DESIGN AND FABRICATION OF FILM FRAME BY GENEVA MECHANISM

PROJECT REPORT Submitted by

M.Krishnakumar A.Prabakaran K.Sudhakar R.Senthilkumar

51608114017 51608114025 51608114304 51608114401

In partial fulfilment for the award of the degree Of

BACHELOR OF ENGINEERING In MECHANICAL ENGINEERING THANTHAI PERIYAR GOVERNMENT INSTITUTE OF TECHNOLOGY, VELLORE-632 002.

ANNA UNIVERSITY: CHENNAI 600 025 APRIL 2011

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ANNA UNIVERSITY:: CHENNAI 600 025

BONAFIDE CERTIFICATE
Certified that this project report DESIGN AND FABRICATION OF FILM FRAME BY GENEVA MECHANISM is the bonafide work of ______________________________ who carried out the project work under my supervision.

HEAD OF THE DEPARTMENT Thanthai Periyar Government Institute Of Technology Vellore -02

SUPERVISOR Tmt.M.KANTHASHOBA.M.E, Asst.prof in Mechanical Engineering, Thanthai Periyar Government Institute Of Technology Vellore -02

Project Viva-Voce examination held on.

Internal Examiner

External Examiner
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ACKNOWLEDGEMENT

We are honoured to express thanks to our principal

Dr. R.ELANGOVAN, M.E, Ph.D., who

always served as a source of

inspiration and encouraged us throughout the project.

We express our heartfelt thanks to our beloved Head of the Department Prof.S.RAJKUMAR.M.E., who has contributed his valuable suggestions, instruction and encouragement in doing this project.

We have no words to express our thanks to our project supervisor and faculty advisor Tmt.M.KANTHASHOBA,
M.E.,Assistant Professor for her keen interest, guidance, inspi-

ration and valuable suggestion during the course of our project.

We express our profound gratitude to the Non-teaching staff of Mechanical Engineering Department for their valuable suggestions.

TABLE OF CONTENTS CHAPTER NO. ABSTRACT LIST OF FIGURES LIST OF SYMBOLS 1 INTRODUCTION 1.1 Geneva Mechanism 1.2 Classification of Geneva mechanism 1.3 Advantages of Geneva Mechanism 1.4 Disadvantages of Geneva Mechanism GEOMETRY OF FILM FRAME BY GENEVA MECHANISM 2.1 Components of Geneva 2.2 Materials WORKINF OF FILM FRAME DESIGN CALCULATION 4.1 Specifications 4.2 Design Calculation for Cam Drive 4.3 Design calculation For Bearing & Geneva Cross FABRICATION PROCEDURE CONCLUSION BILL OF MATERIAL PHOTOGRAPHS BIBILIOGRAPHY TITLE PAGE NO. v vi vii 8 8 9 11 11 12 13 14 16 19 19 19 20 21 26 27 28 33

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ABSTRACT
Geneva drive or Maltese cross is a indexing mechanism that converts the continuous motion into intermittent motion. By means of this mechanism the rotary motion of the driver wheel is converting into intermittent rotary motion of sprocket. The film passed over the sprocket. Due to the intermittent motion, the film advanced frame by frame in front of lens for 1/24 th second in frequency of 48 Hz.

LIST OF FIGURES FIGURE NO. 1 2 3 4 5 TITLE Geneva Mechanism External Geneva Mechanism Internal Geneva Mechanism Spherical Geneva Mechanism Moving Of Film Frame By Geneva Mechanism Working Stages Of Geneva Mechanism Dwell Period Working Process Intermittent Mechanism Ball Bearing Project Model PAGE NO. 8 9 10 10 12

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7 8 9 10 11

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LIST OF SYMBOLS

Z R rD r rp a ds t l L v T 1 2

No. Of Slots Radius of Geneva Wheel Radius of driving wheel Radius of cam radius of pin Centre distance between Geneva cross & the centre of cam disc Diameter Of Shaft Slot Width Slot Length Shaft Length Angle Of Locking Section Semi Indexing Angle (Driven) Semi Indexing Angle (Driver) Gear ratio Indexing Time Ratio Time angular velocity of cam angular velocity of driven disc

