GEARLESS POWER TRANSMISSION USING SOLAR

ENERGY

A PROJECT REPORT
Submitted by:

ARUN KUMAR A (910018114008)

TARAKA RAMANA R (910018114042)
VISHVA B (910018114049)
SHAKTHIVEL T (910018114306)

In partial fulfilment for the award of the degree

of

BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING

ANNA UNIVERSITY REGIONAL CAMPUS

MADURAI: 625019

ANNA UNIVERSITY: CHENNAI 60002

JUNE 2022

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 ANNA UNIVERSITY: CHENNAI -600 025

BONAFIDE CERTIFICATE

Certified that this project report “GEARLESS POWER TRANSMISSION

USING SOLAR ENERGY” is the confide work of “ARUN KUMAR A,
TARAKA RAMANA R, VISHVA B, SHAKTHIVEL T” who carried out
the project under my supervision.

SIGNATURE SIGNATURE
Dr. B.STALIN, M.E., Ph.D. Dr. B. STALIN, M.E., Ph.D.

HEAD OF DEPARTMENT, SUPERVISOR,

ASSISTANT PROFESSOR (Sr. Grade),
Department of Mechanical Engg., Department of Mechanical Engg.,

Anna University Regional Campus, Anna University Regional Campus,

Madurai - 625 019. Madurai – 625 019.

Submitted for the viva-voice held on .

INTERNAL EXAMINER EXTERNAL EXAMINER

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CONTENT

ABSTRACT ...................................................................................................... 5
CHAPTER 1 ...................................................................................................... 6
INTRODUCTION ............................................................................................. 6
1.1BACKGROUND ...................................................................................... 6
1.2 TRANSMISSION SYSTEM: ................................................................... 9
1.3 NEED OF TRANSMISSION SYSTEM: ............................................... 10
1.4 TYPES OF TRANSMISSION: .............................................................. 11
1.4.1 MANUAL TRANSMISSION: ............................................................ 12
1.4.2 INTELLIGENT MANUAL TRANSMISSION (IMT): ....................... 13
1.4.3 AUTOMATED MANUAL TRANSMISSION (AMT): ...................... 15
1.4.4 AUTOMATIC TRANSMISSION (AT): ............................................. 16
1.4.5 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ................ 18
1.4.6 SEMI-AUTOMATIC TRANSMISSION: ........................................... 19
1.4.7 DUAL-CLUTCH TRANSMISSION: ................................................. 20
1.4.8 SEQUENTIAL TRANSMISSION: ..................................................... 21
1.4.9 TORQUE CONVERTER TRANSMISSION ...................................... 23
1.4.10 TIPTRONIC TRANSMISSION: ....................................................... 24
1.5 RENEWABLE SOURCE OF ENERGY: ............................................... 26
1.6 TREND IN RENEWABLE ENERGY: .................................................. 28
1.7 TYPES OF RENEWABLE ENERGY SYSTEMS ................................. 30
1.7.1 WIND ENERGY:................................................................................ 30
1.7.3 SOLAR ENERGY: ............................................................................. 35
CHAPTER 2 .................................................................................................... 38
LITERATURE REVIEW ............................................................................. 38
2.1 GEARLESS TRANSMISSION THROUGH ELBOW MECHANISM: . 38
2.2 GEARLESS POWER TRANSMISSION FOR SKEW SHAFT (A SRRS
MECHANISM) ............................................................................................ 39
2.3 A REVIEW PAPER ON DESIGN AND ANALYSIS OF GEARLESS
TRANSMISSION MECHANISM USING ELBOW MECHANISM ........... 40

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 2.4 ANALYSIS AND SIMULATION OF GEARLESS TRANSMISSION
MECHANISM ............................................................................................. 40
CHAPTER 3 .................................................................................................... 42
EXPERIMENTAL PLAN ............................................................................ 42
3.1 METHODOLOGY:................................................................................ 42
3.2 COMPONENTS .................................................................................... 43
3.2.1 BEARING:.......................................................................................... 43
3.2.2 SHAFT:............................................................................................... 43
3.2.3 FRAME: ............................................................................................. 44
3.2.4 MECHANICAL LINKAGE: ............................................................... 44
3.2.5 ELECTRIC MOTOR: ......................................................................... 45
3.2.6 CYLINDER: ....................................................................................... 46
3.2.7 PULLEY: ............................................................................................ 47
3.3 SCHEMATIC EXPERIMANTAL SETUP ............................................ 48
3.4 WORKING PRINCIPLE: ...................................................................... 48
3.5 SELECTION OF MATERIALS: ........................................................... 50
3.6 LUBRICATION AND COOLING:- ...................................................... 54
CHAPTER 4 .................................................................................................... 55
RESULTS AND DISCUSSIONS ................................................................ 55
4.1 COMPARISON OF GEARED DRIVE WITH GEARLESS DRIVE ..... 55
4.2 MANUFACTURING METHODS:-....................................................... 55
4.4 CAUSE OF FAILURE:- ........................................................................ 55
4.5 MATERIAL:- ........................................................................................ 56
4.6 LIFE AND EFFICIENCY:- ................................................................... 56
4.7 CALCULATIONS: ................................................................................ 56
4.8 FABRICATION OF DESIGNED PROTOTYPE: .................................. 59
CHAPTER 5 .................................................................................................... 61
CONCLUSION ............................................................................................ 61
REFERENCES ................................................................................................ 62

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 ABSTRACT

The Transmission system in automobile functions to transmit the power

produced by engine to the propeller shaft and to wheel. Thus, the movement of
the automobile is complete with the help of gear and its related parts. To replace
the power loss in the belt transmission system, the gear transmission system is
introduced which has minimum friction loss. But as of newer ideas and
technology, the friction loss produced by the transmission system itself is hefty.
To rectify the problem in automobile, new system of transmission is used here
without gear as its components. To add fuel problem in recent times, the
renewable source of energy is used here. The solar panel is used which powers
the battery which in turn powers the motor attached to the gearless transmission
system. By using the slider and linkage mechanism in this gearless transmission
system the power can be transmitted at any angle between 0 to 180 degrees. In
this paper this mechanism is studied and the machine is fabricated and future
applications are suggested.

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 CHAPTER 1

INTRODUCTION
1.1BACKGROUND

The history of power transmission goes back before the industrial revolution. The
mechanical power transmissions mean, engineered to transmit mechanical power
from one place to another place using mechanical devices. The history of power
transmission is old as our ability to produce power in the water wheel. From the
world wide history we may found many types of discoveries done for the power
transmission but the most well documented development of technology's based
on wheels goes to the Greek Roman people. The transverse system used in the
water wheels is limited to change the rotary motion into a reciprocating motion
or vice versa based on the need the power will be used for. This formal system
was used until the 16th century.

Fig 1: Water wheel system

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The proto - Industrial society needs more power in future. The development of
factories mines etc needs the transmission system to do the purposeful work.
Engineer of the time had hardly two choices the first one is to divert the direction
of the river to the needed place to run the rotating machine the second one being
to find the way to transmit the work from already existing water wheel to the
needed form. The mechanical engineers choose the later one since the first one is
costly, also considering the limit of Civil Engineers of the time.

The German people uses of method called Flat rod system

which is mainly used for pumping water from mines beside the rivers. This works
on the principle of crank and connecting rod where the reciprocal motion is
converted into the translating motion adjoining the P voting rods attached to it.
The system pumps the water from the mine to the ground level as for us 4 km
away. This connecting rod and crank mechanism is simple but most of the power
is wasted from the friction and weight of the connecting rod and crank itself. With
the development of the industries the transmission system is most used in the
steam engines at the standard source of power by balancing the use of tark and
speed the further development or needed. This is not only needed in the steam
engine but also used in the industrial revolution where the application of mass
productions requires more tar to transmit power to all machineries on the factory
to a system of belts and pulley drive. The connecting rod and crank shaft lead to
more wastage when there is a need to transport power from one place to another
which is far away from the source. To overcome this gear boxes were used where
the result power is not wasted where it is not required. This gearbox probably the
greatest creation in engineering industries.

