JAY SHRIRAM GROUP OF INSTITUTIONS AVINASHIPALAYAM, TIRUPUR.

AUTOMATIC GEAR CHANGER IN TWO WHEELERS - DC GUN MODEL PROJECT REPORT - 2012 2013

Submitted by

D.VADIVEL. ITI,DME.BE,MISTE.,
In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
IN

MECHANICAL ENGINEERING

ANNA UNIVERSITY CHENNAI.MAY2013

BONAFIDE CERTIFICATE
Certified that this project report AUTOMATIC GEAR CHANGER IN TWO WHEELERS - DC GUN MODEL is the bonafide work of

D.VADIVEL
Who carried out the project work under my supervision.

SIGNATURE

SIGNATURE Dr.R.MAGUTEESHWARAN
HEAD OF THE DEPARTMENT. Mechanical engineering Jay Shriram group of institution, Tirupur.

Prof.V.Suresh
SUPERVISOR. Mechanical engineering Jay Shriram group of institution, Tirupur

Submitted for the University Project Viva-voice held on -MAY 2013

ACKNOWLEDGEMENT
We express our deepest gratitude to our Chairman

Mr.K.M.Thangaraj, for his invaluable guidance and blessing.

We would like to thank our vice chairman

Mr.Karuppannaswamy for his unwavering support during the entire course

of this project. We are grateful to our honorable Treasurer Mr. T.Govindasamy for his kind cooperation and providing us lab facilities to work for our project. We are very grateful to our Principal Dr.C.Rameshkumar for providing us with an environment to complete our project successfully. We are deeply indebted to our Vice Principal/Head of the Department Dr.R.Maguteeswaran, who modeled us both technically and morally for achieving greater success in life. We express our sincere thanks to Mr.P.Satheesh for his constant encouragement and support throughout our course, especially for the useful suggesting given during the course of the project period. We are very grateful to our project co-coordinator Prof.V.Suresh for being instrumental in the completion of our project with his complete guidance. We also thank all the staff members of our college and technicians for their help in making this project a successful one. Finally, we take this opportunity to extend our deep appreciation to our family and friends, for all that they meant to us during the crucial times of the completion of our project.

AUTOMATIC GEAR CHANGER IN TWO WHEELERS - DC GUN MODEL

CONTENTS

CONTENTS

CHAPTER NO
SYNOPSIS LIST OF FIGURES 1 2 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 4.2 4.3 5 6 7 8 9 10 Introduction Literature review Description of equipments Spring DC Gun Tape motor U-slot sensor Relay Control unit Design and drawing Machine Components Block diagram Overall diagram Working principle Merits & demerits Applications List of materials Cost Estimation Conclusion

TITLE

Bibliography photography

LIST OF FIGURES

LIST OF FIGURES

Figure Number
1 Block diagram

TITLE

Overall diagram

SYNOPSIS

SYNOPSIS
The main objective of this concept is used to apply the gear by using automation system in automobiles. This is the new innovative model mainly used for the vehicles to control the vehicle. In this project we 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.

CHAPTER-1

INDRODUCTION

CHAPTER-1 INDRODUCTION
A motorcycle (also called a motor bicycle, motorbike, bike, or cycle) is a single-track, two-wheeled motor vehicle powered by an engine. Motorcycles vary considerably depending on the task for which they are designed, such as long distance travel, navigating congested urban traffic, cruising, sport and racing, or offroad conditions. In many parts of the world, motorcycles are among the least expensive and most widespread forms of motorized transport.

In the two wheelers the transmission is carried out by manually. This may result in fatigue during driving in cities or traffic areas.

CHAPTER-2

LITERATURE SURVEY

CHAPTER-II LITERATURE SURVEY

MOTOR CYCLE:
The first motorcycle was designed and built by the German inventors Gottlieb Daimler and Wilhelm Maybach in Bad Cannstatt in 1885. The first petroleumpowered vehicle, it was essentially a motorised bicycle, although the inventors called their invention the Reitwagen ("riding car"). However, if a two-wheeled vehicle with steam propulsion is considered a motorcycle, then the first one may have been American. One such machine was demonstrated at fairs and circuses in the eastern U.S. in 1867, built by Sylvester Howard Roper of Roxbury, Massachusetts.

