CHAPTER 1

ABSTRACT
In the present world of automobile, gear shifting system are manually and automatic. Gear
shifting system is important in automobile to vary the speed. So automatic gear shifting system
is costly than manually gear shifts system but manually gear shifting system is difficult to
understand for handicap people or it take physical effort to change gear. By applying this gear
shifting system it gives cost reduction in compare of automatic gear shift system and flexible or
simple then manually gear shift system, and by applying this system on automobile it’s easier to
drive two wheeler for everyone. It also reduces the possibility of transmission error of manual
gear system. The purpose of this research is to reduce physical effort of human being and they
can concentrate only in driving and prevent the accidents. In present report we studied literature
review based on this review we define transmission system and gear shifting mechanism to
modify a manual gear shifting mechanism.

1
 CHAPTER 2
INTRODUCTION
In our developed system, both the gear and the clutch are controlled electromechanically by a
microcontroller-based computer system. This system does not require any modification to the
engine. The equipment is mounted externally on the body of the motorcycle. The system shifts
the gear up and down electro-mechanically like a human rider by sensing the speed of the
vehicle, but the system shifts the gear at exactly the correct speed, which produces the smooth
gear changing sequence. This system is different than the traditional automatic transmission used
in cars, because it uses manipulators/electro-mechanical devices, which act similar to the human
foot pressing the gear pedal up and down, and pressing the clutch lever like a human hand.
Automatic gear shifting can be divided into three bases on the mechanism of actuators used
Electro mechanical, Pneumatic and Hydraulic.

2
 CHAPTER 3

LITARATURE SURVEY

Manual transmission is most popular among two wheelers, in which gear can be selected
according to road load and driving conditions. It requires human effort, accuracy and skill to
select particular gear under different conditions. Under city driving condition, it is difficult to
shift the gear frequently while negotiating traffic. The shifting effort and shifting frequency
differs with different age group and genders. It may lead to higher fuel consumption and wear
and tear of the gear if it is not properly operated. To overcome these difficulties alternative
arrangement is essential and one such option is the push button operated gear shifting
mechanism. This kind of gear shifting mechanism is very in two wheelers for special purpose
vehicles. Working prototype of the push button operated gear shifting mechanism has been tested
for its functionality for the entire range of gear shifting. It can be easily incorporated to four
wheelers for shifting gears with minimum alternations and the gear position can be displayed. As
further improvement, the output speed of the gear box can be measured and used as an input for
transmission control.

a):- Paper work 1 :-

Haj Fraj 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.

b):- Paper work 2 :-

Paul D. Walker Presents original research on the response of DCT equipped power trains to
synchronizer mechanism engagement process with and without engine harmonic induced
vibration. The integral design and operation of dual clutch transmissions exposes synchronizer
mechanisms to new sources of vibration during actuation. Traditional manual transmissions

3
release the clutch before synchronization begins, isolating the synchronizer from forced engine
vibration.

c):- Paper work 3 :-

Ferran Reverter Proposed this paper that analyses the accuracy and resolution of direct resistive
sensor-to-microcontroller interfaces using theoretical and experimental methods.

d):- Paper work 4 :-

D. J. Rafiee Present this paper to introduce an automatic feature extraction system for gear and
bearing fault diagnosis using wavelet-based signal processing. Vibration signals recorded from
two experimental set-ups were processed for gears and bearing conditions. Four statistical
features were selected: standard deviation, variance, kurtosis, and fourth central moment of
continuous wavelet coefficients of synchronized vibration signals (CWC-SVS).

4
 CHAPTER 4

CONSTRUCTION AND WORKING

Here, we have three dc gun arrangements in which two dc gun are arranged on either side of the
vehicle pedal rest for applying the gear and one for engagement and disengagement of clutch
which is connected to the clutch cable through coil spring. 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 through the help of
electric power supply and it’s controlled by the control unit. 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 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.
Depending up on the signal the clutch and gears will automatically change with the help of the
control unit. When the vehicle speed increases automatically the clutch and the gear will change
in the vehicle. 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.

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Fig. 4.1 Block diagram of project

6
 CHAPTER 5

COMPONENTS USED IN SYSTEM

This system consist following components

1. Speed sensor
2. Transmission control unit (microcontroller & microprocessor)
3. Actuators
4. Two wheeler gear changing pedal
5. Clutch
6. D.C. Motor (Flywheel)
7. Regulator (Accelerator)

5.1 Speed sensor

A speed sensor or vehicle speed sensor (VSS) is a type of tachometer. It is a sender device used
for reading the speed of a vehicle's wheel rotation. It usually consists of a toothed ring and
pickup.