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 Fig 2: Pumping System at Germany

The first gearbox system was used in world's first automobile and unveiled By
Karl Benz in 1886. This car uses single speed with power shifting between the
engines connected directly with the wheel using a single gear, the system doesn't
function well as there is no control over the speed. If the automobile wants to go
faster the more feel is to be spent which might be strain the engine. To overcome
this, in 1990 two French engineers developed the first multiple gear transmission
system. This multiple gear system consists of n number of gears attached with the
sliding Road. There is a difficulty to engage one gear to another at a right time, if
failed they would grind against one other which might be resulting in total
damage of the system. To avoid this clutch mechanism is introduced which dis
engage the engine from the gear system when using the gears,.

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1.2 TRANSMISSION SYSTEM:

The transmission system is defined as a mechanism that transmit the power

developed from the engine of the automobile to the driving wheel is called as a
transparent system or Power train. The transverse system consist of following
elements,
 Clutch
 The Gear Box
 Propeller Shaft
 Universal Joints
 Differential
 Torque Tube
 Transfer Case
 Rear axle
 Wheel
 Tyres

Fig 3: Transmission System of Automobile

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1.3 NEED OF TRANSMISSION SYSTEM:
 Provide means of connection and disconnection of engine with rest of
power train without shock and smoothly
 Provide a varied leverage between the engine and the drive wheels
 Provide means to transfer power in opposite direction.
 Enable power transmission at varied angles and varied lengths.
 Enable speed reduction between engine and the drive wheels in the ratio of
5:1.
 Enable diversion of power flow at right angles.
 Provide means to drive the driving wheels at different speeds when
required.
 Bear the effect of torque reaction, driving thrust and braking effort
effectively.

DIFFERENCE BETWEEN TYRE AND WHEEL:

TYRE:

The tyre is the outer part of the wheel made up of rubber. It is mostly used
in vehicles for smooth movement.

WHEEL:

It is a device that allows to carry heavy objects with it. It moves the heavy
object easily through rotating on an axle through its centre, facilitating movement
while supporting load.

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1.4 TYPES OF TRANSMISSION:

MANUAL TRANSMISSION

INTELLIGENT MANUAL TRANSMISSION

(IMT)

AUTOMATIC TRANSMISSION (AT)

AUTOMATED MANUAL TRANSMISSION (AMT)

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

SEMI-AUTOMATIC TRANSMISSION

DUAL-CLUTCH TRANSMISSION

SEQUENTIAL TRANSMISSION

TORQUE CONVERTER TRANSMISSION

TIPTRONIC TRANSMISSION
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1.4.1 MANUAL TRANSMISSION:

A manual transmission is a system that requires the driver to manually

select a gear by operating a gear stick and clutch to change gears. This
transmission system is consist of a set of gears (different sizes) along with a pair
of shafts. The input shaft is connected to the engine and the output shaft is
continuously coupled to the input shaft and consists of several gears. In this, the
driver has to select gears manually and engage or disengage the clutch pedal.

Fig 4: Manual Transmission

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This transmission uses a flywheel, pressure plate, and clutch to engage and
disengage the engine from the transmission. The flywheel and pressure plate are
attached to the engine and the clutch is mounted between them.

The word push in clutch means to release the pressure plate which detaches the
clutch from the engine every time you do a shift, you have to push in the clutch
first.

Advantages of Manual Transmission

1. Manual transmission is considered better for off-road purposes.

2. This type of transmission system provide high torque load.
3. These are much more reliable and easier to service than other types.
Disadvantages of Manual Transmission:

1. Not everyone can drive

2. Higher learning curve.
3. These are require more work during driving.

1.4.2 INTELLIGENT MANUAL TRANSMISSION (IMT):

Simply and quite accurately put the IMT is a clutch less manual
transmission. It is similar to a manual gearbox, it has gears and a gear lever. The
driver almost feels like an automatic car as the IMT doesn’t have a clutch pedal,
but just a brake and an accelerator pedal.

In situations like downhill or overtaking, you have complete control over the
gearbox and that is certainly without the headache of operating the clutch pedal.
In this types of transmission system, you don’t need to lift the accelerator while
shifting gears, if you do, it will help things run smoothly.

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 Fig 5: Intelligent Manual Transmission

The IMT transmission system cannot automatically shift gears. On the other hand
with an IMT car compared to a manual transmission car, fuel efficiency and
mileage are subjective and dependent on the driving style of the driver.

Advantages of IMT

1. By using IMT Car, you can have complete control over what gear
your car is in and you won’t have to rely on software.
2. The cost of an IMT is also closer to that of a regular manual
transmission.
3. With IMT, the driver gets relief from a clutch operation, especially
in city stop-go traffic.
Disadvantages of IMT

1. In IMT, gear shifts are not smooth as the system relies on a clutch
which has to be modulated by an actuator.

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1.4.3 AUTOMATED MANUAL TRANSMISSION (AMT):
An automated manual transmission is an enhanced or modified version of
manual transmission that has eliminated the need to engage the clutch pedal when
shifting gears. It is almost similar to a manual transmission but in this system, the
sensors and actuators act as clutch and shift gears.

A car with an AMT does not have a clutch pedal, instead, only the accelerator
and brake pedal. This transmission also allows manual gear shift when needed.
The AMT transmission uses hydraulics and a computer connected to the car’s
Electronic Control Unit (ECU).

Fig 6: Automated Manual Transmission

The gear shift patterns are pre-programmed on this unit and work mainly on the
present RPM range. Once the system calculates maximum RPMs the ECU
engages the actuators which operate the clutch and gearbox. The car uses AMT
is Maruti Suzuki Alto, Hyundai Venue, Tata Nexon, and more.
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Advantages of AMT

1. A significant advantage of the AMT over the manual transmission

is its convenience because operating the clutch is not part of the
diver’s task, so it reduces fatigue.
2. AMT is more fuel-efficient, thus allowing more energy to flow to
the wheels than automatic transmission.
3. You can drive it however you want, which means most AMT
equipped cars also come with the manual mode.
Disadvantages of AMT

1. However, since AMTs depend on predetermined RPM levels, they

can cause unplanned changes during overtaking which can be
troublesome.
2. Higher space requirement and more weight than a manual
transmission.

1.4.4 AUTOMATIC TRANSMISSION (AT):

It is a multi-speed transmission utilized in vehicles that do not require any
driver to change forward gears under normal driving situations. It is consists of a
planetary gear set, hydraulic controls, and a torque converter.

The engine is connected to a torque converter which is then connected to a gear

system and then to the transmission. Inside the torque converter, some parts work
in tandem with each other. The outermost part houses the flywheel which spins
the whole structure.

The rotation pushes the fluid out of the pump at high speed, causing the turbine
to spin. The fluid continues to circulate in the two sections separately and through
the stator. The turbine is connected to the shaft which connects to the rest of the
system and then energy is transferred to the gear system.
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 Fig 7: Automatic Transmission

Advantages of AT

1. The main advantage of automatic transmissions is that they are

simply convenient and easy to use.
2. They provide comfortable driving for the driver and passengers.
3. ATs naturally have more power than any equivalent manual
transmission.
Disadvantages of AT

1. It is a complex system where many different items can fail.

2. Very expensive to main and repair compared to manual
transmission.

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1.4.5 CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
These are pulley-based transmissions primarily used in small vehicles with
smaller engines and they can change gears seamlessly through a constant gear
ratio. This is in opposition to other transmissions that offer a limited number of
gear ratios in fixed stages.

