi Krishna “Design, Analysis And Fabrication of Gearless Power Transmission by
using Elbow Mechanism” International Journal of Engineering Research & Technology (IJERT) Vol. 6 Issue
04, April-2017.
[6] Prof. B. Naveen Bardiya, T. karthik, L Bhaskara Rao “Analysis and Simulation Of Gearless
Transmission Mechanism”, International Journal Of Core Engineering & Management (IJCEM) ,Volume 1,
Issue 6, September 2014, Page.no: 136-142.
[7] Amit Kumar and Mukesh Kumar, “Gearless Power Transmission for Skew Shafts (A SRRS
Mechanism)”International Journal of Advanced Science and Technology Vol.79 (2015), pp.61-72.
[8] Prof. A. Kumar and S. Das, “An arrangement for power transmission between Co-axial shafts of
different diameter” International Journal of Engineering Research And Technology (IJERT), ISSN: 2278-
0181, Volume 2, Issue 2, March 2013, Page .no: 338-347.
[9] Prof. B. Naveen Bardiya, T. karthik, L Bhaskara Rao “Analysis and Simulation Of Gear less
Transmission Mechanism”, International Journal Of Core Engineering & Management (IJCEM) ,Volume 1,
Issue 6, September 2014, Page.no: 136-142.
[10] Prof. Mahantesh Tanodi, “Gearless power transmission offset parallel shaft Coupling”, International
Journal of engineering Research and Technology (IJERT), Volume 3, Issue 3, March 2014, Page.no.129-132.
[11] R.S. Khurmi and J.K Gupta, “Theory of machines”, S. Chand publications, Hyderabad, IInd edition,
2008, Page.no: 569-589.
[12] https://www.youtube.com/watch?v= School of Mechanical and Building Sciences
41
[13] Book s. s. rattan Mc Graw Hill Education (India) private limited, New Delhi.
[14] PSG Design data book by Dr. P. Mahadevan.
42

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DESIGN AND FABRICATION OF GEARLESS POWER TRANSMISSION

Under the guidance of

DEPARTMENT OF MECHANICAL ENGINEERING

RAGHU INSTITUTE OF TECHNOLOGY

K.PRAVEEN KUMAR 213J5A0313

Name of candidates : K.PRAVEEN KUMAR

TITLE OF THE PROJECT : DESIGN AND FABRICATION OF GEARLESS POWER

This dissertation is approved by the board of Examiners

External Examiner : ____________________

Internal Examiner : ____________________

5.7 Method Of Improving Efficiency 36

1.2 NEED OF GEARLESS TRANSMISSION

WORKING PRINCIPLE AND COMPONENTS

Fig 3.1 Gear less power transmission

3.1 COMPONENTS OF THE MODEL

Fig 3.2 Concept drawing of machine and working

3.1.1 VIEW OF PLANES

Fig 3.3 View of the planes

3.1.2 VIEW OF SHAFTS

Fig 3.4 Front view of shaft

Fig 3.5 Side view of shaft

Fig 3.6 Top view of shaft

3.1.3 VIEWS OF SETUP

Fig 3.7 Front view of setup

Fig 3.8 Side view of setup

Fig 3.9 Top view of setup

3.1.4 VIEWS OF THE PINS

(a) (b) (c)

Fig 3.10 Front, Side & Top view of pins

Fig 3.11 View of shafts with holes

3.1.5 ANALYSIS OF MECHANISM

Fig 3.12 Set up view

Fig 3.13 Movement of Link 2 of Link Type 1 in XZ plane

Fig 3.14 Movement of Link 2 of Link type 2 in YZ plane

1) S -sliding pair made between link 1 and shaft 1.

Testing of the machine and for functioning

Power of motor = ¼ H.P = 746 x 0.25 = 186.5 N- m /s

Rpm of motor N= 1440 rpm

Power of motor P =186.5 watt.

P = 2 πN TP /60 --------- (Eq.1)

Where, N = Rpm of motor = 1440 T = Torque transmitted

From eq.1 we get

4.1 DESIGNING OF SHAFT

Following stresses are normally adopted in shaft design

Max tensile stress = 60 N/mm^2

Allowable shear stress = 70 N/mm^2

T max= 1238 x 1.25= 1.525 x 10^3 N-mm

The shaft is subject to pure torsional stress

We know T = 3. 14/16 x allowable stress x d^3

15250 = 3. 14/ 16 x 70x d^3

4.2 DESIGNING OF HUB

Force F = mg = 28 x 9.81 = 275 N

Bending stress = FDî2/( Dô2-Dî2)

= 275 x 32^2 / ( 92^2-32^2)

= 37.84 x 10^ 3 N/m

4.3 DESIGNING OF ELBOW ROD

Same torque is transmitted to bent link shaft

So torque on each shaft = T /3 = 15250 /3 = 5083 N mm T= 3.14/16 x allowable shear stress x d³

5083 = 3. 14/ 16 x 70x d³

Take approximately D=8mm.

Diameter of rod is 8mm and length is 300mm

Here P = power = 186.5 watts

PL/4Z =186.5×300/4×49.92 =280.19 N/mm²