CHAPTER 1 INTRODUCTION
Geneva mechanism is commonly used indexing mechanism where an intermittent motion is required. The Inverse Geneva mechanism, which is a variation of the Geneva mechanism, is used where the wheel has to rotate in the same Direction as crank. It requires less radial space and the locking device can be a circular segment attached to the crank that locks by wiping against a built up rim on the periphery of the wheel. The design and fabricating of a conventional Geneva mechanism is generally simple and inexpensive because there is no specially curved profile on any of the components except straight lines and circular arcs. However, due to the discontinuity of the acceleration at the beginning and ending positions, the shortcoming of using conventional Geneva mechanism is the large impact when the driving crank engages and disengages with the wheel slot.

1.1

GENEVA MECHANISM

Fig.1. GENEVA MECHANISM

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In this mechanism, for every turn of the driver wheel A, the driven wheel B makes a quarter turn. The pin, attached to driver wheel A, moves in the slots causing the motion of wheel B. The contact between the lower parts of driver A with the corresponding hollow part of wheel B retains it in position when the pin is out of the slot. Wheel A is cut away near the pin as shown, in order to provide clearance for wheel B as it moves. If one of the slots is closed, A can make less than one revolution in either direction before the pin strikes the closed slot and, stopping the motion.

1.2

CLASSIFICATION OF GENEVA MECHANISM

1.2.1 EXTERNAL GENEVA MECHANISM: In this type of mechanism, the Geneva cross is connected with cam drive externally which is the most popular and which is represented by the device below fig.

FIG.2. EXTERNAL GENEVA MECHANISM

1.2.2 INTERNAL GENEVA MECHANISM: In this type of mechanism, the Geneva cross and cam drive are connected internally in the closed box, which is also common and is illustrated by below fig.

Fig.3. INTERNAL GENEVA MECHANISM

1.2.3 SPHERICAL GENEVA MECHANISM: In this type of mechanism the Geneva cross is in spherical shape and cam drive are connected in externally, which is extremely rare and is illustrated in below fig

Fig.4. SPHERICAL GENEVA MECHANISM

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1.3 i.

ADVANTAGES OF GENEVA MECHANISM Geneva mechanism may be the simplest and least Expensive of all intermittent motion mechanisms. They come in a wide variety of sizes, ranging from those used in instruments, to those used in machine tools to index spindle carriers weighing several tons. They have good motion curves characteristics compared to ratchets, but exhibit more jerk or instantaneous change in acceleration, than better cam systems Geneva maintains good control of its load at all Times, since it is provided with locking ring surfaces. DISADVANTAGES OF GENEVA MECHANISM i. The Geneva is not a versatile mechanism. The ratio of dwell period to motion is also established Once the no of dwells per revolution has been selected. All Geneva acceleration curves start and end With finite acceleration & deceleration. This means they produce jerk.

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iv.

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CHAPTER 2 GEOMETRY OF FILM FRAME

Fig.5. GEOMETRY OF FILM FRAME In the most common arrangement, the driven wheel has four slots and thus advances for each rotation of the driver wheel by one step of 90 If the driven wheel has n slots, it advances by 360/n per full rotation of the drive wheel.

Fig.6. WORKING STAGES OF GENEVA MECHANISM

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2.1

COMPONENTS

DRIVER GEAR The input is given manually by handle through this Driver gear. Its a one type of continuous motion. CAM & PIN Its main part of this mechanism. Because it converts The continuous rotary motion into intermittent motion by guiding the Geneva cross along its circular path. Then it converts this motion as require for the movement of film frame. GENEVA GEAR OR MALTESE CROSS Its also take part as vital role in this mechanism. Because the rotary intermittent motion produced in this part only. Geneva cross has 4 slots in it, pin goes into along circular movement of cam. SHAFT Shaft holds the all parts of mechanism by horizontally On its threaded portion. There are 2 shafts are provided in this mechanism. SPROCKET It is provided for hold the film frame according to the rotary intermittent motion of the Geneva cross. Pressure rollers also provided for perfect movement of film frame. FILM FRAME Its the component which carries the picture on it and to slide on the sprockets regularly according to the motion.

