DESIGN AND FABRICATION OF GENEVA OPERATED

BELT CONVEYOR
Project report submitted in partial fulfilment of the
Requirements for the Award of the Degree
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by
D Chaitanya Sai (158T5A0304) K Aravind (148T1A0307)
J Manikanta (148T1A0343) M Nani (148T1A0352)
Under the Guidance of
Mr.K.B.S.V.D.Prasad
Assistant Professor
Department of Mechanical Engineering

Department of Mechanical Engineering

Dhanekula Institute of Engineering & Technology
(Affiliated to JNTUK – Approved by AICTE)
Vijayawada – 521139
2017 – 2018

i
 Dhanekula Institute of Engineering & Technology
(Affiliated to JNTUK – Approved by AICTE)
Vijayawada – 521139

CERTIFICATE

This is to certify that the project report entitled Design and Fabrication of Geneva
Operated Belt Conveyor being submitted by

D Chaitanya Sai – 158T5A0304

K Aravind – 148T1A0307
J Manikanta – 148T1A0343
M Nani – 148T1A0352

In partial fulfilment for the award of the Degree in Bachelor of Technology in

Mechanical Engineering to the Jawaharlal Nehru Technological University Kakinada is
a record of bonafied work carried out under my guidance and supervision.

The results embodied in this project report have not been submitted to any other
University or Institute for the award of any Degree or Diploma.

Project Guide Head of Department

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THIS PROJECT WORK IS APPROVED BY THE FOLLOWING
BOARD OF EXAMINERS

1. EXTERNAL EXAMINER:

2. INTERNAL EXAMIER:

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 ACKNOWLEDGEMENT
It is our privilege to express our sincerest regards to our project coordinator,
Mr.K.B.S.V.D.Prasad, Assistant professor of Mechanical Department of Dhanekula
Institute of Engineering & Technology, for their valuable inputs, able guidance,
encouragement, and whole-hearted cooperation and constructive criticism throughout the
duration of our project. We deeply express our sincere thanks to our Head of the
Department Dr.O.Srikanth for encouraging and allowing us to present the project on the
topic “Geneva operated belt conveyor” at our department premises for the partial
fulfilment of the requirement leading to the awards of the B-Tech degree. We take this
opportunity to thank all our lectures who have directly or indirectly helped our project.

We pay our respects and love to our parents and all other family members and
friends for their love and encouragement throughout our career. Last but not least we
express our thanks to our friends for their cooperation and support.

We also expressing our heart full gratitude to all members of faculty and non-
teaching staff who are contributed their might in the successful completion of the project.
We owe a deep respect of gratitude to our family members and friends for their loving
encouragement, timely suggestions and constant support in finishing this project within
stipulated time.

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 ABSTRACT
The Geneva mechanism is a gear mechanism that translates a continuous rotation
into an intermittent rotary motion. The rotating drive wheel has a pin that reaches into a
slot of the driven wheel advancing it by one step. The drive wheel also has a raised circular
blocking disc that locks the driven wheel in position between steps.

Geneva mechanism has many applications such as in watches, projector, etc. But
we used Geneva mechanism for converting rotary motion into an intermittent motion in
production line. Geneva mechanism can be used in material handling in an industry. The
proposed concept will help in production line where many workers are used for the
material handling purpose it also reduce the cost and threshing time requirement of more
number of worker will be completely eliminated as only two workers can carried out the
complete operation.

Generally a belt conveyor consists of a motor to drive the rollers and in our project
a handle is attached to driving wheel. By using hand we operate the driving wheel.

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 CONTENTS

TITLE PAGE NO
CERTIFICATE ii
DECLARATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
CONTENTS vi
CHAPTER 1 – INTRODUCTION 1
1.1 – Introduction of Geneva mechanism 2
1.2 – Classification of Geneva mechanism 3
1.2.1 – External Geneva mechanism 3
1.2.2 – Internal Geneva mechanism 3
1.2.3 – Spherical Geneva mechanism 4
1.3 – Introduction of belt conveyor 5
1.4 – Types of belt conveyors 5
1.4.1 – Roller belt conveyor 5
1.4.2 – Horizontal belt conveyor 6
1.4.3 – Incline and Decline conveyor 7
1.4.4 – Brake and Meter belt conveyor 7
1.4.5 – Metal Piano Hinge conveyor 8
1.4.6 – Wire Mesh belt conveyor 9
1.4.7 – Portable conveyor 9
1.5 – Types of conveyor systems 10
1.5.1 – Pneumatic conveyor system 10
1.5.2 – Vibrating conveyor system 11
1.5.3 – Flexible conveyor system 11
1.5.4 – Vertical conveyor system 11
1.5.5 – Heavy Duty conveyor system 12
1.6 – Components 13
1.6.1 – Driving wheel 13
1.6.2 – Driven wheel 14

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 1.6.3 – Conveyor belt 15
1.6.4 – Rollers 15
1.6.5 – Bearings 15
1.6.6 – Stand 16
1.7 – Working 17
CHAPTER 2 – LITERATURE SURVEY 18
CHAPTER 3 – DEFINE THE PROBLEM 21
3.1 – Design of Geneva mechanism 22
3.2 – Time interval 22
3.3 – Jerking motion 23
CHAPTER 4 – DESIGN 24
4.1 – Material selection 25
4.1.1 – Mild steel composition 26
4.1.2 – Properties of mild steel 27
4.2 – Calculations 28
4.3 – 3D design 31
CHAPTER 5 – FABRICATION 34
5.1 – Welding 35
5.1.1 – Types of welding 36
5.1.2 – Arc welding 37
5.2 – Gas cutting 37
5.3 – Drilling 38
5.4 – Grinding 39
5.5 – Turning 39
RESULT AND DISCUSSION 40
ADVANTAGES & DISADVANTAGES 41
APPLICATIONS 42
CONCULSION 43
BIBLIOGRAPHY 44

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 CHAPTER – 1

INTRODUCTION

1
INTRODUCTION

The Geneva mechanism is a gear mechanism that translates a continuous rotation

into an intermittent rotary motion. The rotating drive wheel has a pin that reaches into a
slot of the driven wheel advancing it by one step. The drive wheel also has a raised circular
blocking disc that locks the driven wheel in position between steps.