In 1894, Hildebrand & Wolf Muller became the first motorcycle available for purchase. In the early period of motorcycle history, many producers of bicycles adapted their designs to accommodate the new internal combustion engine. As the engines became more powerful and designs outgrew the bicycle origins, the number of motorcycle producers increased

Until the First World War, the largest motorcycle manufacturer in the world was India, producing over 20,000 bikes per year. By 1920, this honor went to HarleyDavidson, with their motorcycles being sold by dealers in 67 countries. In 1928, DKW took over as the largest manufacturer.

After the Second World War, the BSA Group became the largest producer of motorcycles in the world, producing up to 75,000 bikes per year in the 1950s. The German company NSU Motorenwerke AG held the position of largest manufacturer from 1955 until the 1970s. NSU Sportmax streamlined motorcycle, 250 cc class winners of the 1955 Grand Prix seasonIn the 1950s, streamlining began to play an increasing part in the development of racing motorcycles and held out the possibility of radical changes to motorcycle design. NSU and Moto-Guzzi were in the vanguard of this development both producing very radical designs well ahead of their time. NSU produced the most advanced design, but because of the deaths of four NSU riders in the 19541956 seasons, they abandoned further development and quit Grand Prix motorcycle racing. Moto-Guzzi produced competitive race machines, and by 1957 nearly all the Grand Prix races were being won by streamlined machines.

From the 1960s through the 1990s, small two-stroke motorcycles were popular worldwide, partly as a result of East German Walter Kaaden's engine work in the 1950s.

Today, the Japanese manufacturers, Honda, Kawasaki, Suzuki, and Yamaha dominate the motorcycle industry, although Harley-Davidson still maintains a high degree of popularity in the United States. Apart from these high capacity motorcycles, there is a very huge market for low capacity (less then 300 cc) motorcycles, mostly concentrated in Asian and African countries. This area is dominated by mostly Indian companies with Hero Honda being the world's largest

manufacturer of two wheelers. Its Hero Honda Splendor model is the highest selling motorcycle in automotive history, having sold more then 8.5 million to date. A 2006 Honda HeroRecent years have also seen resurgence in the popularity of several other brands sold in the U.S. market, including BMW, KTM, Triumph, Aprilia, Moto-Guzzi, MV Agusta and Ducati. Outside of the U.S., these brands have enjoyed continued and sustained success, although Triumph, for example, has been re-incarnated from its former self into a modern world-class manufacturer. In overall numbers, however, the Chinese currently manufacture and sell more motorcycles than any other country and exports are rising. Additionally, the small-capacity scooter is very popular through most of the world. The Piaggio group of Italy, for example, is one of the world's largest producers of two-wheeled vehicles. All these motorcycles are conventional ones that means they use conventional energy source such as fossil fuels (petrol, diesel) which produce harmful gases such as CO2, carbon monoxide, NO, etc. which cause air pollution as well as Global warming. Keeping these facts in mind and also the possible extinction of fossil fuels in another 100 years we have to reduce the use of such fuels and look for other energy sources and here we have powered the two wheeler using electricity produced while its running on the petrol/ diesel.

The principle of conversion of electrical energy into mechanical energy by electromagnetic means was demonstrated by the British scientist Michael Faraday in 1821 and consisted of a free-hanging wire dipping into a pool of mercury. A

permanent magnet was placed in the middle of the pool of mercury. When a current was passed through the wire, the wire rotated around the magnet, showing that the current gave rise to a circular magnetic field around the wire. This motor is often demonstrated in school physics classes, but brine (salt water) is sometimes used in place of the toxic mercury. This is the simplest form of a class of electric motors called homopolar motors. A later refinement is the Barlow's Wheel. These were demonstration devices, unsuited to practical applications due to limited power.

The first real electric motor, using electromagnets for both stationary and rotating parts, was demonstrated by nyos Jedlik in 1828 Hungary. He built an electric-motor propelled vehicle in 1828.

The first English commutator-type direct-current electric motor capable of a practical application was invented by the British scientist William Sturgeon in 1832. Following Sturgeon's work, a commutator-type direct-current electric motor made with the intention of commercial use was built by the American Thomas Davenport and patented in 1837. Although several of these motors were built and used to operate equipment such as a printing press, due to the high cost of primary battery power, the motors were commercially unsuccessful and Davenport went bankrupt. Several inventors followed Sturgeon in the development of DC motors but all encountered the same cost issues with primary battery power. No electricity distribution had been developed at the time. Like Sturgeon's motor, there was no practical commercial market for these motors.

