A PROJECT REPORT

ON

GEARLESS POWER TRANSMISSION

6 LEG KINEMATIC

Department of Mechanical Engineering

CIPET-Ahmedabad
 A PROJECT REPORT
ON

MECHANICAL SPIDER (8 LEG)

PREPARED BY

SR NO ENROLLMENT NO NAME OF STUDENT

1
2
3

GUIDED BY

HELPED BY

Department of Mechanical Engineering

Chhotaudepur

This is to certify that Mr.______________________________________________

Having Enrollment No:.has completed part-I of the project
work having title MECHANICAL SPIDER (8 LEG) He has undergone the process
of Shodhyatra, literature survey and problem definition. He is supposed to carry
out the residue IDP part II work on the same problem during the semester VI for
the final fulfillment of the IDP work which is prerequisite to complete Diploma
Engineering academic.

PROJECT GUIDE HEAD OF DEPARTMENT

Department of Mechanical Engineering

Chhotaudepur
 ACKNOWLEDGEMENT

I am very glad to represent project report on Gearless Power Transmission ". I have
tried my level best to focus upon each and every parameter. In concern with this topic the
detail, necessary figure, definition, tabular analysis has been enumerated in very easy, simple,
compact and lucid manner.

I have been able to achieve this task by the dynamic guidance of Honorable sir; I have
no words to express my Gratitude towards his kind and outstanding treatment while
clarifying my confusion. Because of his reference to the sunshine engineering works, we able
to fabricate our idea as a machine
I also extend my sincere thanks to our esteemed H.O.D. whose guidance and constant
inspiration where a great use in Working on this project
I am also grateful to our honorable faculty member for providing numerous facilities
and guidance due to which this difficult task turned into a convenient task
Last but not least, I am very thankful to my project partners without whose kind
cooperation it was difficult and impossible to go through the leaps and bounds while
preparing this.
 ABSTRACT

The study of manufacturing was very important in order to carried out this project to
ensure that student understand on what are needs to do. This project is about designing and
fabricating a gearless power transmission system.

This project GEARLESS TRANSMISSION being compact and portable

equipment, which is skillful and is having practice in transmitting power at right angle
without any gears being manufactured. The El-bow Mechanism transmits the input power
towards the output side such a way that the angular forces produced in the slacks are
transmitted with the help of rods which takes up the input power and the right angle drive is
transferred towards the output slack and rod assembly. Hence very little friction plays while
the power is being transmitted. Hunting and back lash errors are absent. Therefore, it is
appreciated that efficiency as high as 90-92% are possible in gear less transmission
mechanism.
Why did you choose to work on this project topic?

Here is a wonderful mechanism that carries force through a 90bent rod. Transmitting
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 90, 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.This is a
Mechanical final year project work on Gearless Transmission which is compact and
portable equipment, which is skillful and is having something practice in the transmitting
power at right angle without any gears being manufactured. This project is the equipment
useful to improve the quality of the gear being manufactured and can be made in less time.
This project uses El-bow mechanism which is an ingenious link mechanism of slider and
kinematic chain principle. This is also called as gearless transmission mechanism and is
very useful for transmitting motion at right angles.
t Table of Contents

CHAPTER 1. Introduction
1.1 Background
1.2 Overview
1.3 Objectives
CHAPTER 2. Mechanism
2.1 Overview
2.2 Klann mechanism
2.3 Jansen Linkages Mechanism
CHAPTER 3. Design and calculations
3.1 Dimension Calculation of linkages
3.2 Testing of Dimensions
3.3 Calculation of Degree of freedom
3.4 calculations of Gear Dimension
3.4.1 Bigger Gear calculation
3.4.2 Smaller Gear calculation
3.5 Dimension of Base Plate
CHAPTER 4. Detail and Assembly drawings
CHAPTER 5. Parts and Material
5.1 Base plate
5.2 Electric Motor
5.3 Gear
5.4 Shaft
5.5 Linkages
5.6 Control system
5.7 Batteries
CHAPTER 6. Construction, Fabrication and Working
6.1 Construction
6.2 Fabrication
6.3 Working
6.4 Analysis
6.5 Flow Process and Outline Process Chart
CHAPTER 7. Cost Estimation
CHAPTER 8. Merits of Mechanical Mover
CHAPTER 9. Conclusion
CHAPTER 10. Bibliography
CHAPTER: 1 INTRODUCTION