Geneva mechanism has many applications such as in watches, projector, etc. But
we used Geneva mechanism for converting rotary motion into an intermittent motion in
production line. Geneva mechanism can be used in material handling in an industry. The
proposed concept will help in production line where many workers are used for the
material handling purpose it also reduce the cost and threshing time requirement of more
number of worker will be completely eliminated as only two workers can carried out the
complete operation.

Generally a belt conveyor consists of a motor to drive the rollers and in our project
a handle is attached to driving wheel. By using hand we operate the conveyor.

1.1 INTRODUCTION OF GENEVA MECHANISM

The Geneva mechanism is one of the earliest of all intermittent motion

mechanisms and when input is in the form of continuous rotation, it is probably still the
most commonly used. Geneva is available in variety of sizes. They are cheaper than cams
or star wheels and have adequate to good performance characteristics, depending on load
factors and other design requirements. Figure 1.1.1 shows the typical four slot external
Geneva.

Figure 1.1: Geneva mechanism

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1.2 CLASSIFICATION OF GENEVA MECHANISM

The Geneva mechanisms are classified into three types. They are (1) External
Geneva, which is most popular and (2) Internal Geneva, which is also very common and
(3) Spherical Geneva, which is extremely rare.

1.2.1 External Geneva mechanism

The external Geneva consists of a driver and driven. The driving wheel consists
of a pin and a driven wheel consists of a slots. When the driver pin reaches into slot and
that advances it by one step at a time. The typical figure 1.2 shows the external Geneva
mechanism. The external form is the more common, as it can be built smaller and can
withstand higher mechanical stresses.

Figure 1.2: External Geneva mechanism

1.2.2 Internal Geneva mechanism

The internal Geneva mechanism is a variant on the design. The axis of the drive
wheel of the internal drive can have a bearing only on one side. The angle by which the
drive wheel has to rotate to effect one step rotation of the driven wheel is always smaller
than 180 degrees in an external Geneva drive and always greater than 180 degrees in an

3
internal one, where the switch time is therefore greater than the time the driven wheel
stands still. The figure 1.3 shows the internal Geneva.

Figure 1.3: Internal Geneva mechanism

1.2.3 Spherical Geneva mechanism

In the type of mechanism, the Geneva cross is in spherical shape and cam drive
are connected in externally, which is extremely rare. The driver and driven wheel are on
perpendicular shafts. The duration dwell is exactly 180 degrees of driver rotation. It is
shown in figure 1.4.

Figure 1.4: Spherical Geneva mechanism

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1.3 INTRODUCTION OF BELT CONVEYOR

A conveyor belt is the carrying medium of a belt conveyor system. A belt

conveyor system is one of many types of conveyor systems. A belt conveyor system
consists of two or more pulleys, with an endless loop of carrying medium the conveyor
belt that rotates about them. One or both of the pulleys are powered, moving the belt and
the material on the belt forward. The powered pulley is called the drive pulley while the
unpowered pulley is called the idler pulley. There are two main industrial classes of belt
conveyors. Those in general material handling such as those moving boxes along inside
a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials, such as grain, salt, coal, ore, sand, overburden and
more.

Belt conveyors are universally used in industrial settings and in packaging and
assembling units. They can help in transportation of regular and irregularly shaped items
from one point to another regardless of their weight. The items can travel in a horizontal,
declined or inclined manner, depending on the type of belt conveyor used. They are
placed on the surface of the conveyor and transported from one point to the other through
continuous, non-stop movement.

The belt conveyor comprises of a belt that rests on top of a smooth metal bed or
rollers. When the distance is long, belt conveyors with rollers are the most suitable option,
as the rollers help to reduce friction. It is not necessary for belt conveyors to be straight.
They also can turn corners with a special attachment. In such a case, the shape of the belt
for the corners will be concentric, to facilitate smooth movement around the corners.

1.4 TYPES OF BELT CONVEYOR

There are many different types of conveyors and companies should be able to find
one to suit their needs. Some of the most common types are discussed below.

1.4.1 Roller bed conveyor

As the name suggests, in this type of belt conveyor, the surface for the belt
comprises of rollers. The rollers are selected based on the load of the items to be
transported and the required speed of the belt. Usually there are two rollers in a short belt

5
conveyor. However, the number of rollers may increase if the distance between the two
ends of the belt conveyor is more. Typically, these belt conveyors are used when the items
are loaded onto it with gravity rather than manually. Manual loading can cause
mechanical shock to the rollers, resulting in damage. It is shown in figure 1.5.

Figure 1.5: Roller bed conveyor

1.4.2 Horizontal belt conveyor

This type of belt conveyor consists of a centre drive, gear motor, and take-up.
Based on the drive of the conveyor, it can come with one or two pulleys at the end. The
belt of the conveyor is flexible and the entire system has floor supports along its length.
The figure 1.6 shows the horizontal belt conveyor.

Figure 1.6: Horizontal belt conveyor

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1.4.3 Incline and Decline conveyor

This type of conveyor is similar to a horizontal belt conveyor, but has an additional
component. It comes with a single or double nose over and sometimes it also has a feeder
portion. Typically, this type of conveyor has a rough surface on the belt during incline or
decline rather than making use of a smooth-surfaced belt. This offers more traction to the
items placed on the conveyor and prevents them from rolling backwards or forwards. The
figure 1.7 shows this type of conveyor.

Figure 1.8: Incline and Decline conveyor

1.4.4 Brake and Meter belt conveyor

This conveyor comprises of two parts. The brake belt is installed at the end of the
conveyor and facilitates accumulation of the items, while the meter belt is used to separate
items. Typically, the meter belt has the drive, whereas the brake belt uses the slave drive
from the meter belt. The length of the brake and meter belt is very important. Typically,
it should be about 1/7th of the total length of the accumulation conveyor and this includes
brake and meter belt lengths too. It is shown in below figure 1.9.