1) Special Purpose Speed Sensors:

Road Vehicles: Wheel speed sensors are used in anti-lock braking systems.

Rotary speed sensors for motors: Although motor vehicles occasionally do use drives without
sensors, most need a rotary speed sensor for their regulator system. The most common type is a
two channel sensor that scans a toothed wheel on the motor shaft or gearbox and therefore does
not require a bearing of its own.

2) Speed sensors with Pulse Doubling:

Customers often want a higher number of pulses per revolution than can be achieved in the space
available and with the smallest module m = 1. An industry standard flange-compatible speed

7
sensor has been developed for such application that generates two pulses for each tooth of the
wheel. This makes it possible to achieve 600 pulses per revolution with a target wheel module m
= 1 and a diameter of 300 mm. These speed sensors are currently being tested at a major system
integrators.

Fig 5.1 pulse wheel sensor

5.2 Transmission controller unit

Microcontroller and Microprocessor
A microcontroller is a highly integrated chip, which includes on single chip, all or most of the
parts needed for a controller. The microcontroller typically includes: CPU (Central Processing
Unit), RAM (Random Access Memory), EPROM/PROM/ROM (Erasable Programmable Read
Only Memory), I/O (input/output) - serial and parallel, timers, interrupt controller. For example,
Intel 8051 is 8-bit microcontroller and Intel 8096 is 6-bit microcontroller.

By only including the features specific to the task (control), cost is relatively low. A typical
microcontroller has bit manipulation instructions, easy and direct access to I/O (input/output),
and quick and efficient interrupt processing. Fig 2.3 shows the block diagram of a typical
microcontroller.

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 Fig 5.2 Block diagram of microcontroller

A controller is control some process. At one time, controllers were built exclusively from logic
components, and were usually large, heavy boxes. Later on, microprocessors were used and the
entire controller could fit on a small circuit board. As the process of miniaturization continued,
all of the components needed for a controller were built right onto one chip. A one chip computer
or microcontroller was born. A CPU built into a single VLSI chip is called microprocessor. It
contains Arithmetic Logic Unit (ALU), Instruction Decode and Control Unit, Instruction
register, Program counter (PC), Clock Circuit (internal or external), Reset Circuit (internal or
external) and resisters. For example, Intel 8085 is 8-bit microprocessor and Intel 8086/8088 is 6-
bit microprocessor. Microprocessor is general-purpose digital computer central processing unit
(CPU). The microprocessor is general purpose device and additional external circuitries are
added to make it microcomputer.

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 Fig 5.3 Basic diagram of microprocessor

A digital computer having microprocessor as the CPU along with I/O devices and memory is
knows as microcomputer.

5.3 Actuators

To achieve the goals of automation and process control, the computer must collect data from and
transmit signal to the production process. This is done by using hardware components that act as
intermediaries’ b/w the control system and the process itself. In the last unit process variables
and parameters were defined as being either continuous or analogue. Therefore we must have
some way to accommodate this within the system, so that analogue data can be read in a digital
format, and vice-versa.

An actuator converts the controller command signal into a change in physical parameter. This
change is usually a mechanical alternation, such as a change in position, or a change in velocity.
Just like the sensor, an actuator is also a transducer, as it changes one type of physical quality
into another. Many actuators are fitted with amplifiers, to convert low level control signals into
strong sufficient to drive the actuators.

Three types of actuator may be defined: electrical, hydraulic, and pneumatic. Electric actuators
include electric motors of all kinds, stepper motors and solenoids; hydraulic actuators includes a
wide variety of cylinder-devices compressing hydraulic actuators include a variety of piston-and-
cylinder devices that compress air or other gases to achieve changes in the physical variables.
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 Fig 5.4 Hydraulic actuator

Fig 5.5 Pneumatic Actuators

Fig 5.6 Electro mechanical actuator

5.4 Two wheeler gear changing pedal

Gear changing pedal is attached to gear box externally for gear shifting purpose from one gear to
other it acts similar to gear changing lever .It is made up of Alloy Steel. It is operated
automatically or manually. In automatic gear transmission, gear pedal is operated by electrical
11
device. For e.g., direct current Gun. In manually gear transmission, gear pedal is operated
manually by applying force through leg.

