DESIGN AND ANALYSIS OF GENEVA MECHANISM WITH CURVED SLOTS

Jung-Fa Hsieh
Department of Mechanical Engineering, Far East University, Tainan, Taiwan
E-mail: seznof@cc.feu.edu.tw
Received November 2013, Accepted March 2014
No. 13-CSME-185, E.I.C. Accession 3643

ABSTRACT
A simple yet comprehensive method is proposed for the design of a Geneva indexing mechanism with curved
slots. In the proposed approach, conjugate surface theory is used to derive an analytical description of the
profile of the curved slots with and without an offset feature. Analytical formulae are then presented for the
pressure angle of the Geneva mechanism and the principal curvatures of the curved slots. The effectiveness
of an appropriate offset angle in eliminating the singular points and double-points on the curved slot profile
is then demonstrated. Finally, a Geneva mechanism is fabricated in order to demonstrate the feasibility of
the proposed approach.

Keywords: Geneva mechanism; offset; principal curvature.

DESIGN ET ANALYSE D’UN MÉCANISME DE MOUVEMENT À

CROIX DE MALTE À RAINURES COURBES

RÉSUMÉ
Une méthode simple mais complète est proposée pour le design d’un mécanisme de mouvement à Croix de
Malte d’indexation avec rainures courbes Dans l’approche proposée, la théorie des surfaces conjuguées est
utilisée pour établir une description analytique du profil des rainures courbes avec et sans caractéristiques de
déviation. On présente des formules analytiques de l’angle de pression du mécanisme à Croix de Malte et les
courbures principales des rainures courbes. L’efficacité d’un angle de déviation approprié pour éliminer les
points et doubles points sur le profil de la rainure courbe a été ainsi démontrée. Finalement, un mécanisme
de mouvement à Croix de Malte a été fabriqué pour démontrer la faisabilité de l’approche proposée.

Mots-clés : mécanisme de mouvement à Croix de Malte; déviation; courbure principale.

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NOMENCLATURE
(xyz)0 Configuration of frame (xyz)0 built in Geneva wheel
0S Curved slot surface
rS Roller surface
0n Unit outward normal of slot surface
λ Roller height
r Roller radius
R Distance between z2 and zr axes (driving crank length)
R1 Geneva wheel radius
a1 Distance between z2 and z0 axes
α Half indexing angle
ψ Pressure angle
θ1 Rotation angle of Geneva wheel
θ2 Rotation angle of driving crank
w1 Angular velocity of Geneva wheel
ε1 Angular acceleration of Geneva wheel

1. INTRODUCTION
Indexing mechanisms are of great practical importance in many applications, including weaving looms,
precision measurement instruments, automated packaging and printing machinery, and so forth. One of
the most common forms of indexing mechanism is the Geneva mechanism. The design and machining of
a conventional Geneva mechanism is generally straightforward since its structure consists primarily of no
more than a driving crank and a wheel with straight slots. However, in such mechanisms, a significant impact
load is produced at the initial and final stages of the indexing operation as the roller enters and exits the slot,
respectively. Consequently, conventional Geneva mechanisms are confined to low-speed applications, or to
those in which noise and vibration are of no importance.
Various approaches have been proposed for improving the kinematic characteristics and dynamic perfor-
mance of Geneva mechanisms. For example, Fenton [1] deployed two Geneva mechanisms in series such
that the second wheel accelerated and decelerated smoothly regardless of the motion status of the first mech-
anism. Cheng and Lin [2] reduced the shock in a Geneva mechanism by using non-linear springs as damping
elements. Several studies have attempted to reduce the impact load through a redesign of the slot shape on
the Geneva wheel. For example, Fenton et al. [3] modified the conventional straight slot to a curved slot with
an offset feature at its entrance. Lee [4] used a parametric polynomial expression to design and analyze the
curved slots of a Geneva mechanism. Figliolini and Angeles [5] performed the kinematic synthesis of both
conjugate Geneva mechanisms with curved slots and their pure-rolling cam-equivalents using the pressure
angle as a figure of merit of the transmission force. Lee and Jan [6] presented a systematic method based
on envelope theory to determine the geometry of Geneva mechanisms with curved slots. Hsieh [7] utilized
a homogeneous coordinate transformation method to derive an analytical expression for the curved slots on
a Geneva wheel and to generate the corresponding NC machining code. However, the problem of singular
and double-points on the curved slot profile was not addressed.
Despite the contributions of the studies above, the literature lacks a systematic investigation into the
design and machining of Geneva mechanisms with curved slots. Accordingly, the present study constructs
a mathematical model of a Geneva mechanism with curved slots based on the input-output relationship of
the mechanism and the dimensions of its links and then combines this model with the ability matrix of a
3-axis CNC machine tool (i.e., the position and orientation of the spindle with respect to the table frame)
in order to generate the NC code required to machine the designed Geneva wheel. In designing the curved
slot profile, the offset angle is carefully specified so as to eliminate the singular and double-points on the

