Switch Operated Gear Shifting Mechanism November 2018

CHAPTER 1
INTRODUCTION

This project aims at developing a very easy mechanism of an electromagnetic

shift arrangement for a transmission with gear wheels arranged on a gear shift rotatable
about an axis, which will make the motor bike riders gear shifting very easy. Everyone is
desired for the smooth running of their vehicles, what so ever may be the speed of pickup
of the vehicle a person is operating, but one of the most important system which every
engineer concern about in vehicles is the gear shifting system for ensuring smooth and
desired ride on their two wheelers. Automotive technology has been developed in many
areas, like ABS system, active steering system and other safety systems, which are
implemented to increase the passenger safety and comfort. The development has
concluded also the gearbox, which became much smoother and produces less noise. Gear
shifting mechanism must be easy to use and workable, these demands are very important
especially for physically challenged and special needs people. For some drivers, the gear
shifting can cause some confusing at driving specially at critical situations. A crowded
road on a hill or a sudden detour makes a lot of tension on the driver. so, our project is
determined to give rider a hassle free ride

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NMIT Kanhangad Department of ME
Switch Operated Gear Shifting Mechanism November 2018

CHAPTER 2
METHEDOLOGY

When a gear shifting-up of an automatic transmission is to be effected, the load

applied by the load device is increased, or the load is connected to an output rotation shaft
of the engine via a selectively-connecting device, thereby reducing the rotational speed of
the output rotation shaft of the engine to a required level. In this work, two
electromagnetic coils are coupled to the gear rod of the two ends. The two buttons are
used to activate the electro-magnetic coils so that the gear will be shifted.
Automotive technology has been developed in many areas, like ABS system,
active steering system and other safety systems, which are implemented to increase the
passenger safety and comfort. The development has concluded also the gearbox, which
became much smoother and produces less noise. Gear shifting mechanism must be easy
to use and workable, these demands are very important especially for small cars used by
special needs people. For some drivers, the gear shifting can cause some confusing at
driving specially at critical situations. A crowded road on a hill or a sudden detour makes
a lot of tension on the driver. One of the difficulties in this situation is to choose the right
reduction ratio and engaging it at the right time.

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Switch Operated Gear Shifting Mechanism November 2018

Figure 1 Working model

Figure 2 Solenoid Plunger Diagram

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NMIT Kanhangad Department of ME
Switch Operated Gear Shifting Mechanism November 2018

CHAPTER 3
COMPONENTS USED
3.1. Engine & Gearbox

Table 1 : Engine Specifications

ENGINE Hero Honda Passion bike

NO OF CYLINDERS 1

CAPACITY 97.2CC

MAX TORQUE 8.05NM

POWER 8.2BHP

Table 2 : Gear box Specification

TRANSMISSION TYPE MANUAL

GEAR BOX TYPE SEQUENTIAL

NUMBER OF GEARS 4

DRIVE CHAIN

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Switch Operated Gear Shifting Mechanism November 2018

3.2. Servo Motor

A servomotor is a rotary actuator or linear actuator that allows for precise control
of angular or linear position, velocity and acceleration. It consists of a suitable motor
coupled to a sensor for position feedback. It also requires a relatively sophisticated
controller, often a dedicated module designed specifically for use with servo motors . The
motor is paired with some type of encoder to provide position and speed feedback. In the
simplest case, only the position is measured. The measured position of the output is
compared to the command position, the external input to the controller. If the output
position differs from that required, an error signal is generated which then causes the
motor to rotate in either direction, as needed to bring the output shaft to the appropriate
position. Servomotors are used in applications such as robotics, CNC machinery or
automated manufacturing.

Figure 3 : Servo Motor

Table 3 : Servo Motor Specification
OPERATING VOLTAGE 5V

TORQUE 1.8Nm

OUTPUT ANGLE 180°

OPERATING SPEED 0.19Sec/60°

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Switch Operated Gear Shifting Mechanism November 2018

3.3. Arduino
Arduino board designs use a variety of microprocessors and controllers. The
boards are equipped with sets of digital and analog input/output (I/O) pins that may be
interfaced to various expansion boards and other circuits. The boards feature serial
communications interfaces, including Universal Serial Bus (USB) on some models, which
are also used for loading programs from personal computers. The microcontrollers are
typically programmed using a dialect of features from the programming languages C and
C++. In addition to using traditional compiler tool chains, the Arduino project provides an
integrated development environment (IDE) based on the Processing language project.