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 Figure 1.9: Brake and Meter belt conveyor

1.4.5 Metal Piano Hinge conveyor

This is a hinged type belt conveyor made from steel. It is perfect for transporting
hot and oily components from a punch press and forging machines. It is shown in figure
1.10 in below. This type of belt conveyor can be horizontal, inclined into an ‘S’ shape or
even level.

Figure 1.10: Metal Piano Hinge conveyor

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1.4.6 Wire Mesh belt conveyor

As the name suggests, it has mesh that will facilitate air ventilation. Hence, this
type of belt conveyor is ideal for transporting hot and cold items or components that
cannot be handled using standard duck or PVC belts. The wire mesh is placed on roller
or longitudinal runners and then it is covered with a thick plastic. In addition, there are
toothed pulleys to clasp onto the wire mesh belt. It is shown in figure 1.11.

Figure 1.11: Wire Mesh belt conveyor

1.4.7 Portable conveyor

This conveyor comes with caster wheels allowing it to be rolled from one place
to another. There are different types of portable conveyors and most companies can find
one to suit their needs. There are even portable gravity conveyors that can be extended
depending on the customer’s needs. The figure 1.12 shows the portable conveyor.

Figure 1.12: Portable conveyor

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1.5 TYPES OF CONVEYOR SYSTEMS

There are different types of conveyor systems which are explained in below. The
different types are used in different application areas.

1.5.1 Pneumatic conveyor system

Every pneumatic system makes use of pipes or ducts called transportation lines
that carry a mixture of materials and a stream of air. These materials are such as dry
pulverized or free flowing or light powdery materials like cement, fly ash etc. These
materials can be transported conveniently to various destinations by means of a stream of
high velocity air through pipe lines. Products are moved through various tubes via air
pressure, allowing for extra vertical versatility. Pneumatic conveyors are either carrier
systems or dilute-phase systems; carrier systems simply push items from one entry point
to one exit point, such as the money exchanging pneumatic tubes used at a bank drive-
through window. Dilute-phase systems use push-pull pressure to guide materials through
various entry and/or exit points. It is important to note that either air compressors,
vacuums, or blowers can be used to generate the air flow. This will all depend on what
the engineers think will be the most efficient and economical way of developing the
system. Three basic systems that are used to generate high-velocity air stream:

1. Suction or vacuum systems, utilizing a vacuum created in the pipeline to draw the
material with the surrounding air. The system operated at a low pressure, which
is practically 0.4 – 0.5 below atmosphere, and is utilized mainly in conveying light
free flowing materials.

2. Pressure-type systems, in which a positive pressure is used to push material from

one point to the next. The system is ideal for conveying material from one loading
point to a number of unloading points. It operates at a pressure of 6 atmosphere
and upwards.

3. Combination systems, in which a suction system is used to convey material from

a number of loading points and a pressure system is employed to deliver it to a
number of unloading points.

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1.5.2 Vibrating conveyor system

A Vibrating Conveyor is a machine with a solid conveying surface which is turned

up on the side to form a trough. They are used extensively in food grade applications
where sanitation, wash down, and low maintenance are essential. Vibrating conveyors are
also suitable for harsh, very hot, dirty, or corrosive environments. They can be used to
convey newly cast metal parts which may reach upwards of 1,500 °F (820 °C). Due to
the fixed nature of the conveying pans vibrating conveyors can also perform tasks such
as sorting, screening, classifying and orienting parts. Vibrating conveyors have been built
to convey material at angles exceeding 45° from horizontal using special pan shapes. Flat
pans will convey most materials at a 5° Incline from horizontal line.

1.5.3 Flexible conveyor system

The flexible conveyor is based on a conveyor beam in aluminium or stainless

steel, with low friction slide rails guiding a plastic multi-flexing chain. Products to be
conveyed travel directly on the conveyor, or on pallets/carriers. These conveyors can be
worked around obstacles and keep production lines flowing. They are made at varying
levels and can work in multiple environments. They are used in food packaging, case
packing, and pharmaceutical industries but also in retail stores such as Wal-
Mart and Kmart.

1.5.4 Vertical conveyor system

Vertical conveyor also commonly referred to as freight lifts and material lifts are
conveyor systems used to raise or lower materials to different levels of a facility during
the handling process. Examples of these conveyors applied in the industrial assembly
process include transporting materials to different floors. While similar in look to freight
elevators, vertical conveyors are not equipped to transport people, only materials.

Vertical lift conveyors contain two adjacent, parallel conveyors for simultaneous
upward movement of adjacent surfaces of the parallel conveyors. One of the conveyors
normally has spaced apart filets for transporting bulk food items. The dual conveyors
rotate in opposite directions, but are operated from one gear box to ensure equal belt
speed. One of the conveyors is pivotally hinged to the other conveyor for swinging the

11
pivotally attached conveyor away from the remaining conveyor for access to the facing
surfaces of the parallel conveyors. Vertical lift conveyors can be manually or
automatically loaded and controlled. Almost all vertical conveyors can be systematically
integrated with horizontal conveyors, since both of these conveyor systems work in
tandem to create a cohesive material handling assembly line.

In similarity to vertical conveyors, spiral conveyors raise and lower materials to

different levels of a facility. In contrast, spiral conveyors are able to transport material
loads in a continuous flow. Industries that require a higher output of materials - food and
beverage, retail case packaging, pharmaceuticals - typically incorporate these conveyors
into their systems over standard vertical conveyors due to their ability to facilitate high
throughput. Most spiral conveyors also have a lower angle of incline or decline (11
degrees or less) to prevent sliding and tumbling during operation.

Just like spiral conveyors also a vertical conveyor that use forks are able to
transport material loads in a continuous flow. With these forks the load can be taken from
one horizontal conveyor and put down on another horizontal conveyor on a different
level. By adding more forks more products can be lifted at the same time. Conventional
vertical conveyors have the restriction that the input and output of material loads must
have the same direction. By using forks many combinations of different input- and output
levels in different directions are possible. A vertical conveyor with forks can even be used
as a vertical sorter. Compared to a spiral conveyor a vertical conveyor - with or without
forks takes up less space.