558 Transactions of the Canadian Society for Mechanical Engineering, Vol. 38, No. 4, 2014
 Fig. 1. Geneva mechanism with curved slots.

slot profile without affecting the overall kinematic characteristics of the mechanism. The feasibility of the
proposed methodology is demonstrated by fabricating a Geneva indexing mechanism.

2. SURFACE GEOMETRY
Referring to Fig. 1(a), the angular displacement of the driving crank takes place in the clockwise direction
about center 01 . When the roller on the driving crank engages with the slot on the Geneva wheel and rotates
through an angle 2β , the Geneva wheel rotates about center 00 in the counterclockwise direction through an
angle 2α (referred to as the indexing angle). Figure 1(b) shows that when the roller, with center 0r , enters
the curved axis 00 x0 , which rotates with the Geneva wheel, coincides with axis 00 01 , where θ1 = 0. Thus,
from triangle 0r 00 01 , it follows that
R1 R a1
= = , (1)
Sβ Sα S(π − α − β )
where a1 is the distance between the wheel axis z0 , and the crank axis z1 , R is the length of the driving crank,
R1 is the radius of the Geneva wheel, and S denotes SINE.
In order to specify the slot profile in terms of the designed parameters using conjugate theory, it is first
necessary to label the coordinate frames sequentially, starting with the Geneva wheel (marked as “0” in

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 Table 1. Kinematic parameters of Geneva mechanism.
link bi θi ai αi λi
1 b1 −θ1 a1 0◦ 0
2 0 −θ2 0 180◦ 0

Fig. 2. Roller location with respect to driving crank.

Fig. 1) and ending with the driving crank (marked as “2” in Fig. 1). Once frames (xyz)i (i = 0, 1, 2) have
been assigned to link i according to the Denavit–Hartenberg (D-H) notation [8], the kinematic parameters
can be tabulated as shown in Table 1.
The configuration of frame (xyz)2 with respect to frame (xyz)0 is given by
 
C(θ2 ) + θ1 ) −S(θ2 + θ1 ) 0 a1Cθ1
0
 −S(θ2 + θ1 ) −C(θ2 + θ1 ) 0 −a1 Sθ1 
A2 = Π2i=1 i−1 Ai =  . (2)
 0 0 −1 b1 
0 0 0 1

Note that in Eq. (2), θ1 = θ1 (θ2 ) represents the input-output relation of the Geneva mechanism.
The configuration of the roller frame (xyz)r with respect to frame (xyz)2 (see Fig. 2) is given by the matrix
 
1 0 0 R
2
 0 −1 0 0 
Ar = 
 0 0 −1 0  .
 (3)
0 0 0 1

Similarly, the configuration of the roller frame (xyz)r with respect to frame (xyz)0 is expressed as
 
C(θ2 + θ1 ) S(θ2 + θ1 ) 0 RC(θ1 + θ2 ) + a1Cθ1
0 −S(θ2 + θ1 ) C(θ2 + θ1 ) 0 −RS(θ1 + θ2 ) − a1 Sθ1 
Ar = 0 A2 2 Ar = 

. (4)
 0 0 1 b1 
0 0 0 1

The surface equation, r S, and unit outward normal, r n, of the cylindrical roller can be expressed with
respect to frame (xyx)r as follows:
r
S = [rCθ rSθ − u 1]T (0 ≤ u ≤ λ , 0 ≤ θ ≤ 2π), (5)