The Gearless transmission or El-bow mechanism is a device for transmitting

motions 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 between 3 to 8 the
more the pins the smoother the operation. These pins slide inside hollow cylinders thus
formatting a sliding pair.
This project GEARLESS TRANSMISSION being compact and portable
equipment, which is skillful and is having practice in transmitting power at right angle
without any gears being manufactured. The El-bow Mechanism transmits the input power
towards the output side such a way that the angular forces produced in the slacks are
transmitted with the help of rods which takes up the input power and the right angle drive is
transferred towards the output slack and rod assembly. Hence very little friction plays while
the power is being transmitted. Hunting and back lash errors are absent. Therefore, it is
appreciated that efficiency as high as 90-92% are possible in gear less transmission
mechanism.
CHAPTER-2 MECHANISM

2. Our mechanism has 3 such sliding pairs. These cylinders are placed in a Hollow
pipe and are fastened at 120* to each other. This whole assembly is mounted on fabricated
table. Power is supplied by an electric motor or manual by hand. The working of the
mechanism is understood by the diagram. An unused form of transmission of power on shaft
located at an angle.
CHAPTER-3 DESIGN AND CALCULATION

CHAPTER:-4 DETAIL AND ASSEMBLY DRAWINGS

DETAIL DRAWINGS

PARTIAL ASSEMBLY:-
Chapter:-5 Parts and its material
5.1 Base plate: - The Base Plate is generally made from Aluminum/galvanized iron/ plastic
or acrylic sheet to obtain following properties
1. Light Weight

2. Corrosion Resistance

3. Electrical and Thermal Conductivity

4. Reflectivity

5. Ductility

6. Impermeable and Odorless

7. Recyclability

8. Easy to shape

5.2. ELECTRIC MOTORS

For smooth movement in all directions, two motors are necessary. Two D.C.
motors with rated speeds of 200 rpm are used. These motors are placed in such a way that
each motor drives four legs. The motors are powered by a rechargeable 12V battery
FEATURES OF THE ELECTRIC MOTOR
200RPM 12V DC motor
6mm shaft diameter with internal hole

125gm weight

Same size motor available in various rpm

0.5kgcm torque

No-load current = 60 mA(Max), Load current = 300 mA(Max)

5.3. GEARS
Gears are very important for transmission. Gears are also useful in speed reduction.
Two sets of gears are used for effective transmission. Each set consists of a smaller
gear and two bigger gears. Smaller gear consists of 36 teeth and a larger gear consists
of 60 teeth, thereby giving a speed reduction ratio of 1.68. The gears are spur gears
and are made of nylon plastic gears.
Spur gears or straight-cut gears are the simplest type of gear. They consist of a
cylinder or disk with the teeth projecting radially, and although they are not straight-
 sided in form (they are usually of special form to achieve constant drive ratio,
mainly involutes, the edge of each tooth is straight and aligned parallel to the axis of
rotation. These gears can be meshed together correctly only if they are fitted to
parallel shafts.
Numerous nonferrous alloys, cast irons, powder-metallurgy and plastics are used in
the manufacture of gears. However, steels are most commonly used because of their
high strength-to-weight ratio and low cost. Plastic is commonly used where cost or
weight is a concern. A properly designed plastic gear can replace steel in many cases
because it has many desirable properties, including dirt tolerance, low speed meshing,
the ability to "skip" quite well and the ability to be made with materials not needing
additional lubrication. Manufacturers have employed plastic gears to reduce costs in
consumer items including copy machines, optical storage devices, cheap dynamos,
consumer audio equipment, servo motors, and printer.
5.4. SHAFTS
A drive shaft, driveshaft, driving shaft, propeller shaft (prop shaft), or Cardan shaft is
a mechanical component for transmitting torque and rotation, usually used to connect
other components of a drive train that cannot be connected directly because of
distance or the need to allow for relative movement between them.
Drive shafts are carriers of torque: they are subject to torsion and shear stress,
equivalent to the difference between the input torque and the load. They must
therefore be strong enough to bear the stress, whilst avoiding too much additional
weight as that would in turn increase their inertia.
Four shafts are employed to transfer the power from the motors to the legs. The shafts
are 16 mm in diameter and 115 mm in length. The shafts are made of wood.