5.5 Clutch (Definition and necessity of Clutch)

Clutch is a device used in transmission system of a vehicle to transmit the rotary motion of one
shaft when desired to second shaft of which axis are coincident with that of first. Thus, the clutch
is located between the engine and transmission system. When the clutch is engaged, power
transmits from engine to the driving wheels through the transmission system and the vehicle
moves. When the clutch is disengaged, the power is not transmitted from engine to the driving
wheels and the vehicle stop, while the engine still running. When clutch operated properly it
prevents suddenly jerk motion of the vehicle and this avoids pitting under strain on the remaining
part of the power transmission.

5.6 D.C. Motor (Flywheel)

In this project, you can use D.C. Motor acts as a Flywheel. The function of flywheel is to store
the energy of engine and is transmitted to the wheel through clutch and gear box.

Principle of operation

In any electric motor, operation is based on simple electromagnetism. A current-carrying

conductor generates a magnetic field; when this is then placed in an external magnetic field, it
will experience a force proportional to the current in the conductor, and to the strength of the
external magnetic field. The internal configuration of a DC motor is designed to harness the
magnetic interaction between a current-carrying conductor and an external magnetic field to
generate rotational motion.

5.7 Regulator (Accelerator)

In this project, you have used “Regulator acts as accelerator”. The function of accelerator is to
increase and decrease speed of flywheel connected to engine. In our project, we have used
regulator for the same purpose i.e., to increase and decrease speed of “D.C. Motor as a
Flywheel”.

12
In regulator, the input is a constant voltage, constant frequency ac mains (single or three phase)
and its output is variable voltage .The output voltage can be adjusted to any desired value and it
can be maintained constant. Hence, it is called “Regulator”. It is mostly used for speed control of
fans, blowers, pumps etc.

Fig. 5.7 Regulator

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 CHAPTER 6

PROBLEM STATEMENT

Today use of automobile is growing rapidly and to survive in the market is quite difficult with
previous technologies. So to survive in the market new technologies are mandatory. The
technology must be flexible enough to undertake changes. The technology must continue to
grow. During our study on the recent gear shifting mechanism we find out many problems in
present system.

In the recent trend there are two existing gear shifting system consists

1) Manual gear shifting

2) Automatic gear shifting.

Here are the problems of existing system are explained below:

1) Manual Gear Shifting Mechanism: The problems in manual gear shifting

mechanism are described below

Required More Human Effort – In manual gear shifting mechanism, the gear can be change
with the help lever. To provide motion of lever human effort is required. Without applied human
effort gear cannot be change, so sometime it’s burdensome for car driver.

Transmission Error – In manual shifting mechanism the gear is changed by the driver so that it
may be chance to shifting wrong gear instead of true gear. So in manual transmission system the
chance of transmission error is high.

Lack of Response – We notice that while driving the car hesitates to refuse into gear. Manual
transmissions can have the lack of response, so that car cannot run fast as per required in that
gear.

Humming Sound – Manual transmission will emit the sound while changing the gear. This
sound is louder due to mechanical operation. The clucking sound is always done when we shift
gear within transmission.

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Complex System – The manual transmission system is very complex because it is consist of
complex mechanism like gear, lever operation, Clutch engage & disengage mechanism.

Gears Slipping – If the transmission system is immediately slipping in out of gear while driving,
then chance of accident is high. So it is very risky. The reason behind this problem is due to hold
the gears.

Difficult To Understand – In manual transmission system the gear can be changed manually.
For change gear we must be change lever operation so that it is difficult to remember &
understand.

2) Automatic Gear Shifting Mechanism

There are following problems which occur in automatic gear shifting mechanism.

High Cost – The automatic transmission system is very costly due to its functioning.

Less Efficiency - Automatic gear shifting mechanism have a low efficiency compare to manual
gear shifting mechanism.

Gear Slipping – As per mentioned in manual transmission problem gear slipping problem is
also occurred in automatic transmission system.

Grinding or Shaking – Automatic transmission act a little differently, in automatic

transmission system will take some time to wiggle into gear at first instead of typical smooth
gear shifting.

Delayed Engagement – Delayed engagement is one type of slip in this transmission. The clutch
& brake do not operate instantly; due to this reason delayed engagement is occurred in
automatic transmission system.

The purpose of this research is to reduce people physical effort and they present only in driving
and prevent from accidents. In the present world of automobile, gear shifting system are
manually and automatic. Gear shifting system is important in automobile to vary the speed. So
automatic gear shifting system is costly than manually gear shifts system and manually gear
shifting system is difficult to understand for some people or it take physical effort to change

15
gear. By applying this gear shifting system it gives cost reduction in compare of automatic gear
shift system and flexible or simple then manually gear shift system and by applying this system
on automobile it’s easier to drive car for everyone. It also reduces the possibility of transmission
error of manual gear system.

