Elbow Mechanism PDF

A PROJECT REPORT ON
“POWER TRANSMISSION WITHOUT GEAR”

INDEX OF CHAPTERS
Sr.No. Chapter Name Pg.No.
1. Introduction 6
1.1. Function of transmission.
1.2. Types of transmission.
1.3. Need for project.
1.4. Solution.
2. Construction & Working. 11
2.1. Construction.
2.2. Working.
2.3. Advantages & Disadvantages.
2.4. Simple gear train.
3. Design 17
3.1. System Design.
3.2. Mechanical Design.
3.3. Input Data.
3.4. Design of Propeller Shaft.
3.5. Design of Gears.
3.6. Design of Input Shaft.
3.7. Design of Output Shaft.
3.8. Design of Bearing Bush.

3.9. Design of Bent Pins.
4. Process Sheet 33
4.1. Process Sheet For Pulley.
4.2. Process Sheet For L-H Output Shaft.
4.3. Process Sheet For R-H Output Shaft.
4.4. Process Sheet For R-H Input Shaft.
4.5. Process Sheet For L-H Input Shaft.
4.6. Process Sheet For L-H_BRG_HSG.
4.7. Process Sheet For R-H_BRG_HSG.
4.8. Process Sheet For Central_BRG_HSG.
4.9. Process Sheet For Cover Ring.
5. Test & Trial on ELBOW MECHANISM. 46
6. Operation Table. 48
6.1. Sample Calculation.
7. Result Table. 52
8. Cost Analysis. 54
9. Conclusion & Future Scope 58
10. Bibliography 60
--------DEFINATION OF PROJECT--------
P- Planning before carrying out the work
R- row material required for the work
O- Organization of the work
J- joint effort put in to the work
E- estimation of material required in the work
C- Costing of the work
T- techniques used in performing
Project Abstract / Summary : ABSTRACT

This project “EL-BOW TRANSMISSION” being compact and portable equipm
skilful and is having practice in transmitting power at right angle without an
manufactured. The El-bow Mechanism transmits the input power towards th
such a way that the angular forces produced in the slacks are transmitted w
rods which takes up the input power and the right angle drive is transferred
output slack and rod assembly. Hence very little friction plays while the pow
transmitted.
Hunting and back lash errors are absent. Therefore, it is appreciated
that efficiency as high as 90-92% are possible in gear less transmission me
Why did you choose to work on this
wonderful mechanism that carries force through a 90ºbent rod. Transmittin

motion around an axis usually involves gears, which can quickly become co
inflexible and clumsy-looking, often ugly. So, instead of using gears, this tec
elegantly converts rotational motion using a set of cylindrical bars, bent to 9
simple and smooth process that translates strong rotational force even in re
spaces.A gearless transmission is provided for transmitting rotational veloc
input connected to three bent links. Both the input shaft and the housing ha
axes. The rotational axis of the input shaft is disposed at an angle of 90 de
respect to the rotational axis of the housing. As a result, rotation of the inpu
in a processional motion of the axis of the bent link.
The rotary and reciprocating motion of bent link transmit rotation of prime
mover to 90 degree without any gear system to an output shaft.
CHAPTER NO.1
INTRODUCTION
PROJECT TITLE : ELBOW MECHANISM
INTRODUCTION
The word ‘TRANSMISSION’ on which the project is based upon means the w
mechanism that transmits the power from the engine crankshaft to the rear
However the ‘transmission’ is also being used very commonly in the literatu
mechanism, which provides us with suitable variation of the engine torque
wheels, whenever required. This may be a
gearbox (also called manual transmission) or an automatic transmission.
FUNCTIONS OF TRANSMISSION
The main functions that are performed by the transmission are:
1)The torque or the tractive effort produced by the engine varies with speed
narrow limits. But the practical consideration for the running of automobile
conditions demands a large variation of torque available at the wheels. The
of the transmission is to provide means to vary the leverage or the torque ra
the engine and the road wheels as required.
2)The transmission also provides a neutral position so that the engine and
wheels are disconnected even with the clutch in the engaged position.
3)A mean to back the car by reversing the direction of rotation of the drive i
also provided by the transmission.
TYPES OF TRANSMISSION
The transmissions may be classified into the manual and the automatic typ
manual transmissions are conventionally called gearboxes. Their mechanic
direct drive is about 98%, whereas in reduction gears, it is slightly greater th
most of the time the driving is done in direct drive, friction losses in manual
are very small. That coupled with simplicity and lower initial cost, is the reas
still popular particularly in fuel-efficient automobiles. On the other hand the
engaging and disengaging the clutch along with changing gears while drivin
crowded highway means a lot of fatigue to the driver. Therefore, in luxury v
automatic transmissions are employed which simplify the driving operation
considerably.
NEED FOR PROJECT:
The conventional transmission system used in auto rickshaw is as shown in
The transmission train comprises of the engine as the power plant , and the
box and differential arrangement as the traction device. The power is availa
differential end as two outputs , which is supplied to the wheels individually
double hooke’s joint as the engine is at a higher level as compared to the w
The double hooke’s joint has certain disadvantages that, it does not transmi
angular velocity, so also the efficiency of transmission is low(65%).More ov
efficiency further drops with the increase in angular velocity ie speed outpu
engine. The drive is subjected to inherent vibrations and considerable axial
forces are encountered during power transmission.
Actually the situation is simple that the power from the differential has to b
at right angles to the wheels, and even if the wheels move
over a bump on the road this right angle is not disturbed.
Universal System Used in 3-Wheeler
SOLUTION
ELBOW MECHANISM (ORBITAL TRANSMISSION SYSTEM.)
The orbital transmission system is an adaptation of the original mechanism
mechanism developed by LEO -NARDO-DA- VINCI. This Elbow mechanism
transmitting heavy torque at high speeds between two shafts at right angle
mechanism comprises of two shafts drilled with three holes each on the sa
diameter on each shaft and a set of three bent pins that are made of steel a
exactly 900.
This mechanism is capable of transmitting high speeds (12000 rpm).
The drive is compact and can be made into hermetically sealed units filled
oil in order to increase the life of the drive. This drive has an efficiency as h
In the project we are getting the two inputs to the transmission system from
through simple gear train . gears used over here are of same diameter and
number of teeth on its periphery. One variable speed motor drives the main
through belt and pully. Pully is fitted rigidly on it. The single shaft can be dri
manually as well as using motor drive.
This transmission system is extremely compact and will improve the efficie
transmission of the vehicle and thereby the mileage of the
vehicle.
Chapter No.:- 2
CONSTRUCTION AND
WORKING
CONSTRUCTION
1. ELECTRIC MOTOR:-
Electric motor of following specifications is used Single phase Ac Mo
230 volt,0.5 AMP.
50 Hz
Power = 100 watt Speed = 0 to 6000 rpm
TEFC CONSTRUCTION
COMMUTATOR MOTOR
2. PULLEY:-
pulley is v-belt pulley of 40 degree groove angle and 6mm ‘A’ se
reduction pulley gives an speed reduction ratio of 4.68
.This reduction pulley is mounted at the bearing end of the propeller
shaft.
3. LH&RH INPUT SHAFT:-