1.5.5 Heavy duty conveyor system

Heavy Duty roller conveyors are used for moving items that are at least 500
pounds (230 kg). This type of conveyor makes the handling of such heavy
equipment/products easier and more time effective. Many of the heavy duty roller
conveyors can move as fast as 75 feet per minute (23 m/min).Other types of heavy duty
roller conveyors are gravity roller conveyor, chain driven live roller conveyor, pallet
accumulation conveyor, multi-strand chain conveyor, and chain & roller transfers.

Gravity roller conveyors are extremely easy to use and are used in many different
types of industries such as automotive and retail. Chain driven live roller conveyors are

12
used for single or bi-directional material handling. Large heavy loads are moved by chain
driven live roller conveyors.

Pallet accumulation conveyors are powered through a mechanical clutch. This is

used instead of individually powered and controlled sections of conveyors. Multi strand
chain conveyors are used for double pitch roller chains. Products that cannot be moved
on traditional roller conveyors can be moved by a multi-strand chain conveyor.

Chain & roller conveyors are short runs of two or more strands of double pitch
chain conveyor built into a chain driven line roller conveyor. These pop up under the load
and move the load off of the conveyor.

1.6 COMPONENTS

The main components which are used for Geneva operated belt conveyor are

(1) Driving wheel

(2) Driven wheel

(3) Conveyor belt

(4) Rollers

(5) Bearings

(6) Shaft

(7) Stand

The components are shown in above and these components are required to
fabricate our project in a proper manner. This components are sufficient for our project.
By using this components we made the Geneva operated belt conveyor. Every component
which is used for project is explained below.

1.6.1 Driving wheel

It is also known as Geneva drive. The driving wheel is one of the important
component in the Geneva mechanism. It is a circular disc and consists a pin on its surface.
This pin place a crucial role while in working. The rotating drive wheel is usually
equipped with a pin that reaches into a slot-shaped groove located in the other wheel

13
(driven wheel) that advances it by one step at a time. It is shown in figure 1.13 below.
When the driving wheel is operated, the pin will insert on the slot which is present on the
driven wheel. The rotation of the driven wheel is done by the pin.

Figure 1.13: Driving wheel

1.6.2 Driven wheel

It is also known as Geneva driven. It is the driven part of a Geneva mechanism

and it is shown in figure 1.14 below. It consists of slots on its surface. The driving wheel
has a pin. While in rotation the pin inserts in the slot and advances it by one step at a time.
The slots width are more than the pin diameter i.e. clearance is provided for smooth
running. The figure 1.14 shows the Geneva driven wheel.

Figure 1.14: Driven wheel

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1.6.3 Conveyor belt

It is one of the basic tools in material handling industry. Belt conveyors are most
commonly used in transportation of bulk materials. Belt conveyor systems consist of two
or more pulleys. An endless loop of carrying medium conveyor belt rotates about them.
To move the belt and the material, one or both pulleys are powered. The powered pulley
is called drive pulley and the unpowered pulley is known as idler pulley.

Based on the proposed use, conveyor belts are manufactured using either PVC or
rubber. The belt consists of one or more layers of material. Most belts in general material
handling consist of two layers. Carcass is the name of the under layer that provides linear
strength and shape, while cover is the name of the over layer. Polyester, nylon and cotton
are used most often to create the carcass, while a variety of rubber or plastic compounds
specified by use of the belt are used to create the cover. Belts with regular spaced
partitions are known as elevator belts. They are used to transport loose materials up steep
inclines. Belts conveyors are also used in self-unloading bulk freighters and in live bottom
trucks.

1.6.4 Rollers

It is a revolving cylinder about a central axis. The rollers are generally in the form
of cylinders. The rollers are used to transfer the material from one place to another
through the conveyor. A motor is used to drive the rollers and due to this the rollers are
able to rotate about its axis.

1.6.5 Bearings

A bearing is a machine element that constrains relative motion to only the desired
motion, and reduces friction between moving parts. The design of the bearing may, for
example, provide for free linear movement of the moving part or for free rotation around
a fixed axis or it may prevent a motion by controlling the vectors of normal forces that
bear on the moving parts. Most bearings facilitate the desired motion by minimizing
friction. Bearings are classified broadly according to the type of operation, the motions
allowed, or to the directions of the loads (forces) applied to the parts.

15
 Rotary bearings hold rotating components such as shafts or axles within
mechanical systems, and transfer axial and radial loads from the source of the load to the
structure supporting it. The simplest form of bearing, the plain bearing, consists of a shaft
rotating in a hole. Lubrication is often used to reduce friction. In the ball bearing and
roller bearing, to prevent sliding friction, rolling elements such as rollers or balls with a
circular cross-section are located between the races or journals of the bearing assembly.
A wide variety of bearing designs exists to allow the demands of the application to be
correctly met for maximum efficiency, reliability, durability and performance.

The term "bearing" is derived from the verb "to bear" a bearing being a machine
element that allows one part to bear (i.e., to support) another. The simplest bearings are
bearing surfaces, cut or formed into a part, with varying degrees of control over the form,
size, roughness and location of the surface. Other bearings are separate devices installed
into a machine or machine part. The most sophisticated bearings for the most demanding
applications are very precise devices their manufacture requires some of the highest
standards of current technology. The figure 1.15 shows the different types of bearings.

Figure 1.15: Bearings

1.6.6 Stand

The stand is a bottom part which bares the load of all other components. The
remaining parts are mounted on the base. The stand material must have the capability to
bare the load and the base material must goes under less deformation due to the load
applied on the base.

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1.7 WORKING

We already known that the working of Geneva mechanism, a continuous rotary

motion is converted into the intermittent rotary motion. The Geneva drive consists a
handle which is used for rotate the driver. The Geneva driver consists a pin and driven
consists a slot, when the pin inserts on the slot it advances by one step at a time. The
Geneva driven is coupled to a rollers when the driven advances by one step, the rollers
also rotates and the belt present on the rollers also moved and the material is transferred
from one position to other.