The modern DC motor was invented by accident in 1873, when Znobe Gramme connected the dynamo he had invented to a second similar unit, driving it as a motor. The Gramme machine was the first electric motor that was successful in the industry.

In 1888 Nikola Tesla invented the first practicable AC motor and with it the polyphase power transmission system. Tesla continued his work on the AC motor in the years to follow at the Westinghouse Company.

CHAPTER-3

DESCRIPTION OF EQUIPMENT

CHAPTER-III DESCRIPTION OF EQUPMENTS

3.1. SPRING

The automobile chassis is mounted on the axles not direct but through some form of springs. This is done to isolate the vehicle body from the road shocks which may be in the form of bounce, pitch, roll or sway. These tendencies give rise to an uncomfortable ride and also cause additional stress in the automobile frame and body. All the parts which perform the function of isolating the automobile from the road shocks are collectively.

A Springing device must be a compromise between flexibility and stiffness. If it is more rigid, it will not absorb road shocks efficiently and if it is more flexible it will continue to vibrate even after the bump has passed so we must have sufficient damping of the spring to prevent excessive flexing.

RETURN SPRING

A spring is a flexible elastic object used to store mechanical energy. Springs are usually made out of hardened steel. Small springs can be wound from pre-hardened stock, while larger ones. A spring is a mechanical device, which is typically used to store energy and subsequently release it, to absorb shock, or to maintain a force between contacting surfaces. They are made of an elastic material formed into the shape of a helix which returns to its natural length when unloaded this is called return spring. Springs are placed between the road wheels and the vehicle body. When the wheel comes across a bump on the road, it rises and deflects the spring, thereby storing energy therein. On releasing, due to the elasticity of the spring, material, it rebounds thereby expending the stored energy. In this way the spring starts vibrating, with amplitude decreasing gradually on internal friction of the spring material and friction of the suspension joints till vibrations die down.

3.2 D.C GUN:

INTRODUCTION:

In 1918, French inventor Louis Octave Fauchon-Villeplee invented electric cannon which bear a strong resemblance to the linear motor. He filed for a US patent on 1 April 1919, which was issued in July 1922 as patent no. 1,421,435 "Electric Apparatus for Propelling Projectiles". In his device, two parallel busbars are connected by the wings of a projectile, and the whole apparatus surrounded by a magnetic field. By passing current through busbars and projectile, a force is induced which propels the projectile along the bus-bars and into flight.

During World War II the idea was revived by Joachim Hnsler of Germany's Ordnance Office, and an electric anti-aircraft gun was proposed. By late 1944 enough theory had been worked out to allow the Luftwaffe's Flak Command to issue a specification, which demanded a muzzle velocity of 2,000 m/s (6,600 ft/s) and a projectile containing 0.5 kg (1.1 lb) of explosive. The guns were to be mounted in batteries of six firing twelve rounds per minute, and it was to fit existing 12.8 cm FlaK 40 mounts. It was never built. When details were discovered after the war it aroused much interest and a more detailed study was carried out, culminating in a 1947 report which concluded that it was theoretically

feasible, but that each gun would need enough power to illuminate half of Chicago

CONSTRUCTION:

A railgun consists of two parallel metal rails (hence the name) connected to an electrical power supply. When a conductive projectile is inserted between the rails (from the end connected to the power supply), it completes the circuit. Electrons flow from the negative terminal of the power supply up the negative rail, across the projectile, and down the positive rail, back to the power supply.

This current makes the railgun behave similar to an electromagnet, creating a powerful magnetic field in the region of the rails up to the position of the projectile. In accordance with the right-hand rule, the magnetic field circulates around each conductor. Since the current is in opposite direction along each rail, the net magnetic field between the rails (B) is directed vertically. In combination with the current (I) across the projectile, this produces a Lorentz force which accelerates the projectile along the rails. There are also forces acting on the rails attempting to push them apart, but since the rails are firmly mounted,

they cannot move. The projectile slides up the rails away from the end with the power supply.

A very large power supply providing, on the order of, one million amperes of current will create a tremendous force on the projectile, accelerating it to a speed of many kilometres per second (km/s). 20 km/s has been achieved with small projectiles explosively injected into the railgun. Although these speeds are theoretically possible, the heat generated from the propulsion of the object is enough to rapidly erode the rails. Such a railgun would require frequent replacement of the rails, or use a heat resistant material that would be conductive enough to produce the same effect.