Input shaft is an steel construction where in main shaft is an h
(EN 24) Input shaft supports the reduction pulley at lower end an
places at the upper end .The horizontal plates are drilled with three ho
pitch, these holes receive
the bent pins.
4. BENT PINS:-
Pins are made form high carbon steel; in three sets of 90 ,120,140 d
respectively pins are bent to the desired angle in a special fixtur
bend is not sharp but slightly filleted to avoid stress concentration.
ELBOW MECHANISM
5. CENTRAL BEARING HOUSING:-
The central bearing housing houses two ball bearings 6201 zz in whic
shafts are mounted .The central bearing housing is welded to the base fam
5. LH BEARING HOUSING:-
The LH bearing housing houses ball bearing 6201 zz in which the
LH_ output shafts are mounted .The LH bearing housing is welded to the b
6. RH BEARING HOUSING:-
The RH bearing housing houses ball bearing 6201 zz in which the RH
shafts are mounted .The LH bearing housing is welded to the base fa
7. PROPELLER SHAFT
Pulley is mounted on propeller shaft. Pulley is driven by motor shaft a
drives propeller shaft. Propeller shaft is also manually driven by h
which is located at other end of shaft, which is
fixed.
8. GEARS
4 Gears are used for power transmission from propeller shaft to
wheels through Input and output shaft mechanism.
9. WHEELS
The wheels are of nylon that are fitted at the output shaft ends
ELBOW MECHANISM
WORKING:
Electric motors supply power to the Propeller shafts of the orbital transmiss
means of belt and pulley arrangement. Then, drive is given to the two input
simple gear train mechanism. Gear used over here are spur type and of sam
Therefore, there will be no variation in speed of two wheels. The input sha
move the pins about the central axis, this motion causes the pins to slide to
the output shaft holes which in turn results into rotary motion of the output
Thus the rotary input from the motors is transferred to the output wheel
shafts that cause the wheels to rotate.
ADVATAGES OF ELBOW MECHANISM

1. Better transmission efficiency (90%) as compared to conventional
e’s joint ( 60 to 65 %)
2. Better efficiency of system results in better fuel economy.
3. Radial speed of input and output shaft is same , hence no phase s
4. No vibrations in drive.
5. Efficiency remains almost constant even with increase in transmis
6. Compact as compared to double hooke’s joint.
7. Lower manufacturing cost.
8. Lower maintenance required.
DISADVANTAGES :
1. Slightly high cost of manufacture.
2. Special machines like jig boring is required for manufacture
3. Conventional Transmission system needs to be modified to
the above system/.
Simple Gear Train-

In simple gear train, each shaft carries one wheel only and there no relative
between the axis of the shafts.
Gear used over here are of same diameter and having same number of tee
driving and two gears are driven type. One idler gear is used in intermediate
and driven shaft.
Let,
N1 and T1 is speed and no. of teeth of Driving gear which is fixed on propel
rotated.
N2,T2 and N3 T3 are speed and no. of teeth of driven gear 1 and driven gea

And let say, N4 and T4 is the speed and No. of teeth of Idler gear which is in
between driving shaft and driven gear 1.
Since the driving wheel drives driven gear 2,
N3 x T3 = N1 x T1 ......(1)
As well as driving gear drives Idler gear,
N4 x T4 = N1 x T1 ........(2)
Since Idler gear drives Driven gear 1,
N2 x T2 = N4 x T4 ........(3)
Gear used are of same diameter and same no. of teeth so there is no speed
take place.
NO OF TEETH OF ALL GEARS = T1 = T1 = T3 = T4 ................. (4)
From Equation 1,2,3,4,
N1 = N2 = N3 = N4........................( hence proved)
So we can say that same power is given to driven shafts without any
reduction.
If the input and output gears are exactly the same size, they will turn at the
In many simple gear trains there are several gears between the input gear a
gear.
These middle gears are called idler gears. Idler gears do not affect the spe
of the output gear.
Chapter No.:-3
Design
DESIGN
Design consists of application of scientific principles , technical inf
imagination for development of new or improvised machine or mechanism
specific function with maximum economy and
efficiency.
Hence an careful design approach has to be adopted. The total desig
work, has been split up into two parts;
 SYSTEM DESIGN
 MECHANICAL DESIGN
ELBOW MECHANISM
SYSTEM DESIGN
System design mainly concerns with various physical constrains, deciding b
principle, space requirements, arrangements of various
components etc.
Following parameters are looked upon in system design.