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 CHAPTER – 2

LITERATURE SURVEY

18
LITERATURE SURVEY

P.KaliSindhur, this is to design a mechanism for cutting by giving intermittent

feed. This intermittent feed is given by continuous revolving of circular disk in Geneva
mechanism. We have designed a belt drive with the help of Geneva mechanism is used
for giving feed and gives smooth operation and movement of the feed at required time
interval. The feed from Geneva drive was cut by using slotted lever mechanism. It was
designed using slider crank mechanism. It is placed at right angles at the end of the
Geneva mechanism and overall analysis are calculated at each link.

Han Jiguang Yu Kang, for both inner and outer Geneva mechanism, the
kinematics coefficient of the Geneva mechanism is a stable if the groove number of the
Geneva wheel is a constant. The elliptic crank using as the drive crank of the Geneva
wheel is equal to the mechanism which has a variable length and speed along the elliptical
moving crank. Therefore the kinematics coefficient of the Geneva mechanism is able to
be changed. In this paper the analysis method of the combined Geneva mechanism is
presented. The combined Geneva mechanism is put forward based upon the kinematics
coefficients. The calculation method of the extreme kinematics coefficient is proposed.
In the end, the design example is given.

David B Dooner, This is about kinematic study of a mechanism incorporating a

Geneva wheel and a gear train to achieve intermittent motion. The goal of this mechanism
is to eradicate the acceleration jump at the beginning and end of the Geneva wheel motion.
An epitrochoidal path replace the circular path for the driving pin in a classical Geneva
wheel drive. The epitrochoidal path is generate using a gear train and results in zero
velocity, acceleration, and jerk at the beginning and end of the Geneva wheel motion.
Presented a comparison of the position, velocity, acceleration, and jerk between the
classical Geneva wheel mechanism and the proposed mechanism. Subsequently, the
motion of the Geneva wheel is modified by introducing a non-circular gear pair to alter
the timing of the epitrochoidal path. The motion of the noncircular gear pair is determined
by dropping the extreme jerk of the Geneva wheel.

Brown, S.C. Large, outdoor Belt Conveyor Systems for mass materials are major
sources of industrial noise and often become an environmental emissions problem for
many existing and proposed plants. Deficiency in the industry’s understanding of the

19
complex, underlying conveyor noise generate mechanisms has meant there are relatively
few practical and cost-effective noise management strategies. Alternatively, pressure
from regulators and the community generally has often led to impossible conveyor noise
specifications. This paper presents the results of an innovative programme of research
and testing of conveyors and components. Conveyor noise is shown to be a composite of
noise generating mechanisms, the most leading of which is the dynamic interaction at the
belt/idler roll interface.

Konakalla Naga Sri Ananth, Belt conveyor is the moving of material from one
location to another. Belt conveyor has high weight carrying capacity, huge length of
conveying path, easy design and maintenance and high reliability of operation. Belt
Conveyor system is also used in material movement in foundry shop like deliver and
distribution of moulding sand, moulds and elimination of waste. This paper is to design
the conveyor system used for which include belt speed, belt width, motor selection, belt
specification, shaft diameter, pulley, gear box selection, with the help of standard model
calculation.

20
 CHAPTER – 3

DEFINE THE PROBLEM

21
DEFINE THE PROBLEM

This involves the problem existing in the project. The main problems involved in
our project are discussed briefly in below. The main problems involved in our project are
design of Geneva mechanism, time interval and jerks produced in the mechanism.

3.1 DESIGN OF GENEVA MECHANISM

One of the major problem involved in our project is that the design of Geneva
mechanism. This mechanism includes a particular geometry. Based on this geometry,
formulas and requirements the Geneva wheel is designed. The main thing in our project
is that proper working of the mechanism. This requires more concentration and
fabrication of Geneva mechanism is also a one of the major problem. The number of slots
required for the Geneva driven is also an important parameter. The design of Geneva
mechanism includes the Geneva drive and driven. The centre distance, drive radius,
driven radius, driving pin diameter, driven slot length and width are the important
parameter which are required for the design if Geneva mechanism. Without proper design
the working of the mechanism is impossible. Due to this the design of the Geneva
mechanism considered as the main problem.

3.2 TIME INTERVAL

The time interval is the dwell period of the Geneva driven. We already known that
the Geneva mechanism is a mechanism that converts the continuous rotary motion into
intermittent rotary motion. By the drive pin and the driven slot the mechanism is
produced. For the one revolution of the driver, the driven will move depend upon the
number of slots present in the driven wheel. The time between the two motions of the
driven is known as time interval. The time interval must be considered before the design
of Geneva. One thing must be considered that once the time interval is selected it could
not be changeable. The time intervals are different for various applications. When
particular time is taken that couldn’t be changed and it is applicable for that particular
application. There is a different procedure for calculating the time interval, by using the
formulae. The time interval is depend upon the speed of the driver and this is changed
depend upon the motor speed. But our project is manually operated so that the time
interval is based on the operator. This time interval effects the material transferred time.

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3.3 JERKING MOTION

The jerking motion is produced due to the intermittent motion. This jerking
motion is required in the Geneva operated paper cutting machine. But our project is belt
conveyor, so that the jerking motion will effects the material. Due to this motion the
material may be slip out from the belt. The jerking motion is also effected by the speed.
When the speed of the driver is less, the produced jerking motion is also less and it should
not effects the material, mechanism and machine. While in high speeds the jerking motion
produced will be high and due to this the material which is to be transferred by using this
belt conveyor will be effected. So the main problems involved in our project is mainly
based upon the speed.

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CHAPTER – 4

DESIGN

24
DESIGN

It is the creation of a plan for the construction of an object. In this project we use
CATIA V5 (computer aided three-dimensional interactive application) software for
preparation of 3D solid Model. The design includes the calculations, materials used and
its properties. By assuming the different parameters the calculations are done. The
measurements required for the Geneva mechanism are also calculated. The material
selected, properties of materials and calculations are explained below.