The CVT uses two pulleys between which a steel belt runs. To continuously
change its gear ratio, the CVT simultaneously adjusts the diameter of the “drive
pulley” which transmits torque from the engine, and the “drive pulley” which
transfers torque to the wheels.

Fig 8: Continuously Variable Transmission

The width of these pulleys changes depending on the power required as one gets
bigger and the other gets smaller. Hence this allows delivering strong and smooth
acceleration. Currently, the use of CVTs in their cars includes Toyota, Nissan,
and Honda.

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Advantages of CVT

1. They can provide you a smoothest ride because it eliminates feeling

of shifting.
2. It has greater fuel efficiency because engine is always running
efficiently.
3. It can give you a faster response to a change in driving conditions.

Disadvantages of CVT

1. They are considered unusable in off-road conditions.

2. There is no engine braking capability as seen in the manual
transmission.

1.4.6 SEMI-AUTOMATIC TRANSMISSION:

A semi-automatic transmission is a multi-speed transmission, where part
of its operation is automatic, but requires a driver’s input to drive the vehicle from
stop and change gears manually. It is a combination of manual and automatic
transmission.

It can also provide you with how to control the gears as there is a selection of
both manual and automatic options. The kinetic energy produced by the engine
helps the wheels spin, while gear ratios control how fast or slow your wheels spin.

Importantly, semi-automatics do not have a clutch pedal. Instead, the car’s CPU
and sensors operate the clutch when the driver changes gears, as a result, semi-
autos are actually easier to drive. Semi-automatic transmission is commonly used
in Hyundai cars.

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Advantages of Semi-automatic Transmission

1. They can provide you a smooth shifting compared to manual

transmission.
2. Semi-automatic transmission has fewer inefficiencies in shifting
means no lag time or slippage.
3. You can do gear shifting quickly without any difficulty.

Disadvantages of Semi-automatic Transmission

1. These are complex systems which means that objects are likely to
fail.
2. These types of transmission system are expensive to maintain
compared to manual transmission.
3. Very expensive to repair often it’s more cost-effective to just
replace.

1.4.7 DUAL-CLUTCH TRANSMISSION:

This transmission employs two separate clutches for odd and even gear sets
which allow for especially quick shifts. The design is often similar to two separate
manual transmissions, in that their respective clutches are within a housing, and
operate as a single unit.

The DCT operates like an automatic transmission, requiring no driver input to

change gears. This type of transmission can generally be operated in fully
automatic mode or can be moved manually with the pedals on the steering wheel.

Currently, these gearboxes are mainly found on race cars and high-end sports cars
and they are quite expensive.

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Advantages of Dual-clutch Transmission

1. DCTs offer better fuel economy and better performance than

automatic transmissions.
2. Since they shift smoothly and with a high degree of accuracy, they
are often preferred in the field of performance driving.

Fig 9: Dual Clutch Transmission

Disadvantages of Dual-clutch Transmission

1. They are expensive, this disadvantage is compounded by their

complexity which leads to more frequent and costly repairs.
2. When driving at low speeds, such as in a parking lot or on the
opposite side of the car, it tends to pull and lock.

1.4.8 SEQUENTIAL TRANSMISSION:

A sequential manual transmission allows you to select either the next gear
(e.g., shifting from first gear to second gear) or the previous gear (e.g., shifting

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from third gear to second gear), operated through electronic pedals mounted on
the rear of the steering wheel.

In the vehicle with a sequential gearbox, you simply hit a lever or pedal to click
through each gear, whether you’re up-shifting or down-shifting. In some vehicles,
there is an actual lever that the driver either pushes forward or pulls backward to
shift up or down.

Generally, it is a type of non-synchronous manual transmission used mostly for

motorcycles and racing cars. They are also known as sequential gearboxes or
sequential transmissions.

Fig 10: Sequential Transmission

Advantages of Sequential Transmission

1. The shifting gears in sequential transmission is easier.

2. You can increase or decrease your speed without stopping or
experiencing a drop in speed.

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 3. This mechanism is named because you can only change gears in
sequence.
Disadvantages of Sequential Transmission

1. One disadvantage of a sequential gearbox is that you cannot “skip

the shift” – i.e. change gears non-sequentially.
2. Going again after a panic stop can be a bit difficult as they do not
like to shift easily while stopping.

1.4.9 TORQUE CONVERTER TRANSMISSION

Torque converter transmission is one of the oldest types of automatic
transmission. The first torque converters weren’t designed for any sort of
performance or fuel efficiency. But today’s torque converters are quite responsive
and are suitable for city or highway driving.

The casing attaches to the flywheel, rotating at the same speed as

the crankshaft within the turbine’s housing. Finally, the impeller or centrifugal
pump drives transmission fluid to the turbine fins which in turn spins or transmits
torque to the transmission.

The torque converter is used in the vehicle which is provided with automatic
transmission. The cars offered with Torque Converter are Hyundai Creta AT,
Maruti Suzuki Ciaz AT, etc.

Advantages of Torque Converter Transmission

1. It produces maximum torque as compared to a vehicle equipped with

a clutch.

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 2. It can provide driving comfort to drivers by avoiding changing gears
manually.
3. They remove the clutch pedal and make driving easier.

Fig 11: Torque Converter Transmission

Disadvantages of Torque Converter Transmission

1. The torque converter transmission are less fuel efficient compared

to manual transmission or CVT.
2. These types of transmission system require higher cost to install.

1.4.10 TIPTRONIC TRANSMISSION:

The Tiptronic transmission system is similar to an automatic transmission
in that the driver can exit “automatic mode” and use the paddles to shift up or
down like a manual transmission. The Tiptronic transmission is also known as
Sportmatic or Steptronic transmission.

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It is an automatic gearbox with the ability to change gears manually. A Tiptronic
transmission works in the same way as a manual gearbox, but without the clutch.
This allows you more control gears, which is ideal for going high hills or for
better control when overtaking on the highway.

Fig 12: Tiptronic Transmission

There are safety measures built into the Tiptronic transmission that will
automatically shift in case the driver forgets. These are commonly seen in cars
like Volkswagen models, Audi, Land Rover, Lamborghini models, and more.

Advantages of Tiptronic Transmission

1. Driving a car with a Tiptronic transmission allows you more control

when you change gears.
2. When driving up or down a steep hill, you can manually change
gears to allow for a smoother and safer ride.
3. Automatic shifting in manual mode also assists the driver by
delaying the engine in case of down-shift failure.

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Disadvantages of Tiptronic Transmission

1. The Tiptronic system uses a torque converter instead of the regular

clutch mechanism, this can result in some degree of power loss.
2. Since in manual mode, the ECU shifts gears, there is a slight delay
during the shift, which becomes evident in more aggressive driving.

1.5 RENEWABLE SOURCE OF ENERGY:

All societies need energy services to satisfy their needs (such as cooking,
lighting, heating, communications, etc.) and to support productive services. In
order to secure sustainable development, the delivery of energy services needs to
be safe and cause low environmental impacts. Social sustainability and economic
development require security and easy access to energy resources, which are
indispensable to promote sustainable energy and essential services. This means
applying different strategies at different levels to revamp economic development.
To be environmentally benign, energy services should provoke low
environmental impacts, including greenhouse gas (GHG) emissions.