560 Transactions of the Canadian Society for Mechanical Engineering, Vol. 38, No. 4, 2014
 ∂ rS ∂ rS
 r
 ∂ S ∂ rS 

r T
n= ×  ∂ u × ∂ θ  = [Cθ Sθ 0 0] ,
  (6)
∂u ∂θ
where θ is the polar angle, u is the height parameter of the cylindrical roller, and C denotes COSINE. Once
the input-output relation of the Geneva mechanism has been defined, the conjugate points and slot profiles
can be determined as
0 d(0 Ar r S)
0 T d S
n · = (0 Ar r n)T = 0, (7)
dt dt
where 0 n and 0 S are the unit outward normal and surface equation of the slot with respect to frame (xyz)0 ,
respectively. Equation (7) implies that for continuous contact to be maintained between the slot and the
roller, the relative sliding velocity must be orthogonal to the common normal at the contact point. Imposing
the condition given in Eq. (7) on Eqs. (5) and (6), the conjugate point is obtained as

ĒS(θ ) + F̄C(θ ) = 0, (8)

where Ē and F̄ are defined as Ē = (R + a1Cθ2 )dθ1 /dθ2 + R and F̄ = −a1 Sθ2 dθ1 /dθ2 , respectively.
From Eq. (8), the value of parameter θ at the conjugate point can be derived as

θ̄ = − tan−1 (F̄/Ē). (9)

Note that Eq. (9) yields two values corresponding to the two points of simultaneous contact between
the roller and the slot surface. The conjugate profile of the slots on the Geneva wheel can be obtained
by substituting Eq. (9) into Eq. (5), and then transforming r S to frame (xyz)0 via the matrix manipulation
0 S =0 A r S. That is,
r
 
rC(θ̄ − θ1 − θ2 ) + RC(θ1 + θ2 ) + a1Cθ1
0
 rS(θ̄ − θ1 − θ2 ) − RS(θ1 + θ2 ) − a1 Sθ1 
S = [0 Sx 0 Sy 0 Sz 1]T =  . (10)
 b1 − u 
1

For a curved slot profile with no undercut, a double-point occurs near the roller entry and exit points
during each cycle [6]. At this double-point, the roller may lose contact with the slot wall as the driving
crank rotates, and thus the wheel is no longer properly controlled. Fenton et al. [3] showed that the double-
point problem can be eliminated by adding an offset feature to the curved slot profile. Importantly, the offset
alters the shape of the slot, but has no effect on the kinematic characteristics of the mechanism. Figure 3
presents a schematic illustration of the offset concept. As the roller engages with the slot at new point A,
the original angle between line 00 A and the center line 00 001 increases from α to α + ∆α, where ∆α denotes
the offset angle and 001 is the new crank rotation center. The roller then exits the curved slot at point B. In
the modified slot design, the axis distance 00 001 (denoted as ā1 ) and crank length (denoted as R̄) are related
as follows:
R1 R̄ ā1
= = . (11)
sβ S(α + ∆α) S(π − α − β − ∆α)
Thus, the geometric profile of the slot with an offset feature can be obtained by replacing a1 with ā1 and R
with R̄ in Eqs. (9) and (10).

3. ANALYSIS OF SLOT CURVATURE

When machining the profile of the slots on the Geneva wheel, undercutting may occur even if the cutter
has the same form as the roller. Therefore, the principal curvatures of the slot surfaces must be carefully

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 Fig. 3. Geneva wheel with offset curved slot.

designed in order to prevent the occurrence of singular points and to enable the size of the slot profile to be
properly determined.
In accordance with the basic principles of differential geometry [9], the principal curvatures of the slot sur-
faces can be evaluated using themathematical model of the slot profile developed in Section 2, i.e., 0 S(θ2 , u).
That is, p
K1 , K2 = H ± H 2 − K, (12)
where K1 and K2 are the principal curvatures of the slot profile, and H and K are defined respectively as

LN − M 2 2FM − EN − GL
K= and H= , (13)
EG − F 2 2(EG − F 2 )
where
∂ 2 0S ∂ 2 0S ∂ 2 0S ∂ 0S ∂ 0S ∂ 0S ∂ 0S
L =0 n · , M =0 n · , N =0 n · , E= · , F= · ,
∂ u2 ∂ u∂ θ2 ∂ θ22 ∂u ∂u ∂ u ∂ θ2

and
∂ 0S ∂ 0S
G= ·
∂ θ2 ∂ θ2
are derived in Eqs. (A1–A6) in the Appendix.
From Eqs. (12) and (13), it can be seen that the principal curvatures of the slot profile are related to both
the motion program of the Geneva wheel and the dimensions of the Geneva mechanism.