a) Selection of system based on physical constraints. The mech
has direct norms with the system design hence system is d
that distinctions and dimensions thus obtained in mechanical d
well fitted in to it.
b) Arrangement of various components made simple to utilize
possible space.
c) Ease of maintenance and servicing achieved by means of sim
that enables quick decision assembly of components.
d) Scope of future improvement.
ELBOW MECHANISM
MECHANICAL DESIGN
In mechanical design the components are listed down and stored on the ba
procurement in two categories,
 Design parts
 Parts to be purchased.
For designed parts detailed design is done and dimensions there
compared to next dimensions which are already available in market. T
the assembly as well as the post production and maintenance work. Th
tolerances on work are specified .The process charts are prepared and pass
manufacturing stage.
The parts to be purchased directly are selected from various catalogues an
so as to have case of procurement .
In mechanical design at the first stage selection of appropriate material for
designed for specific application is done.
This selection is based on standard catalogues or data books; eg:- (PSG DE
BOOKS )
(SKF BEARING CATALOGUE ) etc.
APPROACH TO MECHANICAL DESIGN OF ‘PLANETARY SPEED REDU

In design the parts of ‘planetary speed reducer’ we shall adopt the fol
approach ;
a) Selection of appropriate material .
b) Assuming an appropriate dimension as per system design.
c) Design check for failure of component under any possible system of for
ELBOW MECHANISM
INPUT DATA
1) MOTOR DETAILS:
SINGLE PHASE AC MOTOR 230 VOLT, 50Hz , 0.5 Amp POWER = 100 WATT SPEE
rpm
TEFC CONSTRUCTION MOTOR.
2) DIAMETER OF PLATES =45mm
3) PCD OF HOLES ON DISC = 32mm
4) THICKNESS OF PLATES =8mm
5) DIAMETER OF PINS (3No’s)=4mm
6) DIAMETER OF INPUT SHAFT=10mm
7) DIAMETER OF OUTPUT SHAFT=10mm
8) DIAMETER OF DRIVER PULLEY = 16mm
9) DIAMETER OF DRIVEN PULLEY = 75mm 10)SPEED REDUCTION RATIO = 75/
11)SPEED OF MECHANISM (MAX)=1200rpm
(MIN)=0 rpm 12)MAX OUTPUT TORQUE AT 850 rpm = 0.08 kg.m
13) DIAMETER OF PROPELLER SHAFT =
14) NO. OF GEARS = 4
15) PCD OF ALL GEARS = 26mm
ELBOW MECHANISM
DESIGN OF INPUT SHAFT:-
Torque calculation:-
Max Input Power = 100 watt at 6000 rpm. At motor shaft

9
60
I/P 2 ∏ N T 2 x ∏ x 6000 x T
po 60 = 60
we
 T= = 0.1592 N-m
Assuming 100 % efficiency of transmission between motor shaft & Mechanism I/P
shaft .
 = 2 ∏ NT mech i/p
2 ∏ N T motor
O/p 60
60
 T mech i/p = 4.688 x 0.1592
= 0.7463 N-m
Assuming 100% overload;

 factor of safety = 2
 Tdesign = 2 Tmech i/p
 Tdesign =2x0.7463
=1.4926 N.m
 Tdesign = 1.4926 x 103 N.m
MATERIAL SELECTION
Designation Ultimate Tensile strength Yield strength
N/mm2 N/mm2
EN 24 800 600
ELBOW MECHANISM
ASME CODE OR DESIGN OF PROPELLER SHAFT:-
Since the shaft is subjected to variable load at different speed condition sit is necessary
allowance for harmful effects of load fluctuation
Propeller shaft is supported between two bearings and pulley is rigidly mounted on it an
pulley is neglected and cyclic fluctuations occurs while rotating.
According to ASME code permissible value of shear stress may be calculated for variou
fs max = 0.18 fult
=0.18 x 800
= 144 N/mm2
or
fs max = 0.3 x 600
= 180 N/ mm2
Considering minimum of the above values.

 fs max = 144 N/mm2
This is allowable valves of shear stress induced in input shaft of or safe operation . Sha
hole for rivet which reduces its strength ;
 Reducing above value by 25%
 fs max = 0.75 x 144

= 100 N/mm2 Diameter of input shaft =6mm
Check for torsional failure of shaft:-
T=  /16 fs act 3
d
ELBOW MECHANISM
 fs ac t = 16 x T
d 3
16 x 1.4926 x 103
=  x 10 3
fs act = 35.19 N/mm2

 As fs act < fs all
 Shaft is safe under torsional load.
ELBOW MECHANISM
Spur Gear Design :-
1. Outside Diameter = 22mm
2. No. Of Teeth = 19
3. Root Diameter = 18mm
4. Addendum = A = 1mm
5. Dedendum = D = 1mm
6. Pressure Angle = ϕ = 20 degree ( Standard )
7. Base Circle Diameter = 18mm
8. Pitch Circle Diameter = 20mm
9. Circular Pitch = πM = 4mm
10. Module = 1.05mm
11. Circular Tooth Thickness = πM = 2mm
2
12. Whole Depth Of Teeth = 2mm
ELBOW MECHANISM
DESIGN OF INPUT SHAFT:-
Power and Torque is transmitted to both input shaft through simple gear train mechan
to twisting moment only.
According to ASME code permissible value of shear stress may be calculated for variou
fs max = 0.18 fult
=0.18 x 800
= 144 N/mm2
or
fs max = 0.3 x 600
= 180 N/ mm2
Considering minimum of the above values.
 fs max = 144 N/mm2
This is allowable valves of shear stress induced in input shaft of or safe operation . Sha
hole for rivet which reduces its strength ;
 Reducing above value by 25%
 fs max = 0.75 x 144