5.7. BATTERIS
A rechargeable battery, storage battery, or accumulator is a type of electrical battery.
It comprises one or more electrochemical cells, and is a type of energy accumulator. It
is known as a secondary cell because its electrochemical reactions are electrically
reversible. Rechargeable batteries come in many different shapes and sizes, ranging
from button cells to megawatt systems connected to stabilize an electrical distribution
network. Several different combinations of chemicals are commonly used,
including: leadacid, nickel cadmium (NiCd), nickel metal hydride (NiMH), lithium
ion(Li-ion), and lithium ion polymer (Li-ion polymer).
 Rechargeable batteries have lower total cost of use and environmental impact than
disposable batteries. Some rechargeable battery types are available in the
same sizes as disposable types. In total, two batteries are used: a 12 V battery and a 9
V battery. The 12 V batteries power both the motors and are rechargeable. The 9 V
battery powers the wireless remote control system.
CHAPTER-6 CONSTRUCTION, FABRICATION AND WORKING
6.1. CONSTRUCTION
It consists of motor or engine mounted at the top. Out of three spur gear one is
connect to the motor or an engine shaft called Driving gear and remaining two are meshes
with driving gear. The crank is connected to the shaft on which two driven gears are mounted
by the shaft. As the motor made to ON the driving gear drives, another two gear , one is
clockwise while other is anticlockwise as the gears are rotate in opposite direction. Due to
this rotation resulting in the crank rotation Crank moves the forcing link gives the momentum
in a particular line of action with help of supporting link. The work of supporting link is to
move the arm in a particular profile which made by the end point of arm and move back to its
normal position i.e. initial position All these gives the walking motion to the arm like a
spider.
6.2. FABRICATION
6.2.1.SOLDERING
Soldering is a process in which two or more metal items are joined together by
melting and flowing filler metal (solder) into the joint, the filler metal having a lower melting
point than the adjoining metal. Soldering differs from welding in that soldering does not
involve melting the work pieces. In brazing, the filler metal melts at a higher temperature, but
the work piece metal does not melt. In the past, nearly all solders contained lead, but
environmental concerns have increasingly dictated use of lead-free alloys for electronics and
plumbing purposes. Figure 5.1 shows how the process of soldering is done.
6.2..2. DRILLING
Drilling is the process of cutting holes in metals by using a drilling machine .Drills
are the tools used to cut away fine shavings of material as the drill advances in a rotational
motion through the material.
A drill bit is a multi-point tool and typically has a pointed end. A twist drill is the
most common type used. The twist drill or drill bit is made from High Speed Steel,
tempered to give maximum hardness throughout the parallel cutting portion.Flutes are
incorporated to carry away the chips of metal and the outside surface is relieved to produce a
cutting edge along the leading side of each flute.
Twist drills are available with parallel shanks up to 16mm diameter and with taper
shanks up to 100mm diameter and are made from high-speed steel. Standard lengths are
known as jobber-series twist drills, short drills are known as stub series, and long drills as
long series and extra long series. Different helix angles are available for drilling a range of
materials.

6.3. WORKING
The basic working principle of Klann Mechanism is that when the crank is rotated, a
series of relative movements in the various links result in a gait-like movement of the leg. If
all the legs in a device are connected to a single motor, the device will be able to move in
only one direction (or two directions, if the motor can rotate in both directions).
This issue is resolved by using more than one motor. The device can be made to take a
turn by using the motors strategically.
6.4. ANALYSIS
The blue print of the direction of motion for the corresponding directions
of rotation of the motors is given in the table T5.1.
Direction of movement of Direction of rotation ofDirection of rotation of
spider motor 1 motor 2
Forward Clockwise Counter-clockwise
Backward Counter-clockwise Clockwise
Right Clockwise Clockwise
Left Counter-clockwise Counter-clockwise
6.5. Flow chart and Process Planning

FLOW PROCESS CHART

Analyst: Approval; Summary of Activities

Job: Part No; Activity (symbols) Count Time Distances

Material: Operations

Other Detail:- Inspections

Moves

Delays

Storages

Symbol
Seq. Activity Description Time Distance Analysis
 FLOW PROCESS CHART
Analyst: Approval; Summary of Activities

Job: Part No; Activity (symbols) Count Time Distances

Material: Operations

Other Detail:- Inspections

Moves

Delays

Storages

Symbol
Seq. Activity Description Time Distance Analysis
 FLOW PROCESS CHART
Analyst: Approval; Summary of Activities

Job: Part No; Activity (symbols) Count Time Distances

Material: Operations

Other Detail:- Inspections

Moves

Delays

Storages

Symbol
Seq. Activity Description Time Distance Analysis
 FLOW PROCESS CHART
Analyst: Approval; Summary of Activities

Job: Part
Activity (symbols) Count Time Distances
No;