The following objectives of automatic gear shifting mechanism are as follows:

1) Low Cost: This system is less costly compared to automatic gear transmission system but it
is costly compare to manual gear transmission system.

2) Flexibility: This system is flexible compare to the manual transmission system so that it’s
beneficial to use this system compare to the manual gear shifting mechanism.

3) Easy to operate: This is semi-automatic shifting mechanism in which touch screen are used
so that gear can be shift with the help of pressing number so it is easy to operate.

4) Less human effort: With the help of touch screen based gear shifting mechanism, no effort
is required to change gear. Gear can change just with touch the appropriate number on the
screen, so no effort is required

5) Less transmission error: Transmission error is occurring due to the improper gear at the
certain speed. This is eliminating in this project because we provide indicator for wrong gear at
specific speed.

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 CHAPTER 7

METHODOLOGY

4. Working of Microcontroller

4.1 Program logic for the gear shifting microcontroller

When power is supplied to the system, MCU1 first brings the motorcycle gears into neutral by
signaling the gear shifting system backward until the gears come to the neutral position. It will
then wait for a triggering signal from the SPDT switch to execute its next instruction. When an
active low signal from the switch, MCU1 then waits for the active low signal from MCU2 senses
the brake operation by receiving an active high signal from the brake sensing system, and then
sends a signal to the clutch controlling system to press the clutch, and produces an active low
signal for MCU1.

The MCU1 sends a signal to the gear shifting system to shift the gear up and stores the value 1
recording that the motorcycle is in first gear. MCU1 constantly monitors the three signals
coming from the speedometer.

When there are three active high signals coming from speedometer, this indicates that the
vehicle’s speed is below 10 km/h, and the motorcycle should be running in first gear. When
running in first gear, the MCU1 provides an active high signal to MCU2, which causes MCU2 to
release half clutch, not the full clutch, because the motorcycle is starting from 0 km/h and its
momentum is very low. So in order to run the engine smoothly, half clutch need to be released.

As the speed increase above 10 km/h, MCU1 recognized one active low signal and two active
high signals. The MCU1 consider the motorcycle should be in second gear. MCU1 now signal
the gear shifting system to shift the gear up and signals MCU2 to press the clutch. When the
clutch is pressed, the active low signal is sent by MCU2 to MCU1, which then switches off the
spark plug coil/ignition coil. As soon as the gear is shifted up, MCU1 switches on the spark plug
coil, sends an active low signal to MCU2 to release the clutch, and stores the value 2, recording
that the motorcycle is in second gear.

17
As the speed increase beyond 30 km/h, two active low signals and one active high signal are
provided by the speedometer to MCU1. MCU1 now has to bring the motorcycle into third gear.
It signals the gear shifting system to shift the gear up and signals MCU2 to press the clutch.
When the clutch is pressed, the active low signal is sent by MCU2 to MCU1, which switches off
the spark plug coil. When the gear is shifted up, MCU1 switches on the spark plug coil, sends an
active low signal to MCU2 release the clutch, and stores the value 3, recording that the
motorcycle is in third gear.

As the speed increase above 45 km/h, the speedometer sends three active low signals to the
MCU1. MCU1 consider the vehicle should be in fourth gear. MCU1 signals the gear shifting
system to shift the gear up and signals MCU2 to press the clutch. When the clutch is pressed, the
active low signal is sent by MCU2 to MCU1, which switches off the spark plug coil. When the
gear is shifted up, MCU1 switches on the spark plug coil, sends an active low signal to MCU2
release the clutch, and stores the value 4, recording that the motorcycle is in fourth gear.

Let us now suppose that the speed of the vehicle starts to decrease. As it becomes lower than 45
km/h, the speedometer signals two active low and one high signal to the microcontroller which
causes MCU1 to bring the motorcycle into third gear. MCU1 now signals the gear shifting
system to shift the gear down and signals MCU2 to press the clutch. When the clutch is pressed,
the active low signal is sent by MCU2 to MCU1. When the gear is shifted, MCU1 subtract 1
from the stored value resulting in 3, and the motorcycle is in third gear.

Suppose the speed of the vehicle decrease below 10 km/h; then the speedometer sends three
active high signals to MCU1. This signal causes MCU1 to bring back the engine into first gear.
Now the MCU1 signals the gear shifting system to shift the gear down and it sends an active
high signal to MCU2 to press the clutch. When the clutch is pressed, MCU2 produces an active
low signal and sends it to MCU1. Now MCU1 subtract 1 from the stored value.