= 100 N/mm2 Diameter of input shaft =6mm
Check for torsional failure of shaft:-
T=  /16 fs act 3
d
ELBOW MECHANISM
 fs ac t = 16 x T
d 3
16 x 1.4926 x 103
=  x 10 3
fs act = 35.19 N/mm2

 As fs act < fs all
 Shaft is safe under torsional load.
ELBOW MECHANISM
Design of out put shaft:-
Material selection
N/mm2 N/mm2
EN24 800 600

Design check for Torsional Failure
T=/16 fs act d3
Diameter of output shaft = 6mm fs act = 16 x T

 x 63
fs act = 35.19 N.mmd3
 shaft is safe under torsional load.
ELBOW MECHANISM
Design check for bending failure of o/p shaft:-
O/p shaft supports the weight of the bent pins ,discs etc and is held at one end in bush
weigh approx. 0.75 kg
Assuming factor of safety = 2 Bending Load =2 x 0.75
=1.5kg
=15N
fb act = M
Z
f 32 M
b ∏ d3
a
c
t
fb act = 9.86 N/mm2
As fb act < fb all
 shaft is safe in bending .
ELBOW MECHANISM
Design of Bearing bush
Material selection
N/mm2 N/mm2
C30/EN8K 620 400

Bearing pressure pb = load
Project area (Pb) = W
lxd
Where ;
pb = Average bearing pressure N/mm2 P= Radial load on journal (N)
l = Length of journal in contact(mm) d= Diameter of journal (mm)
Here ; d= 10mm
l = 22 mm & Average bearing pressure for steel combination 12.6 N/mm2 Pb act = 12.6
Radial load
Torque = w x r
 W = 1.4926 x 10 3 =497.53 N
PB = 497.53/22 x 10 =2.26
 As Pb act < Pb all
Bearing brush is safe.

Design of Bent Pins:-
Bent pins are torque transmitting elements similar to bolts in ease of flange coupling . M
Tensile strength N/ Yield strength N/

mm2 mm2
Designation
EN9 520 350

a) Design check for shear failure of Pins.
d= diameter of pins = 4 n = no . of pins =3
T= ∏ x d 2 x fs xnx d 4 2
b P
1.49 ∏ x (4)2 x fsb act x 3 x 36 4 2

26 x
10 3
 fsb act = 2.199 N/mm2 As ; fsb act < fsb all
Pins are safe in shear (Torsional)
b) Design check for crushing failure:-
T = n x d x t f x f c b act x dp 2
1.4926 x 103 = 3 x 4 x 7 x f cb act x 36
2
 fcb act = 0.98716 N/mm2 As fcb act < fcb all
Chapter No: 4
Process Sheet
ELBOW MECHANISM
PART NO : OTS - 03
PART NAME : PULLEY MATERIAL SPECIFICATION : EN 9
RAW MATERIAL SIZE: 80X 30 QUANTITY :- 01 NO’S.
Sr. No Description of Jigs & Tools Time in

Operation Fixture
M/c Tools Cutting Tools Measuring Setting Time
Instrument
1.Clamp stock 3 Jaw chuck Lathe - - 20
2.Facing one sides --”-- --”-- Facing tool Vernier -
3.Turning diameter 75 --“-- --“-- Turning tool --“-- 5

through 23.5 mm length
4.Turning  30 --“-- --“-- --“-- --“-- -

through 14.5 mm length
5.Turning groove  --“-- --“-- Grooving tool --“-- 5

50 mm ;3mm deep
6.Chamfer 6 x 45 degree on --”-- --”-- Crank facing tool --”-- 10

face
7.Roughing V groove --”-- --”-- Parting tool --”-- 10
8.Finish V groove --“-- --“-- V- tool Angle protractor 15
9.Centre drill --“-- --“-- Centre drill --“-- 5
Drilling  14.5 hole through --“--

10. --“-- Twist drill  --“-- 5
40 mm 6mm
Reaming  15 hole through --“--

11. --“-- Reaming  6 --“-- 5
40 mm
Parting off to 24mm

12. --“-- --“-- Parting tool --“-- 5
Length
Facing other side to

13. --“-- --“-- Facing tool --“-- 5
23.5 mm length
ELBOW MECHANISM
PART NO : OTS - 07
PART NAME :LH_ OUTPUT SHAFT
MATERIAL SPECIFICATION : EN24
RAW MATERIAL SIZE: 55 x 145 QUANTITY :- 0 4 NO’S.
Operation Fixture
Instrument
2.Facing one sides --”-- --”-- Facing tool Vernier 5
3.Turning outer --“-- --“-- Turning tool --“-- 5

diameter to  48mm
through length
4.Center drilling --“-- --“-- Center drill --“-- 5
5.Turning  15mmthrough --“-- --“-- Twist drill --“-- 5

101 length
6.Turning  --“-- --“-- Turning tool --“-- 5

15mmthrough 86 length
7.Turning  --”-- --”-- Turning tool --”-- 5

8.Turning  10mmthrough --”-- --”-- Turning tool --”-- 5

45 length

Threading M8 threads
10. --”-- --”-- Threading tool --”-- 5
Turning  12mmthrough
11. --”-- --”-- Reamer --”-- 5
length
Grooving as per profile

