Gear Shifting
Gear Shifting
Gear Shifting
POLYTECHNIC COLLEGE
PUDUKKOTTAI – 622507
Done by
NAME REG NO
Also we would like to extend our thanks to our principal & also HOD of
Mechanical Engineering Department Dr. S.G.SHELVARAJ M.E.,Ph.D for his
constant effort in helping us by providing the necessary equipment and materials
that were used to build the project.
Not the more formality but from the depth of our heart, we extend our
sincere thanks to our project guide lecturer in Department
of Mechanical Engineering for his valuable suggestions, motivation, and constant
support.
We are really indebted to our parents, faculty members and our friends for
their timely help, and for the mental and moral support. Along with their blessing
of the almighty, we will continue to feel the success.
We also exhibit our thanks to one and all who had constantly supported us
either directly or indirectly to complete in completing this project successfully.
CONTENTS
CHAPTER
TITLE PAGE NO
NO
ABSTRACT
I INTRODUCTION
II LITERATURE REVIEW
IV METHODOLOGY
V COMPONENTS DESCRIPTION
VI WORKING PRINCIPLE
VII DIAGRAM
VIII FEATURES
IX CONCLUSION
X REFERENCES
ABSTRACT
Motorcycles are widely used around the world particularly in INDIA. The gear
shifting system of the motor-cycle is conventionally manual. This report covers
development of an indigenous gear shifting /changing system for the standard
motorcycle. By this system the manual mechanical gear- shifting will remain
unchanged because an additional electromechanical system is placed on the top
of the lever to shift the gear and automatically control the clutch. So the system
has both the option manual as well as automatic. The system uses low cost
microcontrollers to make the accurate decision for shifting the gear up and
down by observing the speed, and it controls the clutch transmission where
necessary. The complete hardware and software has been tested and the
functioning of the automatic gear shifting system is verified. System is flexible
and can be used with any motorcycle ranging from 50 to 200 cc.
1
INTRODUCTION
2
CHAPTER I
INTRODUCTION
There are already some inventions done of gear box for motorcycle for
transmitting the torque from engine crankshaft to the rear wheel of the
motorcycle. The gear box is used to vary the torque as per the different driving
conditions. The gearbox increases the required torque for start the ride and put
the motorcycle in to motion. After the start or the running of the motorcycle
there is no need of high torque, so now gear box will transmit the optimum
torque to the rear wheel at high speed. For the operation of gearbox and shifting
the gear there is need of some effort of driver of motorcycle. A foot lever is
used to shift the gears in a motorcycle. Also, a clutch is placed between the
engine and the transmission in order to engage and disengage the flywheel with
the transmission. So for smooth driving of motorcycle there is need to time
these two operations perfectly. This gear shifting becomes a tiresome process
for most new drivers. This can also help in reducing accidents.
3
1) Sensors and Actuators A device which detects or measures a physical
property and records, indicates, or otherwise responds to it. An actuator is a
component of a machine that is responsible for moving or controlling a
mechanism or system.
a) The throttle
The throttle controls the engine speed, the function of clutch is to engage
and disengage the transmission, and the gear selector selects the gear. Pull the
clutch towards you using your left hand, and revolution of the engine with
certain r.p.m will be there without moving the bike forward. Releasing of the
clutch while the transmission is "in gear" (ie, not in neutral), and you'll move
the bike forward.
4
because the system does not use Bowden cables and can calibrate itself, it may
require less maintenance.
5
in order to match acceleration and deceleration needs, drivers have to learn how
to use a clutch, when to shift, and the proper timing required for operating a
manual transmission effectively. So this project is to being thinking automatic
transmission is one type of motor vehicle transmission that can automatically
change gear ratios as the vehicle moves, freeing the driver from having to shift
gears manually and to achieve efficient driving which reduces human efforts
and fear while driving. In manual transmissions, the driver can move from gear
to gear, by moving the shifter to the appropriate position. A clutch must be
disengaged before the new gear is selected,to disengage the running engine
from the transmission, which is very confusing and fearable. So for avoiding
this we have design and develop such a system which can be installed in any
two wheeler vehicles that run on roads so that it can overcome drawback of
manual transmission. This is the new innovative model mainly used for the
vehicles to control the vehicle without human efforts. The main objective of this
concept is used to apply the gear by using automation system in automobile
vehicles. This is the new innovative model mainly used for the vehicles to
control the vehicle. Here we are concentrating to design the automatic gear
changing mechanism in two wheeler vehicles by using the electronic devices.
This is very useful for the gear changing mechanism in automobile vehicles. By
using this we can easily control the vehicle and improve the performance of the
vehicle also we can avoid the wear and tear of the gear.
6
LITERATURE SURVEY
7
CHAPTER II
LITERATURE SURVEY
1) Changing gears manually is a gruesome task which has also been very
disturbing for the riders.
8
3) Abrupt stopping of the engine in traffic due to poor handling of clutches can
be avoided.
2) To calculate the dimensions of the magnet to be used and gear ratios being
used
3) To code the required arduino program for the servo motor and the linear
punching actuator.