If this value is 1, then MCU1 does nothing more than monitoring the speed of the vehicle. If the
value is greater than 1, then MCU1 repeats the above process up to the subtraction of 1 fr0om the
stored value the checks whether it is now 1 or not. If it is still not 1, then MCU1 repeats the
process until the value equals 1. It then stops performing the process and goes back to
monitoring of speed of the vehicle.

18
If the speed of the vehicle is lower than the programmed speed limit for the current running gear,
then MCU1 shifts the gear down until the specified gear is engaged. If the speed of the vehicle is
greater than the programmed speed limit for the current gear, then MCU1 shifts the gear up in
order to bring the motorcycle into the correct gear by performing the gear shifting up operation
as defined previously.

4.2 program logic for the clutch controlling microprocessor

MCU2 constantly monitors the active high signal from the brake sensing system and MCU1. If
either of this system sends an active high signal for MCU2, it presses the clutch. When there is
no active high signal to MCU2, it releases the clutch and sends an active low signal to MCU1.
When the clutch is not pressed it sends an active high signal to MCU2. When MCU2 receives
this active high signal after pressing the clutch, it releases the half clutch. This condition is only
valid for first gear. And for all gears, MCU2 will release the full clutch. The main function of
MCU2 is to monitor the active high signals sent by MCU1 and the brake sensing system, to press
the clutch, and if there are no active high signals from any of the system, MCU2 will release the
clutch.

Keywords :-

MCU 1 – Microcontroller Unit 1

MCU 2 – Microcontroller Unit 2

SPDT - Single Pole Double Throw

19
 CHAPTER 8

EXPECTED OUTCOMES

 A complete indigenous automatic gear system for a motorcycle has been developed.
 Since this system changes the gear at the correct speed, motorcycle engine life.
 Also, it provides a resistance against knocking, and it improves fuel consumption.
 This system is flexible and can be implemented on any motorcycle available in market.
 This project will save time and expenses of user.
 Easy to understand.
 Prevent from accident.
 No emit sound while changing gear.
 Applicable for all class.

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 CHAPTER 9

WORK SCHEDULE

For current project work, we are going to complete this project in following manner which is
given below in tabular form. This table provides the information about the current project
work progress according to time. We will try at our level best to meet the desired task
mentioned in the Table given below.

Table 7.1 Plan of Action

S. No. Topic Target Date of

Completion
1. PROJECT CONCEPT DESIGN Sep 20- Oct 10, 2016

2. MARKET SURVEY Feb 10- Feb 15, 2017

3. PURCHASIG OF Mar 04- Mar 10, 2017

COMPONENTS
4. PARTS ASSEMBLING Mar 11- Mar 25, 2017

5. TESTING Mar 26- Mar 30, 2017

6. FINDING PROBLEM Apr 01- Apr 05,2017

& SOLVING THEM
7. FINAL TESTING Apr06- Apr 10, 2017

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 CHAPTER 10

SUMMARY

In this system the automatic gear shifting is done by monitoring the vehicle speed. It could
instead be done by monitoring the crankshaft RPM or the engine’s acceleration. The electro-
mechanical system has to make more efficient, faster and more reliable. We have used two
extra DC self-starter motor taken from 300 cc motorcycles, because they are powerful
enough to shift the gear and control the clutch. A future improvement of the system could use
a DC actuator, which is powerful enough to shift the gear and control the clutch, and
consumes less power or only the power available in a traditional motorcycle battery.

The electro-mechanical system can be made more compact so it can easily be fitted in
existing motorcycle chassis without disturbing the other components. The microcontrollers
can be replaced by automotive microcontrollers. A more efficient gear indication sensor can
be installed, which can shows the gear of the motorcycle in which the engine is running.

22
REFERENCES

[1] “Automobile Engineering” vol-2 by KIRPAL SINGH

[2] J-O Hahn1, J-W Hur, G-W Choi, Y M Cho and K I Lee.Department of Mechanical
Engineering Korea Airforce Academy, South Korea.: ”Self-learning approach to automatic
transmission shift control in a commercial construction vehicle during the inertia phase”

[3] Zhenyu Zhu, Chunxin Xu, College of Mechanical Science and Engineering
JilinUniversity, Changchun, Jilin 130025, China.: ”Experimental Study on Intelligent Gear-
Shifting Control System of Construction Vehicle Based on Chaotic Neural Network”

[4] Muntaser Momani, Mohammed Abuzalata, Igried AlKhawaldeh and Hisham Al-M ujafet,
Department of Mechanical Engineering, Faculty of Engineering Technology, Al-Balqa,
Applied University, Amman, Jordan.:” Automotive Gear Shifting Mechanism

23