12. --”-- --”-- Parting tool --”-- 5
Facing other side

13. --“-- --“-- Facing tool --“-- 5
Clam job on m/c vice

14. 3jaw chuck DRO - --“-- 30
milling m/c
Drilling  3.85 holes

15. --“-- --“-- Twist drill --“-- 5
through thickness 3
No’s
ELBOW MECHANISM
16. Reaming  4 holes thro --“-- --“-- Reamer --“-- 5

thickness 3
No’s
17. Chamfer 0.5 x 45 --“-- --“-- Twist drill --“-- 5
degree B/s of each hole
34
ELBOW MECHANISM
PART NO : OTS - 08
PART NAME :RH_ OUTPUT SHAFTMATERIAL SPECIFICATION : EN24

Operation Fixture
Instrument

through length

101 length
6.Turning  15mmthrough --“-- --“-- Turning tool --“-- 5

86 length


45 length
Threading M8 threads
10. --”-- --”-- Threading tool --”-- 5
Turning  12mmthrough
11. --”-- --”-- Reamer --”-- 5
length
Grooving as per profile

12. --”-- --”-- Parting tool --”-- 5
Facing other side

13. --“-- --“-- Facing tool --“-- 5
Clam job on m/c vice

14. 3jaw chuck DRO - --“-- 30
milling m/c

15. --“-- --“-- Twist drill --“-- 5
through thickness 3 No’s
ELBOW MECHANISM
16. Reaming  4 holes thro --“-- --“-- Reamer --“-- 5

thickness 3
No’s
17. Chamfer 0.5 x 45 --“-- --“-- Twist drill --“-- 5
36
ELBOW MECHANISM
PART NO : OTS - 06
PART NAME :RH_ INPUT SHAFTMATERIAL SPECIFICATION : EN24

Operation Fixture
Instrument

through length
5.Turning  --“-- --“-- Twist drill --“-- 5


12length
7.Grooving as per profile --”-- --”-- Parting tool --”-- 5
8.Facing other side --“-- --“-- Facing tool --“-- 5
9.Clam job on m/c vice 3jaw chuck DRO - --“-- 30

milling m/c

10. --“-- --“-- Twist drill --“-- 5
Reaming  4 holes thro

11. --“-- --“-- Reamer --“-- 5
thickness 3 No’s
Chamfer 0.5 x 45
12. --“-- --“-- Twist drill --“-- 5
ELBOW MECHANISM
PART NO : OTS - 05
PART NAME :LH_ INPUT SHAFT MATERIAL SPECIFICATION : EN24

Operation Fixture
Instrument

through length

76 length

12length
7.Grooving as per profile --”-- --”-- Parting tool --”-- 5
8.Facing other side --“-- --“-- Facing tool --“-- 5
9.Clam job on m/c vice 3jaw chuck DRO - --“-- 30

milling m/c

10. --“-- --“-- Twist drill --“-- 5
Reaming  4 holes thro

11. --“-- --“-- Reamer --“-- 5
thickness 3
No’s
Chamfer 0.5 x 45
12. --“-- --“-- Twist drill --“-- 5
ELBOW MECHANISM
PART NO : OTS - 10 MATERIAL SPECIFICATION: EN 9

PART NAME : LH_BRG_HSG RAWMATERIAL SIZE: 50X20X60
QUANTITY: - 01 NO’S.
Sr. Description of Tools Time in minutes

No Operation
Jigs & M/c Tools Cutting Tools Measuring Setting Time
Fixture Instrument
1. Clamp stock M/C Vice Milling - - 15
2. Facing All Sides Sq. --”-- --”-- Facing cutter Vernier 5

to total length
40x12x50
mm
3. Clamp stock on lathe4 jaw chuck Lathe - - 25
4. Drilling Ø 18.5 --”-- --”-- Twist drill Vernier 15

through thickness
5. Boring Ø 25 --”-- --”-- Boring tool Vernier 15

through
thickness
6. Counter Boring Ø --”-- --”-- Boring tool Vernier 15
32 through
10 thickness
39
ELBOW MECHANISM

PART NAME : RH_BRG_HSG RAWMATERIAL SIZE: 50X20X60

No Operation
Fixture Instrument

to total
length 40x12x50 mm

through thickness
through thickness

32 through
10 thickness
40
ELBOW MECHANISM

PART NAME : CENTRAL_BRG_HSG RAWMATERIAL SIZE: 140X20X50

No Operation
Fixture Instrument

to total
length 135x12x40 mm

through thickness

through thickness

32 through
10 thickness
through
thickness
through thickness

32 through
10 thickness
41
ELBOW MECHANISM
PART NO : OTS - 17 MATERIAL SPECIFICATION : EN9

PART NAME :COVER RING
Sr. Description of Jigs & Tools Time in

No Operation Fixture
Instrument
1. Clamp stock 3 Jaw chuck Lathe - - 10
2. Facing one sides --”-- --”-- Facing tool Vernier 5
3. Turning outer --“-- --“-- Turning tool --“-- 5

through
length
4. Center drilling --“-- --“-- Center drill --“-- 5

through
thickness
through
thickness
7. Counter Boring Ø 45 --”-- --”-- Boring tool Vernier 15
through
40 thickness
8. Counter Boring --”-- --”-- Boring tool Vernier 15
Ø 47 through 8
thickness
9. Threading M48
Threads
through 8mm length
10 Facing other side --“-- --“-- Facing tool --“-- 5
11 Clam job on m/c vice 3jaw chuck DRO - --“-- 30

milling m/c
12 Drilling  3.85 holes --“-- --“-- Twist drill --“-- 5

through thickness 3
No’s
13 Reaming  4 --“-- --“-- Reamer --“-- 5
holes thro thickness 3
No’s
.
.
.
.
ELBOW MECHANISM
14 Chamfer 0.5 x --“-- --“-- Twist drill --“-- 5