CONSIDERATIONS IN RAILGUN DESIGN MATERIALS

The rails and projectiles must be built from strong conductive materials; the rails need to survive the violence of an accelerating projectile, and heating due to the large currents and friction involved. The recoil force exerted on the rails is equal and opposite to the force propelling the projectile. The seat of the recoil force is still debated. The traditional equations predict that the recoil force acts on the breech of the railgun. Another school of thought invokes Ampre's force law and asserts that it acts along the length of the rails (which is their strongest axis). The rails also repel themselves via a sideways force caused by the rails being pushed by the magnetic field, just as the projectile is. The rails need to survive this without bending, and must be very securely mounted.

DESIGN CONSIDERATIONS

The power supply must be able to deliver large currents, sustained and controlled over a useful amount of time. The most important gauge of power supply effectiveness is the energy it can deliver. As of February 2008, the largest known energy used to propel a projectile from a railgun

was 32 million joules.. The most common forms of power supplies used in railguns are capacitors and compulsators. The rails need to withstand enormous repulsive forces during firing, and these forces will tend to push them apart and away from the projectile. As rail/projectile clearances increase, arcing develops, which causes rapid vaporization and extensive damage to the rail surfaces and the insulator surfaces. This limited some early research railguns to one shot per service interval.

The inductance and resistance of the rails and power supply limit the efficiency of a railgun design. Currently different rail shapes and railgun configurations are being tested, most notably by the United States Navy, The Institute for Advanced Technology, and BAE Systems.

HEAT DISSIPATION

Massive amounts of heat are created by the electricity flowing through the rails, as well as the friction of the projectile leaving the device. The heat created by this friction itself can cause thermal expansion of the rails and projectile, further increasing the frictional heat. This leads to three main problems: melting of equipment, safety of personnel, and detection by enemy forces. As briefly discussed above,

the stresses involved in firing this sort of device require an extremely heat-resistant material. Otherwise the rails, barrel, and all equipment attached would melt or be irreparably damaged.

In practice the rails are, with most designs of railgun, subject to erosion due to each launch; and projectiles can be subject to some degree of ablation also, and this can limit railgun life, in some cases severely.

MATHEMATICAL FORMULA In relation to railgun physics, the magnitude of the force vector can be determined from a form of the Biot-Savart Law and a result of the Lorentz force. It can be expressed mathematically in terms of the permeability constant (0), the radius of the rails (which are assumed to be circular in cross section)(r), the distance between the counterpoints of the rails(d) and the current in amps through the system (I) as follows

The formula is based on the assumption that the distance(l) between the point where the force (F) is measured and the beginning of the rails is greater than the separation of the rails (d) by a factor of about 3 or 4 (l > 3d). Some other simplifying assumptions have also been

made; to describe the force more accurately, the geometry of the rails and the projectile must be taken into consideration.

RAIL GUN:

Railguns are being pursued as weapons with projectiles that do not contain explosives, but are given extremely high velocities: 3500 m/s (11,500 ft/s, approximately Mach 10 at sea level) or more (for comparison, the M16 rifle has a muzzle speed of 930 m/s, or 3,000 ft/s), which would make their kinetic energy equal or superior to the energy yield of an explosive-filled shell of greater mass. This would allow more ammunition to be carried and eliminate the hazards of carrying explosives in a tank or naval weapons platform. Also, by firing at higher velocities railguns have greater range, less bullet drop and less wind drift, bypassing the inherent cost and physical limitations of conventional firearms - "the limits of gas expansion prohibit launching an unassisted projectile to velocities greater than about 1.5 km/s and ranges of more than 50 miles [80 km] from a practical conventional gun system."

If it were possible to apply the technology as a rapid-fire automatic weapon, a railgun would have further advantages in increased rate of fire. The feed mechanisms of a conventional firearm must move to

accommodate the propellant charge as well as the ammunition round, while a railgun would only need to accommodate the projectile. Furthermore, a railgun would not have to extract a spent cartridge case from the breech, meaning that a fresh round could be cycled almost immediately after the previous round has been shot.

RESISTANCE

Electrical resistance is a major limitation because when dumping large amounts of electrical energy into a conductor the majority of the energy is converted to heat due to resistance and therefore effectively lost as it is not driving the projectile. This could be overcome through the use of a superconducting material.