4. KINEMATICS
The performance of Geneva mechanisms can be improved by choosing a suitable motion program which
incorporates both zero velocity and zero acceleration at the beginning and end points of each engagement
period. In the present study, the motion program is defined by the following modified sine curve:
 h  i
π θ2 −θd 1 θ2 −θd

 h 4+π τ − 4(4+π) S 4π τ , 0 ≤ θ2 − θd ≤ τ8 ,


 h  i
2 π θ2 −θd 9 θ2 −θd
θ1 (θ2 ) = h 4+π + 4+π τ − 4(4+π) S 4π3 τ + π3 , π8 ≤ θ2 − θd ≤ 7τ8 , (14)

 h  i

 h 4 + π θ2 −θd − 1 S 4π θ2 −θd , 7τ
8 ≤ θ2 − θd ≤ τ,

4+π 4+π τ 4(4+π) τ

562 Transactions of the Canadian Society for Mechanical Engineering, Vol. 38, No. 4, 2014
 Fig. 4. Input-output relation of modified sine motion curve.

Fig. 5. Velocity and acceleration characteristics of Geneva mechanism with curved slots.

where θ1 is the Geneva wheel displacement, θ2 is the driving crank position, and θd is the dwell period. In
accordance with this modified sine curve, the wheel displacement starts from a zero position and rises to a
total height of h over the period of the driving crank rotation, τ.
For illustration purposes, consider the case of a 4-station Geneva mechanism, i.e., N = 4. Let the dwell
period of the Geneva wheel be specified as θ2 = 0◦ to θ2 = 137.34◦ . Furthermore, let the indexing angle
of the Geneva wheel as the driving crank rotates from 137.34◦ to 222.66◦ be equal to 90◦ . Substituting
h = 90◦ , τ = 85.32◦ and θd = 137.34◦ into Eq. (14), the input-output motion curve is found to have the form
shown in Fig. 4. The corresponding velocity and acceleration characteristics are shown in Fig. 5.
Figure 6 shows the geometry relationship between the Geneva wheel and the locking disc at the moment
the driving roller enters the slot. To prevent interference between the wheel and the disc, parameters φ and
ξ relating to the circular arc of the locking disc must be carefully designed. From an inspection of Fig. 6, φ
and ξ can be obtained as

Transactions of the Canadian Society for Mechanical Engineering, Vol. 38, No. 4, 2014 563
 Fig. 6. Geometry relationship between Geneva wheel and locking disc.

Fig. 7. Curved slots with no offset feature.

R̄2 + ā21 − R21

cos ξ = , (15)
2R̄ā1
R21 + ā21 − R2L
cos φ = . (16)
2R1 ā1
When the roller has just entered the slot and the locking disc starts to unlock (or the roller has just exited
the slot and the locking disc starts to lock), it is necessary to satisfy Eq. (15). Meanwhile, to prevent
interference, the angular rotation ξ of the driving crank as the roller engages with the slot must be greater
than that of the Geneva wheel, i.e., (360/N) − 2φ , where N is the number of slots.

5. IMPLEMENTATION
To validate the design methodology presented in Sections 2–4, a Geneva mechanism was constructed with
design parameters of α = 45◦ , R = 120 mm, R1 = 115 mm, b1 = 2 mm, λ = 10 mm, r = 8 mm, and N = 4.
From Eq. (1), parameters a1 and β were obtained as a1 = 169.564 mm and β = 42.66◦ , respectively. The

564 Transactions of the Canadian Society for Mechanical Engineering, Vol. 38, No. 4, 2014
 Fig. 8. Curved slots with offset feature.