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2.2

MATERIALS

Geneva wheel ---------> M S plate Shaft --------------------> M S rod Bearings ----------------> deep groove ball bearing Cam drive --------------> aluminium alloy plate Geneva cross ----------> steel plate Sprockets ---------------> acrylic fibre Pressure roller ----------> polymers Base, stand --------------> steel

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CHAPTER 3
WORKING PRINCIPLE OF FILM FRAME According to the principle of Geneva mechanism, the input is given by motor to the driver gear of the arrangement. In the most common arrangement, the driven wheel has four slots and thus advances for each rotation of the drive wheel by one step of 90. If the driven wheel has n `slot. ELEMENTS

I.

Film frame

A commonly-held misconception is that film projection is simply a series of individual frames dragged very quickly past the projector's intense light source. If a roll of film were merely passed between the light source and the lens of the projector, all that would be visible on screen would be a continuous blurred series of images sliding from one edge to the other. It is the shutter that gives the illusion of one full frame being replaced exactly on top of another full frame.

A rotating petal or gated cylindrical shutter interrupts the emitted light during the time the film is advanced to the next frame. The viewer does not see the transition, thus tricking the brain into believing a moving image is on screen. Modern shutters are designed with a flicker-rate of two times (48 Hz) or even sometimes three times (72 Hz) the frame rate of the film, so as to reduce the perception of screen flickering. Higher rate shutters are less light efficient, requiring more powerful light sources for the same light on screen.

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Fig.8.WORKING PROCESSES OF MOVING OF FILM FRAME Mechanical sequence when image is shown twice and then advanced. Outer sprockets rotate continuously while the frame advance sprockets are controlled by the mechanism shown.

II.

Feed & extraction of sprockets

Smooth wheels with triangular pins called sprockets engage perforations punched into one or both edges of the film stock. These serve to set the pace of film movement through the projector and any associated sound playback system III. Film loop As with motion picture cameras, the intermittent motion of the gate requires that there be loops above and below the gate in order to serve as a buffer between the constant speed enforced by the sprockets above and below
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the gate and the intermittent motion enforced at the gate. Some projectors also have a sensitive trip pin above the gate to guard against the upper loop becoming too big. IV. Film gate pressure plate A spring loaded pressure plate functions to align the film in a consistent image plane, both flat and perpendicular to the optical axis. It also provides sufficient drag to prevent film motion during the frame display, while still allowing free motion under control of the intermittent mechanism. The plate also has spring-loaded runners to help hold film while in place and advance it during motion.

V.

Intermittent mechanism

Fig.9. INTERMITTENT MECHANISM The intermittent mechanism can be constructed in different ways. For smaller gauge projectors (8 mm and 16 mm), a pawl mechanism engages the film's sprocket hole one side, or holes on each side. This pawl advances only when the film is to be moved to the next image. As the pawl retreats for the next cycle it is drawn back and does not engage the film. This is similar to the claw mechanism in a motion picture camera.
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In 35 mm and 70 mm projectors, there usually is a special sprocket immediately underneath the pressure plate, known as the intermittent sprocket. Unlike all the other sprockets in the projector, which run continuously, the intermittent sprocket operates in tandem with the shutter, and only moves while the shutter is blocking the lamp, so that the motion of the film cannot be seen. The intermittent movement in these projectors is usually provided by a Geneva drive, also known as the Maltese cross mechanism.