ENERGY DISSIPATION

The coils have an electrical resistance, and resistive losses are often very significant indeed.

The energy in the magnetic field itself does not simply dissipate; much of it returns to the capacitor when the electric current is decreasing. Unfortunately it does this in the reverse direction (via a 'ringing' mechanism due to inductance of the coils), which can seriously damage polarized capacitors (such as electrolytics).

In the circuit the magnetic field keeps the current in the coil flowing after the capacitor has discharged, so that it keeps discharging and

builds up a negative voltage (see Lenz's law). This is similar to an LC oscillator.

The capacitor charging to a negative voltage can be prevented by placing a diode across the capacitor terminals.

Some designs bypass this limitation by using couple of diodes. Then, diodes reverse polarity to charge capacitors instead with proper polarity again, effectively re-using remaining coil energy.

A coilgun is a type of synchronous linear electric motor which is used as a projectile accelerator that consists of one or more electromagnetic coils. These are used to accelerate a magnetic projectile to high velocity. The name Gauss gun is sometimes used for such devices in reference to Carl Friedrich Gauss, who formulated mathematical descriptions of the electromagnetic effect used by magnetic accelerators.

Coilguns consist of one or more coils arranged along the barrel that are switched in sequence so as to ensure that the projectile is accelerated quickly along the barrel via magnetic forces. Coilguns are distinct from railguns, which pass a large current through the projectile or

sabot via sliding contacts. Coilguns and railguns also operate on different principles.
ELCTRO MAGNATIC GUN DETAILS:

While playing with my can crusher, I noticed that a can placed off center tended to be pushed out of the solenoid. A little searching of the patent literature convinced me that I had inadvertently created a very poor, single stage, coil gun. Presented below is a summary of what I have found so far.

Propellant powered guns are typically limited to muzzle velocities on the order of 2,000 meters per second. This limit is inherent to the use of expanding gas to drive the projectile down a barrel. Barrels simply can't withstand the temperatures and pressures required for higher expansion rates of the propellant combustion products (normally CO2 and NOx). One attempt at a gun for higher velocities used differential pistons (a large one, driven by methane/oxygen combustion, connected to a small one for compression of the drive gas) to provide a high pressure of hydrogen gas (hydrogen is the lightest, and hence fastest expanding, of all gasses). While some success was achieved, the apparatus was cumbersome and the velocities were still limited. For some applications, particularly orbital launching, this is insufficient (earth escape velocity is 11,200 m/s).

Two basic types of electromagnetic gun are described in the patent literature, the rail gun and the coil gun. Both use stored energy sources to produce a large magnetic field and a high electric current through a driving armature. The interaction of the current with the magnetic field generates a force which propels the armature

(and any projectile connected to it). Beyond that, they differ substantially, and each has practical difficulties which has prevented them from being more than laboratory curiosities.

3.3 TAPE MOTOR

An audio tape recorder, tape deck, reel-to-reel tape deck, cassette deck or tape machine is an audio storage device that records and plays back sounds, including articulated voices, usually using magnetic tape, either wound on a reel or in a cassette, for storage. It its present day form, it records a fluctuating signal by moving the tape across a tape head that polarizes the magnetic domains in the tape in proportion to the audio signal. ELECTRICAL Electric current flowing in the coils of the tape head creates a fluctuating magnetic field. This causes the magnetic material on the tape, which is moving past and in contact with the head, to align in a manner proportional to the original signal. The signal can be reproduced by running the tape back across the tape head, where the reverse process occurs the magnetic imprint on the tape induces a small current in the read head which approximates the original signal and is then amplified for playback. Many tape recorders are capable of recording and playing back at once by means of separate record and playback heads in line or combined in one unit. MECHANICAL Modern professional recorders usually use a three-motor scheme. One motor with a constant rotation speed drives the capstan. This, usually combined with a

rubber pinch roller, ensures that the tape speed does not fluctuate. Of the other two motors, one applies a very light torque to the supply reel, and the other a greater torque to the take-up reel, to maintain the tape's tension. During fast winding operation the pinch roller is disengaged and the reel motors provide the necessary power. The cheapest models use a single motor for all required functions; the motor drives the capstan directly and the supply and take-up reels are loosely coupled to the capstan motor with slipping belts or clutches. There are also variants with two motors, in which one motor is used for rewinding only.