Material: Operations

Other Detail:- Inspections

Moves

Delays

Storages

Symbol
Seq. Activity Description Time Distance Analysis
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CHAPTER:-7 ESTIMATION AND COSTING

MATERIAL COST

Sr.no. Description Qty. Rate Amount

1 M.S.ANGEL(30X30X3) 1 Nos. - 1050/-
FOR FRAME
2 Round bar 2 Nos. Rs 50 per kg 200/-
20mm100 mm
3 PEDASTEL BEARING 1000/-
4 Nut Bolts M10 50/-

Total Material Cost 4580/-

LABOUR COST

Sr. Total time

Name of process Rate/hr Rs. Total cost
no. hour
Rs.
1 Turning 3 60 180/-

2 Drilling 3 35 105/-
3 Welding 10 min. 100/-
4 Threading 1 100 100/-
5 Assembly 1 300 300/-
TOTAL LABOUR COST 785/-

OTHER EXPENSES
Sr. No. Other expenses Cost Rs.
1 Telephone 100
2 Internet surfing charge 350
3 Stationary 200
4 printing- zerox charge 400
TOTAL COST 1050
1). Prime cost
= Direct material cost+ direct labour cost+ direct expenses
= 4580.00+785.00+1050.00
= 6415.00 Rs.
2).Factory overhead cost
=10% prime cost
= 641.00 Rs.
3).Factory cost
=prime cost + factory over head
= 6415.00+641.00
=7056.00 Rs.
4).Total production cost
= Factory cost+ sales overhead (5% of F.C)
=7056.00+353.00
=7409.00 Rs.
5). Net desired profit
=15% total production cost
=1111 Rs.
6). Selling price
=T.P.C + profit
=8520.00Rs
CHAPTER-8 MERITS OF MECHANICAL MOVER

8.1. ADVANTAGES OF KLANN MECHANISM

1. Klann Mechanism makes legged mobility easier.
2. It directly converts a rotation into a gait.
3. Easy to build.
4. Initial cost is reasonably low.

8.2. APPLICATIONS OF KLANN MECHANISM

1. Toys could be developed that would fit in the palm of your hand and just large enough
to carry a battery and a small motor. So that it could ride into combat with radio
controlled assault spider bikes.
2. The military, law enforcement, Explosive Ordinance Disposal units, and private
security firms could also benefit from applications of the spider bike. It would
perform very well as a platform with the ability to handle stairs and other obstacles to
wheeled or tracked vehicles. Unmanned operations could be used for reconnaissance,
patrolling, hazardous material handling, clearing minefields, or secure an area without
putting anyone at risk.
3. There would be further benefits if a portion of these tasks should be automated or
made more accurate through Global Positioning Systems, infrared viewing, and audio
and video recording. It could be programmed to patrol a predefined Perimeter at
random intervals.
CHAPTER-9 CONCLUSION

This project can step over curbs, climb stairs, or travel into an area that are currently
not accessible with wheels but does not require microprocessor control or multitudes of
actuator mechanisms.
It would be difficult to compete with the efficiency of a wheel on smooth hard
surfaces but as conditions increase rolling friction, this linkage becomes more viable and
wheels of similar size cannot handle obstacles that this linkage is capable of. Also it allows
the legs to fold up compactly for storage and delivery.
Thus, all the principles and mechanisms involved in a walking robot using are
studied and the practical difficulties in fabrication of a working model are understood.
If implemented properly, automobiles moving on legs using Klann Mechanism have the
potential to change mobility as we know it.
CHAPTER-10 BIBLIOGRAPHY

10.1. REFERENCES
Design and prototype of a six-legged walking insect robot Servet Soyguder and Hasan
Alli Mechanical Engineering Department, Firat University, Elazig, Turkey
Mechanical Design of A Quadruped Robot for Horizontal Ground to Vertical Wall
Movement Abd Alsalam Sh. I. Alsalameh Shamsudin H.M. Amin Rosbi Mamat Center
for Artificial Intelligence and Robotics (CAIRO) Faculty of Electrical Engineering
Universiti Teknologi Malaysia
A study of availability and extensibility of Theo Jansen mechanism toward climbing over
bumpsKazuma Komoda (PY)1, and Hiroaki Wagatsuma 1 Department of Brain Science
and Engineering, Kyushu Institute of Technology 2 RIKEN Brain Science Institute
.

10.2. WEBSITES
1. www.mechanicalspider.com
2. www.mekanizmalar.com/mechanicalspider.html