Figure 4 : Arduino UNO

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NMIT Kanhangad Department of ME
Switch Operated Gear Shifting Mechanism November 2018

3.4. Potentiometer

A Potentiometer is a three- terminal resistor with a sliding or rotating contact that

forms an adjustable voltage divider. If only two terminals are used, one end and the
wiper, it acts as a variable resistor. There are a number of terms in the electronics industry
used to describe certain types of potentiometers:
Slide pot or slider pot: a potentiometer that is adjusted by sliding the wiper left or
right (or up and down, depending on the installation), usually with a finger or thumb
Thumb pot or thumbwheel pot: a small rotating potentiometer meant to be
adjusted infrequently by means of a small thumbwheel.
Trimmer pot: a trimmer potentiometer typically meant to be adjusted once or
infrequently for "fine-tuning" an electrical signal

Table 4 Potentiometer Specification

TYPE ROTARY
ELECTRICAL ANGLE 170°
RESISTANCE 5KΩ
APPLIED VOLTAGE <12V
OPERATING TEMPERATURE -55° to +125°
SHAFT STARTING TORQUE 60gm-cm
WEIGHT 38gm

Figure 5 : Rotary Potentiometer

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NMIT Kanhangad Department of ME
Switch Operated Gear Shifting Mechanism November 2018

3.5. Solenoid Plunger

Electromechanical solenoids consist of an electromagnetically inductive coil wound

around a movable steel or iron slug called the armature, or plunger. Solenoid coils need
more current only during actuation, called the pull in current, to pull the plunger into the
solenoid. However once the solenoid is actuated, the solenoid coil needs approximately
30% of its nominal current, called the hold current, to keep the plunger in the same
position. Solenoid coils operating with nominal current consistently raise the temperature
in the coil due to higher power dissipation. Once the plunger movement is detected, the
steady state current can be reduced to the hold current value to minimize the power
dissipation in the solenoid. The detection of the plunger movement is required to ensure
the proper operation of the valve, relays or contactors

Figure 6 : Solenoid Plunger

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NMIT Kanhangad Department of ME
Switch Operated Gear Shifting Mechanism November 2018

3.6. Mofset

The metal-oxide-semiconductor field-effect transistor (MOSFET, MOS-FET, or

MOS FET) is a type of field-effect transistor (FET), most commonly fabricated by the
controlled oxidation of silicon. It has an insulated gate, whose voltage determines the
conductivity of the device.

Figure 7 : Mofset

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NMIT Kanhangad Department of ME
Switch Operated Gear Shifting Mechanism November 2018

CHAPTER 4
WORKING

4.1. Working Process

All the components are connected to arduino board which is programmed

according to the working of this system. When throttle increases the current in the
potentiometer also increases and viceversa.
To shift gear we usually reduce the speed, and the current in the potentiometer
reduces , this signal is feed into the arduino and it activates the servomotor
The servo motor disengages the clutch by its linear movement.
This above mentioned process happens in micro seconds. After these process
switch is pressed and this signal is feed in to the arduino and arduino operates the
solenoid plunger through mofset.
The solenoid plunger inturn pulls the gear liver according to the switch , if the
gear up switch is pressed the plunger pulls the right liver and reaches the required gear , if
the gear down switch is pressed the plunger pulls left liver. There is two plungers attached
one at left and other at right liver
Though these process looks complicated these process happens in micro seconds.
The rider has only to reduce the throttle and press the required button, the gear
will be changed and he can go back to the previous speed.
Arduino is programmed for sensing the current in the potentiometer, sense the
switch pressed , to activate the servo motor , and to activate solenoid plunger.