According to the study in, fossil fuels are still the main primary energy
sources. A major revolution is required in how energy is produced and used in
order to preserve a sustainable economy capable of providing the required public
services (both in developed and developing countries), and laying effective
support mechanisms to climate change mitigation and adaptation efforts . A major
concern in both developed and developing countries, including emerging
economies, is that without having abundant and accessible energy sources, it is
not possible to maintain the current paradigm in the medium and long term, from
an economic point of view. In accordance with the International Energy Agency
(IEA) reference scenario, the primary global energy consumption will grow
between 40% and 50% until 2030, at an annual average rate of 1.6%. Without a

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major paradigm shift in energy policies throughout the world, fossil fuels are still
expected to cover about 83% of the increase in demand. The reasons for this
strong growth are essentially two: the continuous increase in world population
and the economic convergence between developed and developing countries,
especially with emerging economies such as India and China that are leading the
economic recovery from the recent global economic crisis, and becoming the
major consumers of non-renewable energy sources. This change must be
answered with structural measures, such as by putting a real monetary value to
energy. Some of the promising solutions are accelerating renewable energy
integration, promoting energy efficiency and supporting transport systems
modernization. This can be achieved by promoting more transparent markets to
flourish and creating an enabling environment for competition in all sectors of
the economy and energy production. The sustainability of energy systems is now
an important factor for socio-economic development. Sustainability depends on
three major components i) the security of access to energy, ii) the accessibility of
services and iii) environmental compatibility.

Changing the energy scenario presents itself as a huge challenge whose

solution ultimately depends on the political will of governing bodies to make the
necessary investments on a global scale. In the medium and long term horizon,
investment decisions will affect the cost and the environmental impacts of
infrastructures. Most likely, the energy supply will be the main factor of possible
models for future development at global, regional and national levels.

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1.6 TREND IN RENEWABLE ENERGY:
An increase in an overall world trend in the awareness of climate change
and the need for mitigation efforts is bringing forth huge increase in the
deployment of renewable energy in comparison to fossil fuel energy sources. The
landmark that signals the dawning of this renewable age goes hand in hand with
the degree of advancement in technologies and a higher degree of RES
penetration, which is being achieved around the world. Furthermore, there are
several driving factors for these remarkable growths among which are favourable
government support policy and increasing competitiveness in costs. After several
decades of efforts in research and continuous development in RES, the yearly
growth in the capacity of these plants is becoming greater than the total
investment capacity added in power plants based on coal, natural gas and oil all
combined together. Nowadays, RESs have reached a significant level of share in
energy supply options, becoming one of the prominent global alternative power
supply sources. This trend will continue increasing at faster rates as long as the
world’s desire for industrial scale clean energy sources is on the higher side. The
latest global trends in renewable energy investment status reports indicate that,
renewables represented a 58.5% of net additions to global power capacity in
2014, with significant growth in all regions, which represents an estimated 27.7%
of the world’s power generating capacity, enough to supply an estimated 22.8%
of global electricity. Wind, solar and biomass power generations reached an
estimated 9.1% of the world’s electricity in 2014, up from 8.5% in 2013.
According to renewables status report, the overall cost-cutting achieved to date
helped to ensure such a strong momentum in 2014, reaching an investment boom
up to 29% in solar, and 11% in wind technologies, and geothermal managing to
raise 23%. Further cuts in the cost of generation for both solar and wind look to
be on the cards in 2015. The report on global renewable energy 2015 also
indicates the continued growth of RES participation in parallel proportion with
the energy consumption and the falling oil prices. In addition, issues related to

28
the untapped RES potentials indicate that it still requires a growing effort in
pursuing innovative approaches to increase its participation in order to guarantee
a clean energy future. Concerning the regional expansion of RES utilization, such
growth scheme is not limited to the industrialized regions, but also an increasing
number of developing countries are even becoming important manufacturers and
installers of this fashionable energy source. Another essential growth trend
currently being observed, which is worth mentioning here, is the diversity of
applications of the renewable sources. The use of renewables is no more limited
to the power generation only, but its use is expanding in heat related and
transpiration applications. In this regard, several supporting technologies like heat
supply and storage systems are helping flourish the deployment of these
important energy resources across many countries. Also, a significant
contribution to the world transport sector is being promoted with an increased
share in the use of Ethanol and Biodiesel in combination with fossil fuels. In
relation to the job creation opportunities, renewable energy employment
continues expanding, which according to IRENA, in 2014 an estimated 7.7
million people are working directly or indirectly in this sector. Also, concerning
government policies, the number of countries, states and provinces which adopted
renewable policies and targets tripled since 2004. Regarding investment
mechanisms, innovative approaches have been introduced like in the case of
Asian investment banks, representing a new investment vehicle for renewable
energy projects such as green bonds, yield companies, and crowd funding which
have attached new classes of capital providers and are helping to reduce the cost
of capital for financing renewable energy projects. As a result, the investment
flow in renewables has outpaced fossil fuels for five consecutive years in all
regions. According to the global status report, currently, there is no systematic
linkage between the so-called renewable energy twin pillars: the renewable
energy sources and energy efficiency, in technical as well as policy wise.

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1.7 TYPES OF RENEWABLE ENERGY SYSTEMS

Renewable technologies are becoming increasingly competitive in a

number of countries but government support is still needed to enhance the
development of these schemes in many other countries. The capacity increase of
base renewable generation is estimated to be 128 GW in 2014 out of which 37%
is related to wind, nearly a third to solar energy and more than one quarter to
hydropower. The growth in installed wind power capacity has been developed
mainly onshore, but offshore wind development has also shown substantial.
China continues to have the largest wind power market with a 20 GW installed
capacity.
For instance, to overcome the current dark prospects of biofuels in Brazil, the
government increased the ethanol rate of mixture from 25% to 27% and from 5%
in biodiesel to 7%, and increased gasoline taxes, while Argentina and Indonesia
have increased their biofuels mandates. A long period of low oil prices could
result in neglecting the promotion of energy efficiency and instead returning to
wasteful consumption. However, there is no evidence to date that this has
occurred.

1.7.1 WIND ENERGY:

Wind energy is one of the most promising alternative energy technologies
of the future. Throughout recent years, the amount of energy produced by wind-
driven turbines has increased exponentially due to significant breakthroughs in
turbine technologies, making wind power economically compatible with
conventional sources of energy. Wind energy is a clean and renewable source of
power. The use of windmills to generate energy has been utilized as early as 5000
B.C., but the development of wind energy to produce electricity was sparked by
the industrialization. The new windmills, also known as wind turbines, appeared
in Denmark as early as 1890. The popularity of wind energy however has always

