Hello Friends. Here I comes with higher version of gearless transmission system. In this mechanism, simple gearless transmission of four shafts with four operations is effectively carried out. The shafts are powered by single AC motor. Instead of gears, solid metal bars bend at 90 degree are used for the power transmission. Using this mechanism four machining operations like cutting,grinding,drilling & buffing are done using single motor.
Step 1: Need for the Mechanism:
Sometimes gearless transmission plays vital role for many mechanisms as it avoids use of gears & lowers the maintenance cost. Moreover, there are many individual machines or instruments for operations like cutting, grinding, drilling & buffing operation. What if we can combine these entire requirements & provide a new effective solution? That’s how the concept of this mechanism came in existence. I have already illustrated gearless transmission of two shafts earlier.
This mechanism is upgraded version of the previous one. Hope you like it.
Step 2: Material Required:
1) 1 inch hollow square bar (length as per your size)
2) 4 - solid shafts of equal dimensions. (diameter & length)
3) 8 - pedestal bearing.
4) 4 - circular discs with 3 holes each at equal distance so that it can easily allow movement of a 90 degree bend metal rods.
5)12 - Metal rods of slightly smaller diameter than the holes created in discs so that it can pass through the holes easily after bending it to 90 degree. (You can joint two small rod pieces into 90 degree) 6) AC motor (1/6 hp, 7500 rpm, 75 amps, I have used). Sewing Machine motors are useful. 7) Circular hollow pipes to join at the holes both side so as to provide support for the solid circular rods while transmission.
8) Pulleys of two types. 1 Single pulleys (which carries one v belt) & 1 double pulley (which carries 2 v belts) – 4 inch diameter.
9) 2 -V Belts. One for transmission of power from motor to any of of shaft & other from that shaft to its opposite side shaft.
10) Drill Chuck (UnF 13mm) with drill bit (any size)
11) Cutter wheel – 4 inch
12) Grinder wheel – 4 inch
13) Buffing wheel – 4 inch
14) Nut, Bolt & Washers etc.
Step 3: Construction:
Create a square frame of hollow pipes first as per your dimensions. Mark the distances for mounting pedestal bearings on the frame. Fix the position of shafts & locate the 90 degree bent bars through the circular metal discs which are at one end of shaft. Check manually & ensure whether the shaft moves or not. (i.e. after fixing the arrangement, make sure two shafts properly moves or not by moving one of the shaft manually) . Mount motor properly aligned to one of the shaft as shown in images. (I hope you will do it properly.) Connect motor & the shaft using one single pulley on the motor shaft & one double pulley on one of the four shafts with the v-belt. It will transmit power for two shafts. 50% of work is done now.
For transmitting power to the remaining two shafts, I have used a single pulleys & a v-belt. As the first two shafts are operated by the motor, so for the remaining two shafts, just mount the pulley on the other shaft & adjust its position on shaft with belt coming from the double pulley which is located at the opposite side shaft. The position of pulley is adjusted so that it can move two shafts. (Refer image & video) .It’s not that much critical. Be attentive & be creative to achieve the things.
After completing the transmission work, now it’s time for mounting of the tools at the end of shaft for cutting, grinding, buffing & drilling operations. For mounting the tools, go for proper machining of the shafts to create threads, slots, keyways as required. For cutter & grinder blade you have to create threads as per the dimensions of the lock nuts of the wheels.(Take expert`s advice). Similarly for mounting the chuck for the drilling tool & for buffing wheel the machining necessary threads & keyways are created after machining. Now after doing this mount tools on one end of shaft & the circular places on other end permanently. Finally arrange the shafts as per the pedestal bearing positions as shown in images.
Step 4: Critical Issues:
The proper movement of 90 degree bent rods is the most important. For that, proper alignment of the shafts should be done. Moreover, the rods while moving needs support to maintain the angle. So, pieces of hollow circular bars are attached to the disc plate from both sides of the three holes so that it makes the solid rods in a straight line while moving. In addition to this, don’t fix pulleys on shaft at the beginning. First just move mechanism by pulling the belt. Check whether all things are working properly. Then only go for motor supply.
Step 5: Important:
1) Positions of holes on disc should be same & at equal distance.
2) Proper alignment of shafts & motor.
3) Maintain proper position of 90 degree bent rods.
4) Don`t fix position of pulleys early. First check working of the mechanism by manually pulling the belt. If all things are working properly, go for motor supply.
5) Sometimes you have to change the mounting position of motor from clockwise to anticlockwise. So be careful before mounting the motor permanently.
Step 6: For Detail Working Watch:
Gearless transmission of 4 shafts with 4 operations:
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Step 7: Final Model:
Sorry for bad image quality.