4.1 MATERIAL

Material selection is a process which is performed to select the best materials

which may have the potential to perform well both in industrially and commercially.
Today selection of materials is an important part of industrial designs because the
competition in the market is heavy. Failures arising from bad material selection are not
uncommon in many industries. In an application that demands a high tensile strength, a
material with higher tensile strength must be selected. If the product is to be used
outdoors, it may be necessary to consider the effect of ultraviolet light. If a proper material
selection is not done, the product life tends to be highly unpredictable. Therefore the
material selection process is quite important for the long term success of engineering
applications.

In the field of mechanical engineering, the selection of material is a tedious task

because there are number of factors that have to carefully evaluate before making the final
decision. The main requirement may be the strength of a particular application, but
depending on the working environment and behaviour, several other factors may have to
be considered.

In the selection of materials, a systematic approach is necessary to select the best

materials for a particular application. If a proper technique is followed, first it is required
to carefully define the application requirements in terms of mechanical, thermal,
environmental, electrical, and chemical properties. Then the choices are narrowed down
by the method of elimination. Production techniques also have a major importance in
selecting the best material. Material property data sheets never should be used for the

25
ultimate selection of materials. The actual performance of a particular material under
different conditions may differ from what is expected.

The integrity of a design can be ensured only after a systematic material selection
procedure. Otherwise, the result it is highly susceptible for failures. In the selection
process, materials will be assessed for tensile strength and modulus, flexural strength and
modulus, impact strength, compressive strength, fatigue endurance, creep, and stress-
relaxation properties depending on the application. This will ensure that the design will
have a better probability of succeeding. It will also assure that the design is technically fit
to obtain desired properties.

A great design may fail in the actual working environment. It may be subjected to
a higher load than ever expected. It may be damaged by a chemical. In these ageing and
transient conditions, only a good design with proper material selection may survive.
Therefore the material engineer should have the ability to predict the conditions from
clues he may already have about what a certain product may face in its actual working
conditions. Then he must carefully select the appropriate materials to suit those possible
conditions.

The materials are selected based on the properties and working environment. The
materials which are used for the fabrication of project are shown in below table 4.1.

COMPONENTS MATERIAL USED

Geneva drive Mild steel
Geneva driven Mild steel
Rollers Mild steel
Stand Mild steel

Table 4.1

4.1.1 Mild steel composition

Mild steel contains –

Carbon 0.16 to 0.18 % (maximum 0.25% is allowable)

Manganese 0.70 to 0.90 %

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 Silicon maximum 0.40%

Sulphur maximum 0.04%

Phosphorous maximum 0.04%

Mildest grade of carbon steel or mild steel contains a very low amount of carbon
- 0.05 to 0.26%

4.1.2 Properties of mild steel

Mild steel is the most commonly used steel. It is used in the industries as well in
the different everyday objects we use. Even the pans and spoons of the kitchen are
sometimes made of mild steel. The main target of this article is to discuss about different
mild steel properties. The mild steel is very important in the manufacturing of metal items.
Almost 90% steel products of the world is made up of mild steel because it is the cheapest
form of steel. Mild steel is the most widely used steel which is not brittle and cheap in
price. Mild steel is not readily tempered or hardened but possesses enough strength.

The use of mild steel is huge and a person who is into manufacturing or production
business need to know a lot about the important characteristics of mild steel. The study
of mild steel becomes more significant for a student of mechanical engineering or
metallurgical engineering. Mild steel is an alloy. And alloy is a product made by mixing
metals and non-metals. Sometimes a pure metal cannot full fill all the properties needed
for manufacturing product. So additives are included in the pure metal to obtain some
specific properties necessary for the production. Mild steel is made by adding carbon and
other elements in the iron. These elements improve the hardness, ductility and tensile
strength of the metal.

A small amount of carbon makes mild steel to change it properties. Different

amount of carbon produces different types of steels. There are small spaces between the
iron lattices. Carbon atoms get attached to this spaces and makes it stronger and harder.
The harder the steel the lesser the ductility.

The modulus of elasticity calculated for the industry grade mild steel is 210,000
Mpa. It has an average density of about 7860 kg/m3.

27
 Mild steel is a great conductor of electricity. So it can be used easily in the welding
process.

Because of its malleability, mild steel can be used for constructing pipelines and
other construction materials. Even domestic cook wares are made of mild steel. It is
ductile and not brittle but hard.

Mild steel can be easily magnetized because of its ferromagnetic properties. So

electrical devices can be made of mild steel.

Mild steel is very much suitable as structural steel. Different automobile

manufacturers also use mild steel for making the body and parts of the vehicle.

Mild steel can be easily machined in the lathe, shaper, drilling or milling machine.
Its hardness can be increased by the application of carbon.

Mild steel is very much prone to rust because it has high amount of carbon. When
rust free products are needed people prefer stainless steel over mild steel.

4.2 CALCULATIONS

Assume,

Centre distance between rollers, C = 800mm

Diameter of rollers, D1 = D2 = D = 100mm

𝐷1+𝐷2
Length of belt, L = 𝜋 [ ] + 2𝐶
2

100+100
=𝜋[ ] + (2 ∗ 800)
2

= 1914.15mm

Assumed that the material has to be transferred within 4 seconds through the
whole distance and for every rotation of driving wheel the conveyor belt will move
200mm.

Taking the slots on the Geneva wheel is 4.