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Fig. 7. DWELL PERIOD FOR MECHANISM

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CHAPTER 4 DESIGN CALCULATION SPECIFICATIONS o Number of Slots, o Radius of Geneva wheel, Z= 4 R = 40 mm

4.1

o Distance between centres of Geneva Wheel &driven wheel, a= 56.5 mm o Radius of driving Wheel, o Radius of cam, o Radius of pin, 4.2 rd= 60 mm r= 40mm rp=2.5mm

DESIGN CALCULATION FOR CAM DRIVE o Angle of locking section, = /2 (Z+2) =270

o Semi-indexing angle(driven) = /Z = 45 o o o o Semi-indexing angle (driver) = (Z-2)/(2Z) =45 Gear ratio =1 for Z=4 Radius ratio, = R/r =1.000 Indexing time ratio, = / =0.2500

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4.3

DESIGN CALCULATION FOR BEARING & GENEVA CROSS FOR GENEVA CROSS: o Slot width, t = 5 mm o Length of Slot, l= 25 mm o Shaft diameter, ds= 15 mm o Thickness, b = 5m FOR BEARINGS:

Fig.10

Here we used ball bearings. o Bearing of basic design no. (SKF) = 6000 o Inner diameter of bearing, d = 10 mm o Outer diameter of bearing, D = 26 mm o Static capacity, Co= 19 KN o Dynamic capacity, C = 36 KN o Assume : Time T=0.166 sec Speed N=360 rpm (N=60/T) Angular velocity of driving crank 1= 2N/60 =37.7rad/sec Angular velocity of driven disc 2 =/ (1-) =91.012rad/sec

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CHAPTER 5 FABRICATING PROCEDURE GENEVA WHEEL DESIGN

The basic design criteria of a Geneva wheel is that the centrelines of the slot and crank are mutually perpendicular at engagement and at Disengagement. The crank, which usually rotates at a uniform angular Velocity carries a roller to engage with the slots. During one revolution of the crank the Geneva wheel rotates a fractional part of the revolution, the amount of which is dependent upon the number of slots. The Circular segment attached to the crank effectively locks the wheel Against rotation when the roller is not in engagement and also positions the wheel for correct engagement of the roller with the next slot.

The design of the Geneva mechanism is initiated by specifying the Crank radius, the roller diameter and the number of slots. At least 3 slots Are necessary but most problems can be solved with wheels having from 4 to 12 slots. The angle () is half the angle subtended by adjacent slots I.e. where n is the number of slots in the wheel. Then, defining r2 as the crank radius we have, Where c is the centre distance. Note that the actual Geneva wheel radius is more than that which would be obtained by a zero-diameter roller. This is due to the difference between the sin and the tangent of the angle subtended by the roller, measured from the wheel centre. The final step in the design process is to choose a convenient radius for the circular pert of the Geneva wheel, which meshes with the input wheel locking the Geneva wheel.

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Fig.11. GENEVA WHEEL DESIGN A ball bearing used for fix the shaft on stand on base. The bearing selected according to the diameter of the shaft. The shaft was threaded on its both ends. The driver gear And cam are inserted to the shaft on threaded end. Then the Maltese cross also fitted with sprockets on its end. Sprockets are designed according to the film frame width. Pressure rollers are provided for regular movement of film frame. A handle is fitted to the driver gear manual input. Finally all these arrangements are fit on the base.

Fabricating process
The Geneva Wheel Mechanism, which was manufactured, had 9 parts. They were the two Geneva wheel pieces, two circular locking slots, a Crank Pin, a spacer plate, two Shaft Pins to carry the Geneva wheel and the input shaft and a Base plate.

The Geneva wheel was manufactured by turning a 10 mm thick MS Plate to the external dimensions. Then the profile was punch marked on the plate. The plate was put in a indexing milling machine and the Profile was milled to the required dimensions including the cutting of slots.

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The locking wheel was also punch marked and milled to the required dimensions. The crank pin was made by gas cutting the required shape and the roller pin was fitted at the required distance of 50 mm from the crank centre. All the other components were turned to the required dimensions. The Base plate as cut out of a 4 mm thick transparent acrylic plate. The holes for carrying the shafts were then drilled by using a 16mm drill taking care of the distance between the centres.

Geneva wheel analysis

The Analysis of Geneva wheel is done by drawing the position of the pin and the Geneva wheel at the required position. The position of the Geneva wheel is given by, Differentiating this with respect to time we get, Differentiating again with respect time we get, These equations are valid only in the region (90-b) to (90-b) of the input crank angle. At all other angles the Geneva wheel is stationary and hence both angular velocity and acceleration are zero. Both the angular and acceleration are plotted as a function of input angle in the accompanying plot for an input angular velocity of 1 rad/sec.

