Fabrication of Geneva Wheel Based Auto Roll Punching Machine with IR Sensing

In conventional punching machines, the time required for job setting, marking, and punching operations is relatively high, leading to increased labor cost and reduced efficiency. To overcome these limitations, a Geneva mechanism-based automatic punching machine is proposed, which significantly reduces setup time, labor involvement, and maintenance requirements. This project focuses on the design and fabrication of an automated roll punching machine using the Geneva mechanism, specifically tailored for continuous punching on paper or fabric rolls. The aim is to introduce low-cost automation in industrial applications, particularly in processes requiring repetitive punching tasks. The major components utilized in this system include a DC motor, cam arrangement, chain drive, Geneva wheel mechanism, and punching tool. The setup includes two rollers to move the paper or fabric sheet during operation. A DC motor drives the cam, which features a pin that periodically engages the Geneva wheel. The Geneva wheel, in turn, is connected to a chain drive system that moves the rollers, feeding the material for the punching operation. An IR sensor is incorporated into the system to detect the presence of paper or fabric before each punch cycle. This addition prevents dry runs, ensuring that the punching tool only operates when material is properly in place, thus increasing operational reliability, reducing wear and tear, and avoiding damage to the punch. This prototype is suitable for mass production scenarios and represents a step toward intelligent automation in material handling and processing systems.