45 degree B/s of each
hole
43
43
.
ELBOW MECHANISM
Chapter No.:-5
TEST & TRIAL ON ELBOW
MECHANISM
TEST & TRIAL ON ELBOW MECHANISM
AIM: -
To conduct trial on Orbital Mechanism to determine
a) TORQUE Vs SPEED CHARACTERISTICS
b) POWER Vs SPEED CHARACTERISTICS
In order to conduct trial , an dynobrake pulley cord, weight pan are provided on the output shaft.
INPUT DATA:-
A) Drive Motor AC230 Volt
0.5 Amp, 100 watt
50 Hz, 200 to 4500 rpm
TEFC COMMUTATOR MOTOR
B) Diameter (Effective ) of Dynobrake pulley = 25 mm.
PROCEDURE:-
1) Start motor by turning electronic speed variator knob.
2) Let mechanism run & stabilize at certain speed (say 1300 rpm)
3) Place the pulley cord on dynobrake pulley and add 100 gm weight
note down the out put speed for this load by means of tachometer.
4) Add another 100 gm cut & take reading .
5) Tabulate the readings in the observation table
6) Plot Torque Vs speed characteristic Power Vs speed characteristic
Chapter No.:-6
OBSERVATION TABLE
OBSERVATION TABLE
SR LOADING UNLODING MEAN
NO SPEED
WEIGHT SPEED WEIGHT (gm) SPEED
(gm) rpm rpm
1. 100 1300 100 1300 1300
2. 150 1250 150 1240 1245
3. 200 1200 200 1100 1190
4. 250 1100 250 1080 1090
5. 300 1000 300 1040 1020
6. 350 970 350 930 950
7. 500 880 500 890 885
8. 600 850 600 850 850
9. 700 700 700 690 695
10. 800 650 800 640 645
11. 1000 600 1000 610 605
ELBOW MECHANISM
SAMPLE CALCULATIONS:- (AT 0.6 kg Load)
1) Average Speed :-
N = ( N1 + N2 ) ( 650 + 650 )
= = 650 rpm
2 2
2) Output Torque:-
Tdp = Weight in pan x Radius of Dynobrake Pulley
= (0.6 x 9.81) x 12.5
=73.575 N.mm
Tdp =0.0737575 N.mm
3) Input Power:- (Pi/p)
Pi/p = 2  N Ti/p
60
= 2 x  x 650 x 0.08
60
Pi/p =5.44 watt

4)OutPut Power:-(Po/p)
Po/p = 2  NT o/p
60
= 2 x  x 650 x 0.0737575
60
Po/p = 5.02 watt
4) Efficiency:-
 = Out put power
Input power
= 5.02 x 100
5.44
 = 92.28 %
 Efficiency of transmission of orbital mechanism at 90 degree = 92.28%
Chapter No.:- 7
Result Table
RESULT TABLE
SR LOAD (gms) SPEED TORQUE POWER
NO (rpm) (N.M) (watt)
1. 100 1300 0.01226 1.66
2. 150 1245 0.01839 2.39
3. 200 1190 0.0245 3.053
4. 250 1090 0.0306 3.49
5. 300 1020 0.0368 0.93
6. 350 950 0.0429 4.26
7. 500 885 0.0613 5.68
8. 600 850 0.073575 6.54
9. 700 695 0.086 6.25
10. 800 560 0.098 5.75
11. 1000 440 0.1226 5.52
ELBOW MECHANISM
Chapter No.:- 8
Cost Analysis
ELBOW MECHANISM
BILL OF MATERIALS
SR PART DESCRIPTION QTY MATERIAL
NO. CODE
1. EM-1 MOTOR 01 STD
2. EM -2 PULLEY 01 EN9
3. EM -3 MAIN SHAFT 01 EN24
4. EM -4 MAIN SHAFT BRG HSG 01 EN9
5. EM -5 LH_ IP_SHAFT 01 EN24
6. EM -6 RH_ IP_SHAFT 01 EN24
7. EM -7 LH_ OP_SHAFT 01 EN24

8. EM -8 RH_ OP_SHAFT 01 EN24
9. EM -9 CENTRAL BRG HSG 01 EN9
10. EM –10 LH_BRG_HSG 01 EN9
11. EM –11 RH_BRG_HSG 01 EN9
12. EM –12 BASE FRAME 01 MS
13. EM -13 BRG6201ZZ 04 STD
14. EM -14 WHEELS 03 STD
15. EM -15 BENT PINS 03 EN9
16. EM -16 JACK BOLTS 03 STD
17. EM-17 COVER RING 04 EN9
18. EM-18 PROPELLER SHAFT 1 EN24
19. EM-19 GEAR 04 N8
RAW MATERIAL COST
ELBOW MECHANISM
The total raw material cost as per the individual materials and their correspondin
as follows,
Total raw material cost = Rs 4450/-
MACHINING COST
OPERATION RATE TOTAL TIME TOTAL
Rs /HR HRS COST Rs/-
LATHE 80 16 1280
MILLING 95 9 855
DRILLING 50 3.6 180
TAPPING Rs 3 /- per hole 16 48
TOTAL 2363
TOTAL MACHINING COST = Rs 2363 /-
MISCELLANEOUS COSTS
OPERATION COST(Rs)
Sawing 160
Gas cutting 80
Bench Work 40
Total 280
COST OF PURCHASED PARTS
SR DESCRIPTION QTY COST
NO.
1. Vee Belt 01 75
2. Bolts - 35
3. Electric Motor 01 1200
4. Wheels 03 360
5. Electronic Speed Variater 01 180
6. Bearings 07 400
The cost of purchase parts = Rs 2180 /-
TOTAL COST
TOTAL COST = Raw Material Cost +Machine Cost + Miscellaneous Cost
+ cost of Purchased Parts +Overheads
= Rs 9273/-
Hence the total cost of machine = Rs 9273/-
Chapter No: 09
Conclusion and Future scope
CONCLUSION AND FUTURE SCOPE
Some successful mechanical devices function smoothly however poor fly they
Are made while other does this only by virtue of a accurate construction &
fitting of their moving parts.
This projects which looks very simple & easy to construct was actually
Very difficult to conceive & imagine without seeing an actual one in practice
is an event a fact in the creative mental process nit the forces, which
predominate among the schemes of the active tinkers. Motions demands to be
studied first &we have done that very thing.
We find that while acceptable analysis for existing mechanism can often be
Made quite easily we cannot without insight & imagination make effective
synthesis of new mechanism hence we are mould to present this our projec
less transmission at 90*(El-bow mechanism) which we have managed to