Haj Fraj et al had proposed an optimal control approach for gear shift
operations in automatic transmissions. Starting from a verified model of a
typical power train with an automatic transmission a performance measure for
evaluating the gear shift process in terms of passengers comfort and control
expenditure is developed. The gear shift operation is stated as a multistage
decision process by making use of the dynamic programming method
9
Ferran Reverter et al Proposed this paper that analyses the accuracy and
resolution of direct resistive sensor-to-microcontroller interfaces using
theoretical and experimental methods
10
SELECTION OF
MATERIALS
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CHAPTER III
SELECTION OF MATERIALS
1.Properties:
The material selected must possess the necessary properties for the proposed
application. The various requirements to be satisfied can be weight, surface
finish, rigidity, ability to withstand environmental attack from chemicals,
service life, reliability etc. The following four types of principle properties of
materials decisively affect their selection
Physical
Mechanical
Chemical
Cast ability
Weld ability
Surface properties
Shrinkage
12
2. Manufacturing Case
3. Quality Required
4. Availability of Material
5. Space Consideration
6. Cost
13
METHODOLOGY
14
CHAPTER IV
METHODOLOGY
15
COMPONENT
DESCRIPTION
16
CHAPTER V
COMPONENT DESCRIPTION
Sensor
Relay circuit
DC Stepper Motor
17
connected to the gear pedal. Necessary modification is done on the gear pedal.
The motor is connected to 12v power supply and runs at 500 rpm. The geared
DC stepper motor of model “VJT253” is used for high torque output. Relays are
provided to control the power supply to the motor. Relay 1 is actuated to rotate
the motor in clockwise direction and relay 2 for anticlockwise direction. The
pitch diameter of the gear on the dc motor is 25mm meshes with the gear pedal
which is fitted with spur gear of pitch diameter of 80mm. When the output shaft
DC motor rotates at 45° (anticlockwise), the pedal rotates at 25° which is
sufficient to shift the lever down and the gear shifts up of motorcycle. The same
condition follows with gear down. Fig -4: DC Stepper Motor 2.4
Microcontroller
18
WORKING PRINCIPLE
19
CHAPTER VI
WORKING PRINCIPLE
The control unit is nothing but the microcontroller is a small chip, its
already programmed and feed in the chip for working of our project. One of the
gun is used to apply the gear and another one for reducing the gears. The gears
are applied on the vehicle depending up on the speed of the vehicle. The speed
sensors are placed near the wheel the sensor sense the signal and give the output
signal to the control unit. Depending up on the signal the clutch and gears will
automatically changed with the help of the control unit. When the vehicle speed
increasing automatically the clutch and the gear will change in the vehicles. In
our project, we used Regulator as Accelerator to control speed and D.C.Motor
as Flywheel to store energy.
We have provided a specific limit of speed for each gear so that when we
accelerate the regulator the speed of D.C. Motor increases at that time the speed
sensor sense the range of speed which is mounted near the dc motor. And the
signal of speed increase sense by speed sensor is given to microcontroller. In
microcontroller, the program is already feed for that speed range, the
microcontroller checks the speed and for that specific speed range the output
signal is send to the D.C. Gun through relay circuit due to which D.C. Gun
strikes on gear changing pedal and gear increase takes place. Simultaneously the
clutch is operated automatically by D.C. Gun which is also operated by
microcontroller through relay. And similarly, when we deaccelerate the
regulator the speed of dc motor decreases and another dc gun is operated which
is mounted on other end of gear changing pedal to decrease the gear. And thus
through this mechanism the gear change can be done automatically.
20
DIAGRAM
21
CHAPTER VIII
DIAGRAM
22
COST ESTIMATION
23
CHAPTER VIII
COST ESTIMATION
1 Motor 1 Rs.400
2 Sensor 1 Rs.500
3 Microcontroller 1 Rs.1300
4 Relay 1 Rs.600
5 Transformer 1 RS.800
Total Rs.3600
LABOUR COST
Welding
Grinding
Power hacksaw
OVERHEAD CHARGES:
24
The overhead charges are arrived by ”manufacturing cost”
= Rs. 4800
= Rs. 1000
TOTAL COST
= Rs. 5800 /-
25
FEATURES
CHAPTER IX
26
FEATURES
Ease of use
Automatic bikes are easy to operate, especially in stop-and-go traffic, and don't
require any practice before riding.
Faster acceleration
Automatic bikes are typically faster than manual bikes due to less fuel
consumption and power generation per kilometer.
Safer to operate
Automatic motorcycles can stop quickly in confined areas and don't stall
because the computer shifts gears on its own.
Automatic bikes are ideal for beginners or those who want an easy-to-operate
bike for congested traffic conditions
27
CONCLUSION
CHAPTER X
28
CONCLUSION
After achieving the desired gear shifting technology, we ever able to get a
smooth ride in all city conditions. We have found that there is an improvement
in the fuel efficiency. This gear shifting technology has improvised the auto-
clutch featured bike into automatic transmission vehicle. The complete gear
changing mechanism has been controlled by the acceleration of the bike. The
vehicle can be used in manual mode by switching off the power supply to the
electrical components. A switch has been provided for this optional mode. The
programmed embedded ‘C’ codes, in the microcontroller, were optimized and
were the key source for changing gears in city limits as well as highways.
Maintaining aproper pulse range, as in the program, or a constant speed of the
vehicle resulted in better fuel efficiency. Fuel efficiency has been improved by
2km to 4km. After implementing this technology we have come to a conclusion
that no human operation is necessary, other than accelerating, to ride the motor
bike.
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REFERENCES
CHAPTER XI
30
REFERENCES