30
depended on the price of fossil fuels. For example, after World War II, when oil
prices were low, there was hardly any interest in wind power. However, when the
oil prices increased dramatically in the 1970s, so did worldwide interest in the
development of commercial use of electrical wind turbines. Today, the wind-
generated electricity is very close in cost to the power from conventional utility
generation in some locations. Where does wind come from? Wind is a form of
solar energy and is caused by the uneven heating of the atmosphere by the Sun,
the irregularities of the Earth’s surface, and rotation of the Earth. The amount and
speed of wind depends on the Earth’s terrain and other factors. The wind turbines
use the kinetic energy of the wind and convert that energy into mechanical energy,
which in turn can be converted into electricity by means of a generator. 2 There
are essentially two types of wind turbines: The horizontal-axis variety, and the
vertical axis design. The horizontal-axis design is used more commonly and looks
like an Old Dutch windmill, whereas the vertical-axis design looks like and
eggbeater. These wind turbines generally have either two or three blades, called
rotors, which are angled at a pitch to maximize the rotation of the rotors. The
horizontal-axis design is slightly more efficient and dependable than the vertical-
axis windmill. Most of the windmill models that are currently in production are
thus horizontal-axis windmills. Utility scale turbines can produce anywhere from
50 kilowatts to several megawatts of energy. These large windmills are generally
grouped together in a windy area in what is called a wind farm. The proximity of
the windmills in a wind farm makes it easier to feed the produced electricity into
the power grid. Wind energy offers many advantages compared to fossil based
power and even some other types of alternative energy, which explains why it is
the fastest growing energy source in the world. The two main reasons are
cleanliness and abundance. The fact that wind is a renewable resource gives it a
major advantage over oil and the non-renewable resources. Considering that
environmental pollution is being linked to several global problems that might
eventually threaten the existence or at the very least worsen human living
31
conditions, the fact that windmills do not produce any emissions whatsoever is
another reason to increase the use of wind turbines. Increasing the percentage of
wind power used by the United States would not be unreasonable, seeing that the
price of wind power is between 4 and 6 cents. Even though wind energy has many
environmental and supply advantages, there are several disadvantages that limit
the usability of wind power. The main disadvantage to wind power is that it is
unreliable. Wind does not blow at a constant rate, and it does not always blow
when energy is needed. Furthermore, the windiest locations are often in remote
locations, far away from big cities where the electricity is needed. Just like with
any other energy plant, people oppose it because of aesthetic reasons. The rotor
noise produced by the rotor blades is another reason for opposition. Wind seems
to be a very good source of alternative energy. Its biggest setback is its
unreliability, but in combination with other, more reliable sources, wind energy
should be used extensively to supplement the demand for energy.

Fig 12: Wind Mill

32
1.7.2 BIOMASS:
As a pending global energy crisis appears more and more imminent, it is
important to consider many different options for new energy sources. Renewable
energy sources are ideal because they are more efficient, environmentally friendly
and, ultimately, better for consumers. Biomass can be converted into fuels
through a number of different processes, including solid fuel combustion,
digestion, pyrolysis, and fermentation and catalysed reactions. Electricity is
generated in many places through solid fuel combustion. The majority of
America’s electricity is fuelled by coal combustion. However, many states,
especially California, are encouraging companies to use biomass fuels to generate
electricity. These products are usually wood matter, vegetation, waste from
lumber yards, and the like.25 Power plants burn such fuels to heat a boiler, and
the resulting steam powers turbines & generators.26 This process still releases a
lot of carbon dioxide and other polluting gases into the environment, but helps
eliminate waste efficiently. Digestion is another process that makes use of
existing waste. The term is a misnomer. Digestion is the naturally occurring
process of bacteria feeding on decaying matter and making it decompose. It is
that which releases gases like methane, hydrogen, carbon monoxide, etc.27 In
many landfills, owners are experimenting with set-ups to best collect the gases
produced by such bacteria. The standard system includes pipelines running
through the waste to collect the gases. Animal feed lots and other facilities are
also exploring tapping such resources. A zoo in upstate New York is using their
elephant manure to do the same thing. Benefits of this process include the relative
lack of impurities in the gases produced and the fact that the synthesis gases
(carbon monoxide and hydrogen) can be converted to any kind of hydrocarbon
fuel. A third process, pyrolysis, creates a product much like charcoal, with double
the energy density of the original biomass, making the fuel highly transportable
and more efficient.

33
 Fig 15: Biomass Energy

Anhydrous pyrolysis heats the biomass at intense temperatures in the

absence of oxygen or water. Scientists assume that this is the process that
originally produced fossil fuels (under different conditions). Most industrial
processes of pyrolysis convert the biomass under pressure and at temperatures
above 800° F (430° C). A liquid fuel can also be produced using this process. The
most widely used alternative fuel, ethanol, is created through fermentation of
organic materials. Ethanol has a current capacity of 1.8 billion gallons per year,
based on starch crops such as corn. Again, the fuel conversion process takes
advantage of a natural process. Microorganisms, especially bacteria and yeasts,
ferment starchy, sugary biomass products (like corn), yielding products like
ethanol, which can be used as fuels in a variety of applications. Biodiesel is an
increasingly popular fuel, especially in the transportation sector. This monoalkyl
ester is formed by combining fuel-grade oil, processed from sources like
vegetable oil, animal fats, algae and even used cooking grease, with an alcohol

34
(like methanol or ethanol), using a catalyst. It shows great promise as both a neat
fuel (used alone) and as an additive to petroleum diesel. Using biomass could be
the answer to the energy questions made more imminent by the recent crises that
have further threatened our oil supply. The current technologies take advantage
of many natural, long-utilized processes in order to create “new” kinds of fuel.
Upon further observation, one realizes that these fuels are very basic, using the
most readily available energy sources with very simple, standardized processes
that greatly reduce pollution and offer hope for the future.

1.7.3 SOLAR ENERGY:

“Solar energy is one of the purest and clean forms of energy we receive on
earth, without any environmental degradation. Thanks to the never-ending solar
radiations we receive, it is responsible for all the life processes taking place on
earth. If we tap into this energy systematically, this can be the largest source of
energy, and even a tenth of energy from solar rays on earth can solve the entire
energy crisis In India, however, the potential of energy from solar rays is about
750GW. If this energy is utilized, we won’t need any other source of energy in
our country. There are many ways converting solar energy to electricity, but most
widely used ones are by using photo-voltaic cells (also called solar cells) and
concentrated solar power, where solar rays are focused and the concentrated
power generates heat to run the solar plant. Solar energy has gained a lot of
significance in recent decade, due to shortage of non-renewable sources of
energy. As on 30 June 2015, the installed grid connected solar power capacity is
4,060.65 MW, and India expects to install an additional 10,000 MW by 2017 and
a total of 100,000 MW by 2022. India being the first country in the world to setup
the ministry of non-conventional energy resources, Gujarat has been a leader in
solar power generation and contributes 2/3rd of the 900 MW of photovoltaic in
the country There have been a few initiatives from the government, such as the

35
Indian Solar Loan Programme, which has focused on financing solar home power
systems, to increase the use of solar energy for domestic use. It may also include
lighting, irrigation or water heaters. Notably, Bangalore city has the largest
deployment of solar water heaters in India. Solar industry has Investment 2015
also highlights a record $119 billion in new investment. Gujarat and Rajasthan
alone account to more than 88% of total solar energy produced in India. As an
entrepreneur, the potential for innovation is endless in this sector, as the whole
world is moving in a direction to minimize the use of renewable energy and opting
for solar devices. Right from automobiles to domestic appliances and handheld
devices, solar is going to dominate the market in our near future. Moreover, as
the efficiency of solar cells is less than 10%, there is huge scope for innovators
to develop energy efficient solar devices and make it cost-effective to address the
demands of the large population in our country.”

Fig 17: Solar Plate

“There is a vast potential for use of solar energy devices / systems in

industries for process heat and other thermal applications. Presently energy for
these applications is being met mainly through fuel oil which is not only import
dependent but also creating huge GHG emissions in atmosphere resulting threat

36
to our planet. India is consuming over 100 million tons of oil every year for
various uses. Out of this, almost 40% is being consumed in the industrial sector
alone. Further, 40-50% of this consumption is in thermal form alone with
temperature range below 250 c which comes to around 15 million tons of fuel oil
per annum. The applications include mercerizing, drying and finishing in textile
industry, cooking, drying and canning in food industry, craft pulping, bleaching
and drying in pulp and paper industry, drying and cleaning in leather industry and
various such applications in many more industries. The working fluid required
for these applications is pressurized hot water, steam or hot air in temperature
range of 60-250 C. There are number of solar energy technologies which can be
used for such applications and reduce consumption of fuel oil mainly during day
time. The technologies include solar water heating systems, steam generating
systems and air heating systems based on flat plate or evacuated tube collectors
and automatically tracked solar concentrating collectors.”