successfully device after long & hard input in conceiving its working princip
Chapter No.:-10
BIBLIOGRAPHY
BIBLIOGRAPHY
 A.G.Erdman& G.N. Sandor
-“Mechanism Design ”,
 Newell Harton -“Ingenious Mechanism For Designers
 PSG - “DESIGN DATA HAND BOOK”(1998)

 V.B.BHANDARI -
“Design of Machine Elements”,
Tata Mc – Graw Hill Publication (1999)
 R.S.KHURMI & J.K.GUPTA -

“A Text Book of Machine Design”. Eurasia Publication (1990)
-
and portable equipment, which is
ht angle without any gears being
put power towards the output side
ks are transmitted with the help of
drive is transferred towards the
plays while the power is being
appreciated
ss transmission mechanism.
oose to work on this project topic :

Here is a
ent rod. Transmitting rotational
n quickly become complicated,
using gears, this technology
drical bars, bent to 90º, in a clever,
onal force even in restricted
ting rotational velocity from an
and the housing have rotational
at an angle of 90 degree with
rotation of the input shaft results
t rotation of prime
ut shaft.
d upon means the whole of the
ankshaft to the rear wheels.
monly in the literature for a
f the engine torque at the road
atic transmission.
sion are:
ne varies with speed only within
ning of automobile under different
e at the wheels. The main purpose
rage or the torque ratio between
hat the engine and the road

gaged position.
otation of the drive is
nd the automatic types. The

xes. Their mechanical efficiency in
s slightly greater than 90%. As
on losses in manual transmissions
nitial cost, is the reason these are
n the other hand the operation of
ng gears while driving over a
herefore, in luxury vehicles
he driving operation
shaw is as shown in the figure.
ower plant , and the clutch –gear
The power is available at the
wheels individually by means of
compared to the wheels.
, it does not transmit constant
s low(65%).More over this
ocity ie speed output from the
d considerable axial and radial
differential has to be transmitted

ove
d.
STEM.)
original mechanism named Elbow
Elbow mechanism is capable of
shafts at right angles. This
oles each on the same pitch circle
t are made of steel and bent at
(12000 rpm).
y sealed units filled with lubricating
s an efficiency as high as 93%.
mission system from the one shaft
same diameter and having same
otor drives the main propeller shaft
gle shaft can be driven by both
l improve the efficiency of power

the
Single phase Ac Motor

gle and 6mm ‘A’ section .This
4.68
nd of the propeller
main shaft is an high grade steel

ey at lower end and the horizontal
drilled with three holes of equal
ets of 90 ,120,140 degree

e in a special fixture such that the
ess concentration.

gs 6201 zz in which the input

lded to the base fame.
in which the
g is welded to the base fame.
1 zz in which the RH_ output

elded to the base fame
en by motor shaft and then it

manually driven by hand wheel
propeller shaft to the both
m.
ft ends

he orbital transmission system by

ven to the two input shaft through
spur type and of same diameter.
eels. The input shaft rotate to
s the pins to slide to and fro inside
motion of the output shaft.
he output wheel
ared to conventional double hook
el economy.
e , hence no phase shift.
increase in transmission speed.
ed for manufacture.
eds to be modified to incorporate
nd there no relative motion
ame number of teeth. one gear is

used in intermediate to one driving
ch is fixed on propeller shaft and
ear 1 and driven gear 2 respectively.
dler gear which is intermediate
so there is no speed reduction
............. (4)
shafts without any speed
they will turn at the same speed.

een the input gear and the output
o not affect the speed
ples , technical information and

hine or mechanism to perform a
ed. The total design

onstrains, deciding basic working
design.
straints. The mechanical design
hence system is designed such
ed in mechanical design can be
e simple to utilize every
d by means of simplified layout

ents.

nd stored on the basis of their

dimensions there obtained are
ailable in market. This simplifies
aintenance work. The various
e prepared and passed to
rious catalogues and are specified
opriate material for the part to be
books; eg:- (PSG DESIGN DATA
TARY SPEED REDUCER’

shall adopt the following
design.
ssible system of forces.