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APPLICATIONS & USES STEPPER MECHANICAL WATCHES PLOTTERS CNC MACHINE IRON RING CLOCK
Modern film projectors may also use an electronically controlled indexing mechanism or stepper motor, which allows for fast-forwarding the film. Geneva wheels having the form of the driven wheel were also used in mechanical watches, but not in a drive, rather to limit the tension of the spring, such that it would operate only in the range where its elastic force is nearly linear. Geneva drive include the pen change mechanism in plotters, automated sampling devices Indexing tables in assembly lines, tool changers for CNC machines, and so on. The Iron Ring Clock uses a Geneva mechanism to provide intermittent motion to one of its rings.

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MERITS
o The sequence of slides can be altered to meet specific needs. o May be adopted to group or to individual user o One can control the length of time each one is shown to allow for explanation, questions from the audience, or discussion of the problem at hand. The audience will focus its attention on the one slide being shown. o Easily handled, stored and rearranged for various uses. o The room need not be extremely dark for projection.

DEMERITS o The fixed sequence does not permit easy flexibility. o Can get out of sequence and be projected incorrectly if slides are handled individually use of the never automatic projectors will alleviate this problem as the sequence can be worked out and loaded into the special car bridge before presentation.

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CHAPTER 6 CONCLUSION
Geneva drive indexing mechanism converts the continuous motion of the driver wheel into intermittent rotary motion of the sprocket. According to the film length, the cam wheel diameter was chosen. Cam with pin arrange-

ment integrated with Geneva drive. Input shaft having driver wheel at one end and cam drive at the other end. Geneva drive and sprocket are mounted on the output shaft. By cam with Geneva drive arrangement the continuous motion of the driver wheel converts into intermittent motion of sprocket. Due to sprocket rotation the film advances frame by frame in front of the lens. Thus the slide show of the film was obtained successfully.

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BILL OF MATERIALS: Driver wheel ---------------------> 150/ Cam drive ---------------------> 250/-

Geneva cross --------------------> 200/ Sprockets ------------------------> 150/ Shafts ----------------------------> 200/ Bearings -------------------------> 100/ Base & stand --------------------> 300/ Bolts & nuts ---------------------> 50/-

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PHOTOGRAPHS

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MOVIE PROJECTOR

KODAK 35mm SLIDE PROJECTOR

AUTOMATED SLIDE PROJECTOR

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FILM SLIDE PROJECTOR

SLIDE PROJECTOR

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LCD PROJECTOR

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KODAK FILM PROJECTOR

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BIBLIOGRAPHY C.Y. Cheng, Y. Lin, Improving dynamic performance of the Geneva mechanism using non-linear spring elements, Mechanism and Machine Theory 30(1995) 119129. E.A. Dijksman, Jerk-free Geneva wheel driving, Journal of Mechanisms 1 (1966) 235283. E.A. Fenton, Geneva mechanisms connected in series, ASME Journal of Engineering for Industry 97 (1975) 603608. E.A. Sadek, J.L. Lloyd, M.R. Smith, A new design of Geneva drive to reduce shock loading, Mechanism and Machine Theory 25 (1990) 589595. F.L. Litvinov, Gear Geometry and Applied Theory, PrenticeHall, New Jersey, 1994.Fig. 12. Embodiment of the design and operation sequence. F.L. Litvinov, Theory of Gearing, NASA, Washington, DC, 1989.

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 G. Figliolini, J. Angeles, Synthesis of conjugate Geneva mechanisms with curved slots, Mechanism and Machine Theory 37 (2002) 10431061. H.P. Lee, Design of a Geneva mechanism with curved slots using parametric polynomials, Mechanism and Machine Theory 33 (3) (1998) 321329. J.J. Lee, K.F. Huang, Geometry analysis and optimal design of Geneva mechanisms with curved slots, Journal of Mechanical Engineering Science, Proceedings of the Institution of Mechanical Engineers, Part C 218 (4) (2004) 449454045.

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