1
One driving wheel rotation = 4 rotation of Geneva wheel

28
 2𝜋𝑟 = 200𝑚𝑚

200
𝑟=
2∗𝜋

𝑟 = 31.83𝑚𝑚

For Geneva wheel, r = 31.83*4 = 127.32mm

Taking,

Drive pin diameter, P = 20mm

Allowed clearance, t = 4mm

For Geneva mechanism,

Centre distance between driver and Geneva wheel,

𝑑𝑟𝑖𝑣𝑒 𝑐𝑟𝑎𝑛𝑘 𝑟𝑎𝑑𝑖𝑢𝑠 (𝑎)

C= sin(180⁄𝑛)

Where, n = driven slot quantity

𝑎
C= 180
sin( )
4

C = a/0.707

And, r = Geneva wheel radius = √𝑐 2 − 𝑎2

But we know that, r = 127.32mm

√𝑐 2 − 𝑎2 = 127.32

√(𝑎/0.707)2 − 𝑎2 = 127.32

𝑎 = 127.19𝑚𝑚

We have that C = a/0.707

= 127.19/0.707

= 179.9mm

Slot length on Geneva wheel, S = (𝑎 + 𝑟) − 𝐶

29
 = (127.19+127.32) - 179.9

= 74.6mm

Slot width, w = 𝑝 + 𝑡

= 20 + 4

= 24mm

Stop arc radius, y = 𝑎 − (𝑝 ∗ 1.5)

= 127.19 − (20 ∗ 1.5)

= 97.19mm

Stop disc radius, z = 𝑦 − 𝑡

= 97.19 − 4

= 93.19mm

Clearance arc, v = 𝑟𝑧/𝑎

= 127.32 ∗ 93.19/127.19

= 93.28mm

The Geneva drive and driven figures are shown in below.

Figure 4.1: Geneva wheel geometry

2𝜋𝑁
The angular velocity of the Geneva drive, 𝜔 = 60

30
 Assume N = 60rpm

𝜔 = 2𝜋 ∗ 60/60 = 6.283 rad/sec

Torque, T = 𝜔 ∗ 𝑟

= 6.283 ∗ 0.127

= 0.797 𝑁/𝑚2

Linear velocity of a belt, v = 200 mm/sec = 0.2 m/sec

The angle of contact between the belt and pulley, 𝜃 = 180° = 3.14 rad

T1/T2 = 𝑒 𝜇𝜃

𝜇 = Co-efficient of friction = 0.3

T1/T2 = 𝑒 0.3∗3.14 = 2.56

T1 = 2.56 T2

We know that, P = (T1-T2)*V

P = 2𝜋NT/60

= 2∗ 𝜋 ∗ 60 ∗ 0.797/60

= 5.01 watts

Substitute p value and T1 value in above equation, we get

5.01 = (2.56T2 - T2)*0.2

T2 = 16.05 N

T1 = 2.56T1 = 2.56*16.05 = 41.1 N

4.3 3D DESIGN

It is the creation of a plan for the construction of an object. In this project we use
CATIA V5 (computer aided three-dimensional interactive application) software for
preparation of 3D solid Model. Following figures showing the 3D solid models of various
components of project by using modelling software CATIA V5.

31
Figure 4.2: Geneva drive

Figure 4.3: Geneva driven

32
 Figure 4.4: Belt Conveyor

Figure 4.5: Geneva operated belt conveyor

The individual parts and assemble is shown in above figures are drawn by using
CATIA V5 3D modelling software. The design calculations, material used and properties
of the materials which are required for our project is completed.

33
CHAPTER – 5

FABRICATION

34
FABRICATION

Fabrication is a process of doing a work by using the different operations, such as

welding, grinding, drilling and etc. The operations which are used in fabrication of our
project are explained below. In the fabrication of this project a long square pipe is used
for making stand and by using the gas cutting the square pipe is cut with required
dimensions. These square mild steel pipes are welded together to get the stand with
required dimensions. The bearings are fixed to stand by using bolts and nuts. A hand
drilling machine is used to make holes on the stand with required dimensions. Then the
bolts and nuts are tightened. A mild steel solid shaft is used as rollers. The shaft diameter
at the both ends are turned on the lathe to insert into the bearings. The rollers are fixed in
between the two bearings. At one side of the shaft will be little bit of length present at
outside of the bearing. The circular mild steel plate with required dimensions are taken.
Then a pin is welded to it at proper position and also a handle is attached to it. Then the
Geneva drive fabrication is completed. Again a same diameter mild steel plate is taken
and four slots are marked on it. By using gas cutting the slots are removed. The curves
also removed by gas cutting and it is welded to the one side of shaft. Before assemble the
grinding machine is used for the finishing. The Geneva drive is assembled at some to the
driven with the help of bearing. Now assemble the all parts, so that the fabrication of
Geneva operated belt conveyor is done. The operations which are used for the fabrication
of this project such as welding, drilling, gas cutting, grinding and turning are explained
below.

5.1 WELDING

Welding is a fabrication process that joins materials, usually metals or

thermoplastics, by causing fusion, which is distinct from lower temperature metal-joining
techniques such as brazing and soldering, which do not melt the base metal. In addition
to melting the base metal, a filler material is typically added to the joint to form a pool of
molten material that cools to form a joint that is usually stronger than the base material.
Pressure may also be used in conjunction with heat, or by itself, to produce a weld.
Welding also requires a form of shield to protect the filler metals or melted metals from
being contaminated or oxidized.

35
 Although less common, there are also solid state welding processes such as
friction welding or shielded active gas welding in which metal does not melt.

5.1.1 Types of welding

Oxy fuel welding – also known as oxyacetylene welding or oxy welding, uses fuel
gases and oxygen to weld and cut metals.

Shielded metal arc welding (SMAW) – also known as "stick welding or electric
welding", uses an electrode that has flux around it to protect the weld puddle. The
electrode holder holds the electrode as it slowly melts away. Slag protects the weld puddle
from atmospheric contamination.

Gas tungsten arc welding (GTAW) – also known as TIG (tungsten, inert gas), uses
a non-consumable tungsten electrode to produce the weld. The weld area is protected
from atmospheric contamination by an inert shielding gas such as argon or helium.

Gas metal arc welding (GMAW) – commonly termed MIG (metal, inert gas), uses
a wire feeding gun that feeds wire at an adjustable speed and flows an argon-based
shielding gas or a mix of argon and carbon dioxide (CO2) over the weld puddle to protect
it from atmospheric contamination.

Flux-cored arc welding (FCAW) – almost identical to MIG welding except it uses
a special tubular wire filled with flux; it can be used with or without shielding gas,
depending on the filler.

Submerged arc welding (SAW) – uses an automatically fed consumable electrode

and a blanket of granular fusible flux. The molten weld and the arc zone are protected
from atmospheric contamination by being "submerged" under the flux blanket.