Specifications 1. High quality, low price. 2. Long life, low noise. 3. OEM, new design. 4. Smooth and quiet operation. Typical applications: 1) Cassette Tape recorder 2) Audio 3) Other industrial equipment Packing: 200pcs/carton Volume: 0.029cbm N.W.: 15.5kg G.W.: 16.0kg

Specifications: Technical Characteristic(only for reference, we are capable of meeting the sourcing needs of diverse buyer).

3.4 U-SLOT SENSOR:

The slot sensors are U-shaped and the active face is located between the two arms. The sensor is actuated when an object passes the slot. Slot sensors detect laterally approaching targets reliably, regardless of their distance to the active face.

Slot sensors, sometimes called optical fork sensors because of their "forked" shape, detect objects that pass between the two armsone with the emitter, the other with the receiver. The fixed slot width provides reliable opposed-mode sensing of objects as small as 0.30 mm. The ultra-small PM series of u-shaped photoelectric sensors provides a wide range of 29 different models to suit any of your application needs. With the industry's smallest size, the PM series plays a key role in the miniaturization of your equipment. All models are equipped with two outputs, one for Light-ON and the other for Dark-ON sensing. This increases the versatility of the sensor for use in existing applications. The series is also available in a connector type to maximize ease of installation and allow for wire replacement if the cable is severed. The PM series conforms to the European EMC Directive and carries UL Recognition.

BGL Series

The BGL series of photoelectric slot sensors offer laser-like accuracy with highly visible red LED or Class II laser emission for resolutions down to 0.3mm. These self-contained thru beam sensors, configured in a simple U shaped housing, save mounting and machine setup time. Typical thru-beam fiber optic applications can be solved using BGL slot sensors, saving installation time and cost. Since the BGL slot sensor is completely self-contained, it replaces the two thru-beam cables and the fiber optic amplifier, eliminating the need for special mounting brackets.

FEATURES
Highly visible emission Extremely rugged single piece metal housing High resolution Light/Dark operation selectable High switching frequency Adjustable sensitivity M8 connection with 3600 LED indicator

APPLICATIONS
Parts sensing on conveyer rails and conveying belts Label discrimination with transparent substrates Parts dimension verification Parts counting in assembly lines Tool break monitoring Position verification

 Feed verification on automatic assembly equipment Checking for complete count Level monitoring in tanks Handling and assembly technology

With opposed mode sensing pairs in U-shaped housings Banner SL10 & SL30 Series Slot Sensors are ideal for sensing of color marks on clear film.

Holds easy-to-use opposed mode sensor pairs in rugged U-shaped housing Available with 10 mm sensing slot (SL10 models) or 30 mm sensing slot (SL30 models)

Ideal for detecting registration marks, holes or gear teeth; edge guiding; and counting

Features molded-in beam guides to simplify installation and alignment Offers fixed sensitivity, 4-turn manual sensitivity adjustment or push-button programming, depending on model

Uses either visible red or infrared sensing beam, depending on model

If you are looking for Banner Slot Sensors, please call us on (800) 894 - 0412 or email us at [email protected] we will do our best to help you find the Banner SLM Series Sensor that you are looking for at the most competitive prices possible. If you are searching for Banner C-GAGE Label Sensors technical information (data-sheets) please use the Banner Datasheets OR Product Selection Guide page links.

The SR31 series is composed of slot sensors with infrared LED emission, distinguished by an elevated 10 kHz switching frequency and by a sturdy and compact metal housing. The detection sensitivity is adjusted by means of a trimmer. The dark/light operating mode is configured according to the connection. The series includes M8 connector versions with NPN output, or PNP output; cable versions present both NPN/PNP outputs. The SR31 sensors have a 30 mm wide and 42 mm deep slot. These sensors are suitable for detecting opaque labels on a transparent support, to control material presence and continuity, to detect synchronism pulses on toothed or holed wheels, or as on-off edge guide.