input-output relation of the designed mechanism was specified as shown in Fig. 5. Figure 7 shows the slot
profile obtained from Eqs. (9) and (10). It can be seen that the profile contains both singular points and
double-points. As a result, the Geneva mechanism is unsuitable for practical applications.
Figures 8(a–c) illustrate the profiles of the curved slots given offset angles of ∆α = 3◦ , 5◦ and 70, re-
spectively. (Note that in each figure, labels A and B indicate the entry point and exit point of the driving
roller, respectively.) It is noted that the shape of the slot and the relative location of the entry and exit
points are both dependent on the magnitude of the offset. Figure 8(a) shows that given an offset angle of
∆α = 3◦ , the slot profile still contains singular points and double-points. However, given offset angles of
∆α = 5◦ or ∆α = 7◦ , the singular points and double-points both disappear, as shown in Figs. 8(b) and (c),
respectively.
For the Geneva mechanism shown in Fig. 8(b), parameters ā1 and R̄ have values of ā1 = 169.522 mm
and R̄ = 130.002 mm, respectively. Figure 9 shows the principal curvatures of the designed slot. It is noted
that one of the principal curvatures (i.e., K1 ) is equal to zero since the slot has a 2D profile. The results
indicate that the designed slot has a minimum radius of curvature of 28.0662 mm. Thus, it is inferred that
a cylindrical end miller with a diameter of 8 mm is required to machine an undercut-free slot profile. (Note

Transactions of the Canadian Society for Mechanical Engineering, Vol. 38, No. 4, 2014 565
 Fig. 9. Variation of principal curvatures of designed slots.

Fig. 10. Photographs of Geneva mechanism with curved slots.

that readers interested in the problem of generating the NC equations required to produce the corresponding
Geneva wheel using a 3-axis machine tool are referred to [7].)
Substituting R1 = 115 mm, R̄ = 130.002 mm, RL = 80 mm, and ā1 = 169.522 mm into Eqs. (15) and (16),
parameters φ and ξ are found to have values of φ = 24.203◦ and ξ = 42.659◦ , respectively. The circular-arc
angle of the Geneva wheel cutout is then obtained as (360/N)-2φ = 41.594◦ . From Fig. 5, it can be seen
that when the driving roller enters the slot and the crank rotates through 42.659◦ , the Geneva wheel rotates
through 45◦ . In other words, interference does not occur between the locking disc and the Geneva wheel as
the crank rotates.
The feasibility of the proposed design methodology was confirmed by machining a Geneva wheel mecha-
nism with the parameter settings described above. Figure 10 presents photographs of the machining process
and the finished Geneva wheel mechanism, respectively. An experimental test showed that the indexing
mechanism functioned satisfactorily. Thus, the basic feasibility of the proposed design methodology was
confirmed.

566 Transactions of the Canadian Society for Mechanical Engineering, Vol. 38, No. 4, 2014
6. CONCLUSIONS
This paper has presented a systematic approach for the design of a Geneva indexing mechanism with curved
slots. A kinematic model of the indexing mechanism has been derived utilizing the homogeneous coordinate
transformation method and conjugate surface theory. In addition, analytical expressions have been derived
for the slot profile with and without an offset feature, respectively. Finally, analytical formulations have
been presented for the principal curvatures of the slots on the driven wheel. It has been shown analytically
that the use of an appropriate offset angle eliminates the singular points and double-points on the slot profile,
and therefore improves the control of the indexing wheel. The feasibility of the proposed methodology has
been confirmed by designing and fabricating a mock-up Geneva wheel mechanism.

APPENDIX
E = 1, (A1)
F = 0, (A2)
 2     
dθ1 dθ1 dθ1 dθ1
G = (R̄2 + 2R̄rCθ̄ + r2 ) + 1 + (2ā1 rC(θ̄ − θ2 ) + 2ā1 R̄Cθ2 ) +1 + ā21 ,
dθ2 dθ2 dθ2 dθ2
(A3)
L = 0, (A4)
M = 0, (A5)
2 2
d 2 θ1 dθ1 2 d 2 θ1
   
dθ1 dθ1
N= + 1 + R̄Cθ̄ + 1 + R̄Sθ̄ + ā1C(θ̄ − θ 2 ) + ā 1 S(θ̄ − θ2 ) . (A6)
dθ2 dθ2 dθ22 dθ2 dθ22

ACKNOWLEDGMENT
The author gratefully acknowledges the financial support provided to this study by the National Science
Council of Taiwan under Grant No. NSC100-2221-E-269-009.

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