37
 CHAPTER 2
LITERATURE REVIEW

2.1 GEARLESS TRANSMISSION THROUGH ELBOW MECHANISM:

Authored by S.S Pawar, Ankur Naidu, Panlgopal Vallabhanent March 2017

“From this article we came to know about the transmission of power with
minimum losses. The main Criterion for this work is to find the efficiency of the
machine by using a gear less transmission system. A lot of investigations are
going with the new ideas to transmit power using different mechanisms on among
them here they have used a new mechanism by replacing bubble gear with 90
degree elbow that is used to transmit power by this they have prude it is a
possibility to transmitting power at right angles without gears efficiently the
power is transmitted with 6 elbows connected really at an angle of 60 degree. In
this literature work they have used to non-parallel and coplanar served this
mechanism is known as gearless elbow mechanism which consist of rods that is
of elbow type. This mechanism works on the principle of slider and kinematics
principle. Generally to transmit motion from one shaft to another is done by
parallel and coplanar bevel gearing system some disadvantages involved in bevel
gearing is a complexity in its manufacturing .so to overcome this the gearless
Transmission Systems is used. As a result from their work they have found out
that found out that this type of gearless transmission is very smooth and desirable
but it can be used for only some constant RPM engines the driven shaft and
driving shaft uses a pin a type of data connection for joints suitable for the
revolutionary torque this gear less power transmission is best Ideas in the future
technology sure it will replace heavy usage of gears which will be Replace with
simple usage of say Joseph that will reduce her use an overall manufacturing
cost.”

38
2.2 GEARLESS POWER TRANSMISSION FOR SKEW SHAFT (A SRRS
MECHANISM)
Authored by Amit Kumar and Mukesh Kumar April 2017

“This literature work gave a brief introduction about the power

Transmission used in skew shaft. Here they have used number of pins or links
that is of odd numbers. From their work we may come to conclusion that if more
pins or links used motion will be very smooth but increasing the number of pins
will cause more cost strength of the shaft. The pins are fixed at drilled holds. The
dimension of the components are all are given very precisely and accurately. It
arrangement allow us to change angle between Shafts during intermittent motion
or during a regular motion having rotational motion along its own axis. With this
system we can achieve a very smooth and we use the system very effectively with
the minimum amount of power losses in the transmission system. From this work
it is seen that the gearless type of transmission used to here can be implemented
in both intersecting shaft and screw shaft. From this work it is seen that the
gearless type of transmission used here can be implemented in both intersecting
shaft and skew shaft. By doing this power transmission system can reduce the
losses the cost, the time and also the space. By their experimental setup and the
discussion they had discussed here we came to an observation that this proposed
arrangements used for any set of diameters with any profile of any angle but with
the exception that shaft must be having only a rotational motion about its own
axis. By this a desired smooth motion can be achieved and it is possible only with
equal speed of driving shaft and driven shaft by employing pins at appropriate
rate.”

39
2.3 A REVIEW PAPER ON DESIGN AND ANALYSIS OF GEARLESS
TRANSMISSION MECHANISM USING ELBOW MECHANISM
Authored by Kiran and Ashish Kumar Shrisvastava Dec 2017

“From this paper we can offer a data of strength speed torque transibility
of the album mechanism. They have undergone for theoretical and analytical
techniques, one among such techniques includes FEA technique. The parameters
used for this processing of systems are number of pins materials and their
dimensions like elements speed and torque. The ideal layout was found by
presiding various methods and find out the optimised layout to make this
mechanism higher than the regular one. As a result of their study they had found
where outcomes is. Some among them are, the material used here is an it's a
stainless steel of road type and the 3 number of pins are used to make a
transmission possible from the study they found out that deficit deficiency of 92%
is obtained.”

2.4 ANALYSIS AND SIMULATION OF GEARLESS TRANSMISSION

MECHANISM
Authored by Naveet Bardiya, Karthik and Bhaskara Rao March 2018

“From this paper the real time study of mechanism is analysed using a solid
works package software. From the analysis the response of the elbow rods
coupled with the shaft is evaluated using an analysing technique. Analysis were
carried out by running a mechanism with the motor with 15 revolutions per
minute, the reaction forces and the reaction moments where plated against time
interval of 5 seconds. The same process was done at higher speeds with the
regular intervals. The time forces were plotted and compared with allowable
stresses. Theoretical calculations were made to get all over stress with the help of
40
data values from the design data book. Overall outcome we can found that
response of elbow and shaft where investigate to find the permissible speed of
mechanism. After analysing the working system using the solid work software
the post processes were done by applying motor torque at variable speeds. With
the time in travel of 5 seconds the von Moises stress distributions were obtained
from this graph we can conclude that elbow rods reaches it’s All Over stress value
at 140 RPM while the hub reminds say at all speed. So we can conclude that a
very smooth and safe mechanism can be obtained by running the machine below
140 RPM. With considering safety norms the gearless transmission mechanism
is capable of working under 120 RPM in normal condition.”

41
 CHAPTER 3

EXPERIMENTAL PLAN
3.1 METHODOLOGY:
o Study of Research Papers
o Design of shaft, rod and bend links
o Fabrication of shaft, rod and elbow
o Mounting of shaft on Iron board
o Assemble of all parts
o Evaluating design moments
o Finally using in application

Fig 17: Concept Drawing of Gearless Power Transmission

42
3.2 COMPONENTS:

3.2.1 BEARING:
“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. Many bearings also
facilitate the desired motion as much as possible, such as 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.”

Fig 18: Bearing

3.2.2 SHAFT:
“A shaft is a rotating machine element, usually circular in cross section,
which is used to transmit power from one part to another, or from a machine
which produces power to a machine which absorbs power. The various members
such as pulleys and gears are mounted on it.”

43
 Fig 19: Shaft

3.2.3 FRAME:
“We are design the frame to light weight material on the frame mounted the pedal
and gear mechanism. The material use like aluminium-stainless steel.”

Fig 20: Frame

3.2.4 MECHANICAL LINKAGE:

“A mechanical linkage is an assembly of bodies connected to manage
forces and movement. The movement of a body, or link, is studied using
geometry so the link is considered to be rigid. The connections between links are
modelled as providing ideal movement, pure rotation or sliding for example, and
are called joints. A linkage modelled as a network of rigid links and ideal joints
is called a kinematic chain.”

44
 Fig 21: Mechanical Linkage

3.2.5 ELECTRIC MOTOR:

“An electric motor is an electrical machine that converts electrical energy
into mechanical energy. The reverse of this would be the conversion of
mechanical energy into electrical energy and is done by an electric generator. In
normal motoring mode, most electric motors operate through the interaction
between an electric motor's magnetic field and winding currents to generate force
within the motor. In certain applications, such as in the transportation industry
with traction motors, electric motors can operate in both motoring and generating
or braking modes to also produce electrical energy from mechanical energy.
Found in applications as diverse as industrial fans, blowers and pumps, machine
tools, household appliances, power tools.”

45
 Fig 22: Electric Motor

3.2.6 CYLINDER:
“A cylinder is one of the most basic curved geometric shapes, with the
surface formed by the points at a fixed distance from a given line segment, known
as the axis of the cylinder. The shape can be thought of as a circular prism. Both
the surface and the solid shape created inside can be called a cylinder. The surface
area and the volume of a cylinder have been known since ancient times. In
differential geometry, a cylinder is defined more broadly as any ruled surface
which is spanned by a one-parameter family of parallel lines. A cylinder whose
cross section is an ellipse, parabola, or hyperbola is called an elliptic cylinder,
parabolic cylinder, or hyperbolic cylinder respectively.”