Infrared LED emission Sensitivity trimmer adjustment Elevated switching frequency Metal housing with wide slot

3.5 RELAY
A relay is an electrically operated switch. Current flowing through the coil of the relay creates a magnetic field which attracts a lever and changes the switch contacts. The coil current can be on or off. So relays have two switch positions and they are double throw (changeover)

switches. Relays allow one circuit to switch a second circuit which can be completely separate from the first. The link is magnetic and mechanical. The coil of a relay passes a relatively large current,

typically 30mA for a 12V relay, but it can be as much as 100mA for relays designed to operate from lower voltages. Most ICs (chips) cannot provide this current and a transistor is usually used to amplify the small IC current to the larger value required for the relay coil. The maximum output current for the popular 555 timer IC is 200mA so these devices can supply relay coils directly without amplification. Relays are usually SPDT or DPDT but they can have many more sets of switch contacts, for example relays with 4 sets of changeover contacts are readily available. Most relays are designed for PCB mounting but you can solder wires directly to the pins providing you take care to avoid melting the plastic case of the relay. The animated picture shows a working relay with its coil and switch contacts. You can see a lever on the left being attracted by magnetism when the coil is switched on. This lever moves the switch contacts. There is one set of contacts (SPDT) in the foreground and another behind them, making the relay DPDT.

3.6 CONTROL UNIT:

MICROCONTROLLER: INTRODUCTION: Microcontrollers are destined to play an increasingly important role in revolutionizing various industries and influencing our day to day life more strongly than one can imagine. Since its emergence in the early 1980's the microcontroller has been recognized as a general purpose building block for intelligent digital systems. It is finding using diverse area, starting from simple children's toys to highly complex spacecraft. Because of its versatility and many advantages, the application domain has spread in all conceivable directions, making it ubiquitous. As a consequence, it has generate a great deal of interest and enthusiasm among students, teachers and practicing engineers, creating an acute education need for imparting the knowledge of microcontroller based system design and development. It identifies the vital features responsible for their tremendous impact, the acute educational need created by them and provides a glimpse of the major application area.

MICROCONTROLLER: A microcontroller is a complete microprocessor system built on a single IC. Microcontrollers were developed to meet a need for microprocessors to be put into low cost products. Building a complete microprocessor system on a single chip substantially reduces the cost of building simple products, which use the microprocessor's power to implement their function, because the microprocessor is a natural way to implement many products. This means the idea of using a

microprocessor for low cost products comes up often. But the typical 8-bit microprocessor based system, such as one using a Z80 and 8085 is expensive. Both 8085 and Z80 system need some additional circuits to make a microprocessor system. Each part carries costs of money. Even though a product design may requires only very simple system, the parts needed to make this system as a low cost product. To solve this problem microprocessor system is implemented with a single chip microcontroller. This could be called microcomputer, as all the major parts are in the IC. Most frequently they are called microcontroller because they are used they are used to perform control functions. The microcontroller contains full implementation of a standard

MICROPROCESSOR, ROM, RAM, I/0, CLOCK, TIMERS, and also SERIAL PORTS. Microcontroller also called "system on a chip" or "single chip microprocessor system" or "computer on a chip". A microcontroller is a Computer-On-A-Chip, or, if you prefer, a single-chip computer. Micro suggests that the device is small, and controller tells you that the device' might be used to control objects, processes, or events. Another term to describe a microcontroller is embedded controller, because the microcontroller and its support circuits are often built into, or embedded in, the devices they control. Today microcontrollers are very commonly used in wide variety of intelligent products. For example most personal computers keyboards and implemented with a microcontroller. It replaces Scanning, Debounce, Matrix Decoding, and Serial transmission circuits. Many low cost products, such as Toys, Electric Drills,

Microwave Ovens, VCR and a host of other consumer and industrial products are based on microcontrollers.

Microcontroller is a general purpose device, which integrates a number of the components of a microprocessor system on to single chip. It has inbuilt CPU, memory and peripherals to make it as a mini computer. A microcontroller combines on to the same microchip:

The CPU core Memory(both ROM and RAM) Some parallel digital i/o

Microcontrollers will combine other devices such as: A timer module to allow the microcontroller to perform tasks for certain time periods. A serial i/o port to allow data to flow between the controller and other devices such as a PIC or another microcontroller. An ADC to allow the microcontroller to accept analogue input data for processing.

Microcontrollers are: Smaller in size Consumes less power Inexpensive

Micro controller is a stand alone unit, which can perform functions on its own without any requirement for additional hardware like i/o ports and external memory. The heart of the microcontroller is the CPU core. In the past, this has traditionally been based on a 8-bit microprocessor unit. For example Motorola uses a basic 6800 microprocessor core in their 6805/6808 microcontroller devices. In the recent years, microcontrollers have been developed around specifically designed CPU cores, for example the microchip PIC range of microcontrollers.