Electro slag welding (ESW) – a highly productive, single pass welding process
for thicker materials between 1 inch (25 mm) and 12 inches (300 mm) in a vertical or
close to vertical position.

Electric resistance welding (ERW) – a welding process that produces coalescence

of laying surfaces where heat to form the weld is generated by the electrical resistance of
the material. In general, an efficient method, but limited to relatively thin material.

36
5.1.2 Arc welding

This process use a welding power supply to create and maintain an electric arc
between an electrode and the base material to melt metals at the welding point. They can
use either direct (DC) or alternating (AC) current, and consumable or non-consumable
electrodes. The welding region is sometimes protected by some type of inert or semi-inert
gas, known as a shielding gas, and filler material is sometimes used as well. By using this
type of welding, we completed the welding process required for fabrication. The figure
5.1 shows the arc welding.

Figure 5.1: Arc welding

5.2 GAS CUTTING

Apart from using hacksaw, power saw, chisels, etc. for metal cutting operation,
gas cutting is extensively used now-a-days in industry. The process consists of preheating
the metal to be cut to its ignition temperature.

The preheating is done by oxy-acetylene gas flame, which is supplied from

surrounding openings of the cutting torch. When this temperature is attained, a jet of high
pressure oxygen from a central opening of the cutting torch is directed on the red hot
metal. The metal is rapidly oxidized, and slag is formed. This slag is washed out by the
jet of oxygen. It employed only when the ignition (oxidation) temperature of the metal
being cut is lower than its melting point. The process involves ensuring that the melting
points of the formed oxides are lower than that of the base metal itself. Although acetylene
is commonly used as a fuel in this process, other gases can also be used including butane,

37
methane, propane, natural gas. Hydrogen is sometimes used as a fuel gas, especially under
water to provide a powerful pre-heating flame. The gas cutting is shown in figure 5.2.

Figure 5.2: Gas cutting

5.3 DRILLING

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-
section in solid materials. The drill bit is usually a rotary cutting tool and it has multipoint
cutting edges. The bit is pressed against the work piece and rotated at rates from hundreds
to thousands of revolutions per minute. This process is used for making holes on
materials. The figure 5.3 shows the drilling operation.

Figure 5.3: Drilling

38
5.4 GRINDING

Grinding is an abrasive machining process that uses a grinding wheel as the

cutting tool. The grinding wheel consists of a small abrasive particles which have the
sharp cutting edges. This process is used to obtain fine surface finish. In grinding the
material is removed by means of large number of cutting tools constituted by projected
abrasive particles. The figure 5.4 shows the grinding operation.

Figure 5.4: Grinding

5.5 TURNING

Turning is a form of machining, a material removal process, which is used to

create rotational parts by cutting away unwanted material. The turning process requires a
turning machine or lathe, work piece, fixture, and cutting tool. It is shown in figure 5.5.

Figure 5.5: Turning

39
 RESULT AND DISCUSSION
The design and fabrication of the Geneva operated belt conveyor is completed
within the limited time and the results obtained from this project is good. Due to the
decrease in dimensions the result obtain is little bit less than expected. But the working is
in proper condition. The Geneva drive pin is smoothly inserts on to the Geneva driven
slot, due to this the working is done properly. A shaft is used as a roller and it is welded
to driven wheel. Because of this joint the roller will able to rotate with the driven. This
tends to the movement of the belt.

Generally the belt used for the conveyor is a leather or rubber. But in this a thin
light weight belt is required. Because it is not required to bear high loads. Due to this a
thin paper is used as a conveyor belt and for the demo, it is sufficient. The required
conveyor belt movement is obtained by this project. The smooth running of Geneva
mechanism is obtained. The fabrication is completed by using the different operations
and with the help of the design. The obtained movement of the belt conveyor is less, so it
takes more time. But this project is manual operated when a motor is attached to the driver
the time taken to move the material is became less.

40
 ADVANTAGES

 Available in a wide variety of sizes.

 Maintains good control of its load at all times.
 Have little wear leading to a very long life span.
 Low cost.
 Saves Man Power.
 Saves time.
 Time delay can be achieved easily.
 Convey the material at regular interval of time.
 Easy setup in an industry.
 Does not require stepper motor.

DISADVANTAGES

 Very difficult to change timing once design is chosen.

 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.

41
 APPLICATIONS

 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.

42
 CONCULSION

We have successfully calculated the angular velocity and acceleration of the

Geneva wheel. For the designed Genera wheel and the roller conveyor the time required
by the material to cross the entire belt is calculated accurately. The entire modelling of
the project is done with the help of CATIA V5.

In addition to this. The project work has provided us an excellent opportunity and
experience, to use our limited knowledge. We gained a lot of practical knowledge
regarding, planning, purchasing, assembling and machining while doing this project
work. We feel that the project work is good solution to bridge the gates between
institutions and industries.

We are proud that we have completed the work with limited time successfully.
“The Geneva Operated Belt Conveyor” is working with satisfactory condition. We have
done to our ability and skill making work, let us add. The proposed concept wills a few
more lines about our impression project work. Help in production line where many
workers are used for the material handling purpose it also reduce the cost and threshing
time requirement of more number of worker will be completely eliminated as only two
workers can carried out the complete operation. The project objective originally is to
convey the material handling at regular interval of time.

43
 BIBLIOGRAPHY

(1) P. Kali Sindhur, “Cutting mechanism by giving feed through Geneva

mechanism”, International journal of innovation science, Engineering &
Technology, vol 2 issue 4, April 2015.
(2) Han Jiguang Yu Kang, “Analysis & Synthesis of Geneva mechanism with elliptic
crank”, International journal of hybrid information technology, vol 8 No.8, 2015.
Page no: 253 – 260
(3) David B. Dooner, “Kinematic geometry of gearing”, April 2012.
(4) Brown, S.C.Large, “Belt conveyor system”.
(5) Konakalla Naga Sri Ananth, “Design & Selecting the proper conveyor belt”,
International journal of advanced engineering technology, E – ISSN 0976-3945.

44