Fig 23: Cylinder

46
3.2.7 PULLEY:
“A pulley is a wheel on an axle or shaft that is designed to support
movement and change of direction of a taut cable or belt along its circumference.
Pulleys are used in a variety of ways to lift loads, apply forces, and to transmit
power. In nautical contexts, the assembly of wheel, axle, and supporting shell is
referred to as a "block." A pulley may also be called a sheave or drum and may
have a groove or grooves between two flanges around its circumference. The
drive element of a pulley system can be a rope, cable, belt, or chain that runs over
the pulley inside the groove or grooves.”

Fig 24: Pulley

47
3.3 SCHEMATIC EXPERIMANTAL SETUP:

Fig 24: Experimental Setup

3.4 WORKING PRINCIPLE:

“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. 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 brackets wooden table.
Power is supplied by an electric motor. The working of the mechanism is
understood by the diagram. An unused form of transmission of power on shaft
located at an angle. Motion is transmitted from driving to the driven shaft through

48
the rods which are bent to conform to the angles between the shafts. These rods
are located at the holes equally spaced around a circle and they are free to slide
in & out as the shaft revolves. This type of drive is especially suitable where quite
operation at high speed is essential but only recommended for high duty. The
operation of this transmission will be apparent by the action of one rod during a
revolution. If we assume that driving shaft “A” is revolving as indicated by arrow
the driven shaft B will rotate counter clockwise. As shaft a turns through half
revolution C shown in the inner and most effective driving position slides out of
both shafts A & B. The first half revolution and rod “C” then will be at the top
then during the remaining half this rod “C” slide in wards until it again reaches
to inner most position shown in Fig. in the meanwhile 4 Mechanical projects:
Learnmech.com the other rods have of course passed through the same cycle of
movements all rods are successively sliding inwards and outwards. Although this
transmission is an old one many mechanics are sceptical about its operation,
however it is not only practicable but has proved satisfactory for various
applications when the drive is for shafts which are permanently located at given
angle. Although this illustration shows a right angle transmission this drive can
be applied also to shafts located at intermediate angle between 0* and 90*.In
making this transmission, it is essential to have the holes for a given rod located
accurately in the same holes must be equally spaced in radial and circumferential
directions, each rod should be bent to at angle at which the shaft are to be located.
If the holes drilled in the ends of the shafts have “blind” or closed ends, there
ought to be a small vent at the bottom of each rod hole for the escape of air
compressed by the pumping action of the rods. These holes are useful for oiling
to avoid blind holes shafts may have enlarged port or shoulder. This transmission
may be provided centrally and in line with the axis of each shaft and provided
with a circular groove at each rod or a cross-pin to permit rotation of the shaft
about the rod simply active as a retaining device for shipping and handling
purposed.”
49
3.5 SELECTION OF MATERIALS:
“The proper selection of material for the different part of a machine is the
main objective in the fabrication of machine. For a design engineer it is must that
he be familiar with the effect, which the manufacturing process and heat treatment
have on the properties of materials.”

“The Choice of material for engineering purposes depends upon the following
factors:

 Availability of the materials

 Suitability of materials for the working condition in service
 The cost of materials
 Physical and chemical properties of material
 Mechanical properties of material

The mechanical properties of the metals are those, which are associated
with the ability of the material to resist mechanical forces and load. We shall now
discuss these properties as follows:”

“Strength: It is the ability of a material to resist the externally applied forces

Stress: Without breaking or yielding. The internal resistance offered by apart to

an externally applied force is called stress.

Stiffness: It is the ability of material to resist deformation under stresses. The

modules of elasticity of the measure of stiffness.

Elasticity: It is the property of a material to regain its original shape after

deformation when the external forces are removed. This property is desirable for
material used in tools and machines. It may be noted that steel is more elastic than
rubber.”

50
“Plasticity: It is the property of a material, which retain the deformation
produced under load permanently. This property of material is necessary for
forging, in stamping images on coins and in ornamental work.

Ductility: It is the property of a material enabling it to be drawn into wire with

the application of a tensile force. A ductile material must be both strong and
plastic. The ductility is usually measured by the terms, percentage elongation and
percent reduction in area. The ductile materials commonly used in engineering
practice are mild steel, copper, aluminium, nickel, zinc, tin and lead.

Brittleness: It is the property of material opposite to ductile. It is the property of

breaking of a material with little permanent distortion. Brittle materials when
subjected to tensile loads snap off without giving any sensible elongation. Cast
iron is a brittle material.

Malleability: It is a special case of ductility, which permits material to be rolled

or hammered into thin sheets, a malleable material should be plastic but it is not
essential to be so strong. The malleable materials commonly used in engineering
practice are lead, soft steel, wrought iron, copper and aluminium.

Toughness: It is the property of a material to resist the fracture due to high impact
loads like hammer blows. The toughness of the material decreases when it is
heated. It is measured by the amount of absorbed after being stressed up to the
point of fracture. This property is desirable in parts subjected to shock an impact
loads.

Resilience: It is the property of a material to absorb energy and to resist rock and
impact loads. It is measured by amount of energy absorbed per unit volume with
in elastic limit. This property is essential for spring material.

Creep: When a part is subjected to a constant stress at high temperature for long
period of time, it will undergo a slow and permanent deformation called creep.

51
This property is considered in designing internal combustion engines, boilers and
turbines. ”

“Hardness: It is a very important property of the metals and has a wide verity of
meanings. It embraces many different properties such as resistance to wear
scratching, deformation and machinability etc. It also means the ability of the
metal to cut another metal. The hardness is usually expressed in numbers, which
are dependent on the method of making the test. The hardness of a metal may be
determined by the following test”

a) Brinell hardness test

b) Rockwell hardness test

c) Vickers hardness (also called diamond pyramid) test and

d) Shear scaleroscope.

The science of the metal is specialized and although it overflows into a real
mess of knowledge it tends to shut away from the general reader. The knowledge
of materials and their properties is of great significance for a design engineer. The
machine elements should be made of such a material that has properties suitable
for the conditions of operations. In addition to this, a design engineer must be
familiar with the manufacturing processes and the heat treatment shave on the
properties of the materials. In designing the various part of the machine it is
necessary to know how the material will function in service. For this certain
characteristics or mechanical properties mostly used in mechanical engineering,
practice are commonly determined from standard tensile tests.

In engineering practice, the machine parts are subjected to various forces,

which may be due to either one or more of the following.”

52
  Energy transmitted
 Weight of machine
 Frictional resistance
 Inertia of reciprocating parts
 Change of temperature
 Lack of balance of moving parts

“The selection of the materials depends upon the various types of stresses
that are set up during operation. The material selected should with stand it.
Another criteria for selection of metal depend upon the type of load because a
machine part resist load more easily than a live load and live load more easily
than a shock load. Selection of the material depends upon factor of safety, which
in turn depends upon the following factors.

1. Reliabilities of properties

2. Reliability of applied load

3. The certainty as to exact mode of failure

4. The extent of simplifying assumptions

5. The extent of localized

6. The extent of initial stresses set up during manufacturing

7. The extent loss of life if failure occurs

8. The extent of loss of property if failure occurs

Materials selected in m/c: - Base plate, motor support, sleeve and shaft
Material used: - Mild steel”

53
REASONS:

 Mild steel is readily available in market

 It is economical to use
 It is available in standard sizes
 It has good mechanical properties i.e. it is easily machinable.
 It has moderate factor of safety, because factor of safety results in
unnecessary wastage of material and heavy selection. Low factor of safety
results in unnecessary risk of failure
 It has high tensile strength
 Low co-efficient of thermal expansion

3.6 LUBRICATION AND COOLING:-

A few open gears drives are lubricated by grease but gear units are usually
totally enclosed and oil lubricated. The arrangement for lubrication is simple and
easy, since it requires only a leak proof housing in which the gears are placed and
oil is filled. This lubricating also acts as cooling medium. The heat generated and
it then spreads to other areas. In the gearless drive lubrication and cooling plays
a very major role. The efficiency of the mechanism is affected by lubrication.
Although the system of lubrication and cooling is complex and discussed in the
next chapter but gives good result due to sliding contact between pins and
cylinders, heat generated is more and thus effective cooling is a must.