CHAPTER-4

DESIGN AND DRAWING

CHAPTER-4 DESIGN AND DRAWING

4.1 MACHINE

COMPONENTS

The automatic gear changer in two wheelers- DC gun model is consists of the following components to full fill the requirements of complete operation of the machine.

Tape motor U-Slot sensor Control unit DC gun Spring to Gear Box

DRAWING

4.2 BLOCK DIAGRAM

4.3 DRAWING FOR AUTOMATIC GEAR CHANGER IN TWO WHEELERS - DC GUN MODEL

CHAPTER -5

WORKING PRINCIPLE

CHAPTER-V WORKING PRINCIPLE

Here we have two dc gun arrangements which are arranged on either side of the vehicle pedal rest for applying the gear. The dc gun is fixed at the end of the flat pedal rest. The plate rest has pivot at the center. The guns are operated with the help of electric power supply and it is controlled by the control unit. One of the guns 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. For this purpose, here we are using a tape motor with a U slot sensor such that the speed can be varied through the tape motor. Depending up on the signal the clutch and gears will automatically changed with the help of the control unit. When the vehicle speed increases automatically the clutch and the gear will change in the vehicles. The arrangement is clearly shown in the below diagram.

CHAPTER -6

MERITS AND DEMERITS

CHAPTER-VI MERITS AND DEMERITS

MERITS

Automatic method Quick response is achieved Simple in construction Easy to maintain and repair Cost of the unit is less Continuous operation is possible without stopping

DEMERITS We need to alter gear shifter which may increase the vehicles weight and will reduce the drivers comfort.

CHAPTER -7

APPLICATIONS

CHAPTER-VII APPLICATIONS

It is applicable in all types of two wheelers which has gear transmission.

CHAPTER-8

LIST OF MATERIALS

CHAPTER-VIII LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS The various factors which determine the choice of material are discussed below.

1. Properties:

The material selected must posses 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 a. Physical b. Mechanical c. From manufacturing point of view d. Chemical The various physical properties concerned are melting point, thermal Conductivity, specific heat, coefficient of thermal expansion, specific gravity, electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile, Compressive shear, bending, torsional and buckling load, fatigue resistance, impact

resistance, eleastic limit, endurance limit, and modulus of elasticity, hardness, wear resistance and sliding properties.

The various properties concerned from the manufacturing point of view are,

Cast ability Weld ability Surface properties Shrinkage Deep drawing etc.

2. Manufacturing case:

Sometimes the demand for lowest possible manufacturing cost or surface qualities obtainable by the application of suitable coating substances may demand the use of special materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately the material. For example, it would never be desirable to go casting of a less number of components which can be fabricated much more economically by welding or hand forging the steel.

4. Availability of Material:

Some materials may be scarce or in short supply. It then becomes obligatory for the designer to use some other material which though may not be a perfect substitute for the material designed. the delivery of materials and the delivery date of product should also be kept in mind.

5. Space consideration:

Sometimes high strength materials have to be selected because the forces involved are high and space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of material plays an important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-maintenance of the designed part are involved in the selection of proper materials.

CHAPTER-9

COST ESTIMATION

CHAPTER-IX COST ESTIMATION

1. LABOUR COST: Lathe, drilling, welding, grinding, power hacksaw, gas cutting cost 2. OVERGHEAD CHARGES: The overhead charges are arrived by manufacturing cost Manufacturing Cost =Material Cost +Labour Cost =6000+1200 =7200 Overhead Charges =20%of the manufacturing cost =2000 3. TOTAL COST: Total cost = Material Cost +Labour Cost +Overhead Charges

Total cost for this project =6000+1200+2000=9200

CHAPTER-10

CONCLUSION

CHAPTER-X CONCLUSION

The project carried out by us made an impressing task in the field of automobile department. It is very useful for driver while drive the vehicle at any places without any tension.

This project has also reduced the cost involved in the concern. Project has been designed to perform the entire requirement task which has also been provided.

BIBLIOGRAPHY

BIBLIORAPHY
1. Design data book -P.S.G.Tech.

2.

Machine tool design handbook Central machine tool Institute, Bangalore.

3. Strength of Materials

- R.S.Kurmi

4. Manufacturing Technology - M.Haslehurst.

5. Design of machine elements- R.s.Kurumi