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Switch Operated Gear Shifting Mechanism November 2018

Figure 8 : Working circuit

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NMIT Kanhangad Department of ME
Switch Operated Gear Shifting Mechanism November 2018

CHAPTER 5
CALCULATIONS

5.1. Force Exerted by Plunger

Relative permeability of air and coil: - 1

Current density in coil: - 1*106 Amp. / m2
Cross-sectional area of coil = Height * Width= 0.04*0.011= 4.4*10-4 m2
Let,Ampere turn density (ATD) = Current density (I)
Current density = 1*106 A/m2
Ampere turn (AT) = Ampere turn density*Area of coil = 1*106 * 4.4*10-4=440
Hg = AT/g = 440/0.002=2,20,000 Amp./Meter
Where, g is air gap distance
Bg = μo* Hg = 4π * 10-7 * 220,000=0.276 Tesla
Force exerted on plunger fe = 0.5*(Bg/μo)*A
Where, A is plunger cross sectional area= π / 4 * d2 = π / 4 * (0.025)2=4.9 * 10-4 m2
fe = 0.5 * (0.276 / 4π * 10-7) * 4.9 * 10-4 , fe = 54 N

Figure 9 : Solenoid Plunger Dimension

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Switch Operated Gear Shifting Mechanism November 2018

Figure 10 : Solenoid Gear Shifting Mechanism

*All dimensions in mm
Torque on gear shaft
From front = 54 * 0.09 = 4.86 Nm
From rear lever =54 * 1.10 =5.94 Nm

5.2. Minimum Force on Selector Shaft

Minimum torque on gear shaft = 4.86 Nm

Length of lever attached to the other end of gear shaft = 45mm = 0.045 m
Lever of gear shaft applies force on selector shaft
Force at the end of lever = Flever = Torque on gear shaft / Length of lever
Flever = 4.86 / 0.045 = 108 N
Thus, min. Force on selector shaft is 108N.

5.3. Torque Applied on Clutch Disengaging Shaft

Torque of motor = 1.5 Nm

Length of lever = 0.035 mm
Force on lever attached to motor =1.5/0.035 = 42.65 N
Length of lever attached to disengaging shaft = 40 mm = 0.04 m
Force on lever = 42.65 N
Torque on Shaft = 42.85 * 0.04 = 1.71 Nm

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Switch Operated Gear Shifting Mechanism November 2018

CHAPTER 6
RESULTS

Table 5 : Results
AMPERE TURN 440

FORCE EXERTED ON PLUNGER 54N

TORQUE ON FRONT END 4.86Nm

TORQUE ON REAR END 5.84Nm

TORQUE AT THE END OF LEVER 108N

FORCE ON LEVER ATTACHED TO 42.62N
MOTOR
TORQUE ON SHAFT 1.71Nm

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Switch Operated Gear Shifting Mechanism November 2018

CHAPTER 7
ADVANTAGES AND DISADVANTAGES

7.1. Advantages

 Seamless shift gearboxes.

 The driver is not required to manually operate the clutch.
 The driver is not required to lift off the accelerator when changing up through the
gears.
 The driver suffers from no loss of drive.
 Fuel efficient.
 Simple driving control.
 Less fatigue to driver.
 Noiseless gear shifting.
 No shocks or jerky during driv

7.2. Disadvantages

 In case of slopes the bike can only move in neutral

 Errors in circuit may lead to accident

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Switch Operated Gear Shifting Mechanism November 2018

CHAPTER 8
CONCLUSION

From this project we can reduce the difficulty in changing the gear with our legs
and disengaging the clutch etc. the rider will get more riding comfort he just has to
decelerate and press the switch to shift gear.
It will help in heavy traffic situations and sudden gear changing situations like
hump or when passing through a pit.
The switch operated gear changing mechanism is more reliable and efficient gear
changing mechanism and very easy to use.

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Switch Operated Gear Shifting Mechanism November 2018

REFERENCES

[1] P.L. Kohli, Head, Department of Automotive Engineering, G B Pant Polytechnic,

New Delhi, “Automotive Electrical Equipment.”

[2] Dr. Kripal Singh, Professor and Head (Retd.) Mechanical Engineering Dept., Punjab
Engineering College, Chandigarh, “Automotive Transmission.”

[3] www.mechengg.com

[4] www.howstuffworks.com

[5] D. Mangeelal, Associate Professor, Dept. Of Mechanical Engineering, I.B. Institute of

Engineering & Technology, “Button Operated Electromagnetic Gear Shifting System.”

[6] Manoj Rajpara, Department of Mechanical Engineering, Smt. S.R. Patel Engineering
College, Dabhi, Unjha “Button Operated Gear Changing System for Two Wheeler

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