WER = 100 WATT SPEED = 200 TO 4500
DUCTION RATIO = 75/16 =4.688
8 kg.m

t & Mechanism I/P

88 x 0.1592
0.7463 N-m

ndition sit is necessary to make proper
igidly mounted on it and the weight of
e calculated for various relations.
or safe operation . Shaft is provided a

mple gear train mechanism and subjected
e calculated for various relations.

or safe operation . Shaft is provided a

16 x T
 x 63
19 N.mmd3

:-
held at one end in bush bearing which

(N)
)
6 N/mm2 Pb act = 12.6 N/mm2

e of flange coupling . Material Selection

Time in minutes
Setting Time M/c Time Total Time
20 - 20
- 5 5
5 10 15
- 30 30
5 10 15
10 3 13
10 10 20
15 25 40
5 2 7
5 2 7
5 3 8
5 7 12
5 2 7

Time in minutes
10 - 10
5 2 7
5 13 18
5 2 7
5 3 8
5 3 8
5 12 17
5 12 17
5 10 15
5 12 17
5 12 17
5 2 7
5 2 7
30 - 30
5 3 8

5 5 10
5 12 17

Time in minutes
10 - 10
5 2 7
5 13 18
5 2 7
5 3 8
5 3 8
5 12 17
5 12 17
5 10 15
5 12 17
5 12 17
5 2 7
5 2 7
30 - 30
5 3 8

5 5 10
5 12 17

Time in minutes
10 - 10
5 2 7
5 13 18
5 2 7
5 3 8
5 12 17
5 2 7
5 2 7
30 - 30
5 3 8
5 5 10
5 12 17

Time in minutes
10 - 10
5 2 7
5 13 18
5 2 7
5 3 8
5 12 17
5 2 7
5 2 7
30 - 30
5 3 8
5 5 10
5 12 17

Time in minutes
15 - 15
5 14 19
25 25
15 10 25
15 10 25
15 10 25

Time in minutes
15 - 15
5 14 19
25 25
15 10 25
15 10 25
15 10 25

Time in minutes
15 - 15
5 14 19
25 25
15 10 25
15 10 25
15 10 25
15 10 25
15 10 25
15 10 25

Time in minutes
10 - 10
5 2 7
5 13 18
5 2 7
15 10 25
15 10 25
15 10 25
15 10 25
5 2 7
30 - 30
5 3 8
5 5 10

5 12 17

.
ator knob.
eed (say 1300 rpm)
nd add 100 gm weight into , the pan ,
eans of tachometer.
ble
Vs speed characteristic

and their corresponding rates per kg is
pe
er poor fly they
onstruction &
ct was actually
ctual one in practice. It
forces, which
demands to be
m can often be
ake effective
esent this our project gear
have managed to
g its working principle.
chanism For Designers & Inventors”
90)

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A PROJECT REPORT ON

“POWER TRANSMISSION WITHOUT GEAR”

3.8. Design of Bearing Bush.

5. Test & Trial on ELBOW MECHANISM. 46

9. Conclusion & Future Scope 58

Project Abstract / Summary : ABSTRACT

Why did you choose to work on this

wonderful mechanism that carries force through a 90ºbent rod. Transmittin

Universal System Used in 3-Wheeler

3. LH&RH INPUT SHAFT:-

ADVATAGES OF ELBOW MECHANISM

Simple Gear Train-

Following parameters are looked upon in system design.

APPROACH TO MECHANICAL DESIGN OF ‘PLANETARY SPEED REDU

Max Input Power = 100 watt at 6000 rpm. At motor shaft

Assuming 100% overload;

Considering minimum of the above values.

 fs max = 0.75 x 144

fs act = 35.19 N/mm2

 fs max = 0.75 x 144

fs act = 35.19 N/mm2

EN24 800 600

Diameter of output shaft = 6mm fs act = 16 x T

 shaft is safe under torsional load.

 shaft is safe in bending .

C30/EN8K 620 400

Bearing brush is safe.

Tensile strength N/ Yield strength N/

EN9 520 350

1.49 ∏ x (4)2 x fsb act x 3 x 36 4 2

Sr. No Description of Jigs & Tools Time in

1.Clamp stock 3 Jaw chuck Lathe - - 20

2.Facing one sides --”-- --”-- Facing tool Vernier -

3.Turning diameter 75 --“-- --“-- Turning tool --“-- 5

4.Turning  30 --“-- --“-- --“-- --“-- -

5.Turning groove  --“-- --“-- Grooving tool --“-- 5

6.Chamfer 6 x 45 degree on --”-- --”-- Crank facing tool --”-- 10

7.Roughing V groove --”-- --”-- Parting tool --”-- 10

8.Finish V groove --“-- --“-- V- tool Angle protractor 15

9.Centre drill --“-- --“-- Centre drill --“-- 5

Drilling  14.5 hole through --“--

Reaming  15 hole through --“--

Parting off to 24mm

Facing other side to

1.Clamp stock 3 Jaw chuck Lathe - - 10

2.Facing one sides --”-- --”-- Facing tool Vernier 5

3.Turning outer --“-- --“-- Turning tool --“-- 5

5.Turning  15mmthrough --“-- --“-- Twist drill --“-- 5

6.Turning  --“-- --“-- Turning tool --“-- 5

7.Turning  --”-- --”-- Turning tool --”-- 5

8.Turning  10mmthrough --”-- --”-- Turning tool --”-- 5

9.Turning  --”-- --”-- Turning tool --”-- 5

Grooving as per proﬁle

Facing other side

Clam job on m/c vice

Drilling  3.85 holes

16. Reaming  4 holes thro --“-- --“-- Reamer --“-- 5

Sr. No Description of Jigs & Tools Time in

1.Clamp stock 3 Jaw chuck Lathe - - 10

2.Facing one sides --”-- --”-- Facing tool Vernier 5

3.Turning outer --“-- --“-- Turning tool --“-- 5

5.Turning  15mmthrough --“-- --“-- Twist drill --“-- 5

6.Turning  15mmthrough --“-- --“-- Turning tool --“-- 5