54
 CHAPTER 4
RESULTS AND DISCUSSIONS

4.1 COMPARISON OF GEARED DRIVE WITH GEARLESS DRIVE

“The gearless drive is capable of transmitting motion at any fixed angle
between 0* to 90*. This desired effect is also possible with help of bevel gear.
Gearless differ to a great extent not only in their manufacturing method or
working principle but also in other aspects etc. the aspects have been discussed
below:

4.2 MANUFACTURING METHODS:-

Bevel gears, which are straight teeth or spiral teeth are manufactured on
special purposes machines. These require large amount of calculation and every
pair or set of gear are made together and there is no interchangeability. The
gearless drive has this advantage that it can be machined and manufactured on
conventional machines and it provide complete freedom of interchangeability. II)
4.3 WORKING PRINCIPLE:-

A gear comprises of a frustum of a cone with teeth out on its periphery .The
driving gear mounted on the input shaft meshes with the driven gear and thus
provides motion at right angle to the input shaft. The working of the gearless drive
has been explained in the earlier chapter and it obviously very different from the
above.

4.4 CAUSE OF FAILURE:-

Starting with the principle that failure id the result of the stress i.e.
condition more severe than the material can with stand. The various type of
failures such as pitting, corrosion, erosion, fatigue etc. Cause the wearing of the
gear tooth resulting in the tooth leads to the replacement of the entire gear set,
which is very expensive. The effect of pitting, erosion, corrosion etc. will be
present in the gearless drive also but the effect of these will be not be as severe
as in the case of geared drive, failure will take place in the piston e.g...Either

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bending or crack of the pins, but the main advantage is that only particular pin
will have to be replaced instead of case of failure

4.5 MATERIAL:-
The material chosen for any component must

1. be easily available

2. be capable of being processed in the desired emanations and

3. Have the necessary physical properties.

The gears generally fail due to bending, fatigue and impact and the gears
are also responsible for the failure of the components in the gears have to very
carefully determined since it may lead to pitting.

4.6 LIFE AND EFFICIENCY:-

“Designed life represents the total period of operation, regardless of any
variations of torque or speed, which may occur during that the time. The geared
drive is capable of giving an efficiency of about 40% and certain errors like
backlash, hunting etc... cannot be eliminated. In the gearless drive, although the
life has not been calculated but it is assumed that its life will be in comparison to
that of geared drive but its efficiency could be as high as 85% to 92% with proper
lubrication and cooling.”””

4.7 CALCULATIONS:
Let us consider the weight of the whole system (along with solo rider) = 140 kg

Weight of the model = 140 * g = 1400 N

Weight on each tyre = 1400/4 = 350 N

Considering co -efficient of friction between road and tyre = 0.7

Frictional force on each wheel = 350*0.7 = 245 N

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Thus, the minimum force required to move the tyre = 245 N

Taking 16 inch tyre with radius of tyre, r = 0.2032 m

Torque required to move on tyre = 245*0.2032 = 49.784 N-m

Torque on each link = 49.784 / 3 = 16.594 N-m

Radius = 0.05 m

Tangential force = 16.594 / 0.05 = 331.88 N

Diameter of each link = 10 mm = 0.01 m

Shear force = force / cross sectional area

Shear force = 331.88 / 3.14*0.25*0.01*0.01

Shear force = 4.227 * 10^6 N/mm^2

Taking link material C-45 from PSG data book

Torque = 45 N/mm^2

The maximum stress included is with in permissible limit

For maximum stress Torque = 45*10^6 N/m^2

Maximum torque = 8.835 N-m

Power of motor = ¼ H.P = 746 x .25 = 186.5 N- m /s

Rpm of motor = 1440 rpm

Power of motor = P = 186.5 watt.

P = 2 πN TP /60

Where, N = Rpm of motor = 1440

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T = Torque transmitted

186.5 = 2π×140×T/60

T = 1.23 N-m

T = 1238 N-mm

POWER (H.P) TORQUE (N-m) Max Speed (RPM)

1 8.835 806.72
2 8.835 1613.44

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4.8 FABRICATION OF DESIGNED PROTOTYPE:

59
60
 CHAPTER 5
CONCLUSION
The gearless power transmission system was mainly made in order to
reduce the usage of gears which are complex in design and to reduce the wear
conditions that occur in gear over a period of time which would require high cost
of manufacturing for the replacement of the gear. This mechanism is simple, cost
effective, and efficient compared to gears.

The gearless power transmission is one of the budding ideas of the

technology. It has a high scope in future to replace the cumbersome usage of gears
which will be replaced simple, elegant usage of the shafts that will change the
overall cost management of the industries using gear technology presently to gain
more profits.

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 REFERENCES
[1] Khurmi R S (2014), a textbook of machine design, Eurasia publishing house
(P) ltd., New-Delhi, ISBN No. 9788121925372

[2] Design of Machine Elements by V B Bhandari, Tata McGraw Hill

Publications

[3] Amit Kumar, Mukesh Kumar, "Gearless Power Transmission for Skew Shafts
(A SRRS Mechanism)", International Journal of Advanced Science and
Technology, Vol.79, pp. 61-72, 2015.

[4] Atish Lahu Patil, Vinay Prabhakar Jadhav, Sagar Padmakar Patil, Roshan
Suresh Shelar, "Gearless Mechanism in Right Angle”, International Journal on
Recent Trends and Innovation in Computing and Communication, Vol.4, Issue 4,
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[5] Navneet Bardiya, Karthik.T, L Bhaskara Rao, "Analysis and Simulation of

Gearless Transmission Mechanism”, International Journal of Core Engineering
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[6] Jagushte G, S Kudalkar Hrishikesh, Patil Vikas, Varak Vishal, "Design,

Analysis and Fabrication of Gearless Transmission by Elbow Mechanism”,
International Journal for Scientific Research & Development, Vol.4, Issue 2, pp.
688-689, 2016.

[7] Gearless Transmission Through Elbow Mechanism

[8] Gearless Power Transmission for Skew Shaft (A SRRS Mechanism)
[9] A Review Paper on Design and Analysis of Gearless Transmission
Mechanism Using Elbow Mechanism

[10] Analysis and Simulation of Gearless Transmission Mechanism

62
[11] Ashish Kumar, Puneet Pawar, Sagar Rana, Shishir Bist, "Multi-Angular
Gearless Drive”, International Journal of Scientific & Engineering Research,
Vol.6, Issue 7, pp. 974-977, 2015. [6]. Kalaikathir Achchagam, "Design Data
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[12] NPTEL – Mechanical – Mechatronics and Manufacturing Automation,

Module 5, pp. 21-24

[13] Somraj, R. and Sailesh, B., 2017. Design and fabrication of gearless power
transmission for skew shafts. International Research Journal of Engineering and
Technology (IRJET), 4(04).

[14] Rana, M.J. and Rahman, A.M.M., Development and Performance Test of
Gearless Power Transmission System.

[15] Htway, Z., Khine, M.M., Lin, N. and Myint, K.M., Stress Analysis and
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(Myitkyina) 1st University Research Journal of Science, Engineering and
Engineering Education,(URJSEE) Volume 01, November, 2019, pp.110-113.

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