FSAE QUICK SHIFT SYSTEM

Department of Mechanical Engineering

National Institute of Engineering

By

VINAYAKA MALLYA S
USN: 4NI15ME183
SHAMANTH M
USN: 4NI16ME430
Agenda
 What is Formula SAE
 Vehicle Systems
 Paddle Design
 Pneumatic System
 Microcontroller and Circuit
 Path Detection and Tracking
 Power
 Controls
What is Formula SAE?
 Categories of FSAE competition

Static Event
Cost Event 100
Business Plan Presentation 75
Design Presentation 150
Dynamic Event
Acceleration Test 75
AutoX 100
Skidpad 75
Fuel Efficiency 100
Endurance 325
TOTAL 1000
Formula Race Car Systems

SUBSYSTEMS
Brakes Chassis

Ergonomics Power Train

Bodyworks Suspension

Electronics
Design Requirements

 Redesigning the shifting device for formula student race car

 Faster shifting with less system weight setup
 Ensuring the reliability of the shift system
 Practical considerations such as costs, availability of replacement parts
 The shift system should be compact and withstand excessive force
Force Measurements
 Shown in the table is the force requirement of Duke 390 running at idle 1900 rpm with a lever
length of 65mm

Force table – Upshift Force table – Downshift

Gear position Force in Kg Gear position Force in Kg

From Neutral to 1st gear 5.8 From 1st gear to Neutral 4.8

From 1st to 2nd gear 5.6 From 2nd to 1st gear 5.4

From 2nd to 3rd gear 5.4 From 3rd to 2nd gear 5.3

From 3rd to 4th gear 5.2 From 4th to 3th gear 5.1

From 4th to 5th gear 5.1 From 5th to 4th gear 5.0
Pneumatic circuit designed for NIE collegiate vehicle
ACTUATING MECHANISM

 After extensive research and comparative study, the following are the types of
actuation
 Mechanical Push/Pull cable
 Electric Solenoid Actuator
 Electric Motor
 Voice Coil Actuator
Mechanical Push/Pull Cable

 Bi-directional linear motion is required to shift

 The Engine consists of a 6 speed sequential
transmission
 In order to shift up and down, two motions in opposite
direction are required
 The mechanical shifter uses a mechanical lever placed
on the drivers left hand side inside the cockpit
 The motion is obtained by a heavy duty push pull cable
 Pneumatic Gear Shifter
• DA cylinder is selected based on the force requirement and
pressure
• The force is provided by a onboard compressor or a gas tank
Pressure in
Force in N
Force VS Pressure
bar
Parker D15 Parker D19 Parker D23 300
250
Thrust Pull Thrust Pull Thrust Pull
200
1 18 17 28 28 42 40
150
2 35 34 57 55 83 79
100
3 53 51 85 83 125 119 50

4 71 68 113 111 166 158 0

0 1 2 3 4 5 6 7
5 88 85 142 138 208 198
D15 Thrust D15 Pull D19 Thrust
6 106 102 170 166 249 238 D19 Pull D23 Thrust D23 Pull
Working of Electro-pneumatic shift system

 Paddles are connected to micro switch

 This gives the input to the
microcontroller
 The Microcontroller sends the signal to
ECU
 ECU cuts the throttle off
 Arduino controls the solenoid DCV
 Solenoid actuates the pneumatic actuator
 Thus the required up/down shift is done
 Force VS Displacement for Gear
Force VS Displacement for Clutch Shift
GCU Program Logic

• Based on drivers request

GPU controls the upshift or
downshift
• Launch and Neutral is
executed with the help of
Gear Control Unit
Microcontroller
• Arduino mega is used to carryout
the accurate control of shifts
• It takes input from the micro
switch of the paddles
• Arduino receives data from gear
position sensor, GPS,
Accelerometer, Engine rpm and
mode selectors
• It also supports launch control,
Neutral mode and console display
• It can be easily paired with the
OBD II and obtain various engine
data
• GPS module can be integrated
GPS Module integration
• The GPS NMEA 0183 profiles the GPS Data
• The module creates map with online utility
• Powerful and extremely customizable.
PATH DETECTION
• Cone detection belongs to image
processing
• The positive and negative sample
images are trained using Haar Cascade
• Cascade is a classifier used to detect
the object
• Cascade superimposes the positive
image over the negative image
• After training .xml file is generated
• This data along with the camera live
feed data is given as the input to the
control unit.
• The control unit generates the
autonomous track path
PATH TRACKING OF AUTONOMOUS FSAE

• The tire cornering stiffness is utilized to

design the path tracking controller

Lateral slip angle

• Straight A-B: Firstly, the vehicle should accelerate to the
limit speed from point A until it achieves the maximum
speed
• Clothoid B-B: The steering angle increases and the braking
force decreases to zero gradually along the clothoid B-B
• Curve B-C: The vehicle steers with the limit safe speed
along the segment B-C.
• Clothoid B-C: The vehicle speeds up and the steering angle
decreases gradually along the segment B-C to exit the
corner.
Electronic shift control circuit
 The paddles actuates the micro switch
 This gives the signal to the microcontroller
 Based on the signal from gear position sensor the gear
position is determined
 This data is used by the microcontroller and sends the
signal to ECU
 The ECU cuts off the engine and the 4/3 solenoid valve is
energized
Power requirements of shift system
 The ECU is powered by 12V car battery
 The microcontroller needs a 5V DC, a stepdown D to D converter is used
 The micro switch of the paddle is connect to 5V DC
 The 4/3 solenoid valve requires 12V DC to operate
 The signal from the microcontroller is 5V and with the help of Relays 12V
DC is controlled and supplied to the solenoid valve
Gear Position Sensor
 Placed inside the engine casing
 Detects the gear position
 Gear positions can be detected from the varying resistance

1st Gear 502 Ω

2nd Gear 472 Ω
3rd Gear 380 Ω
4th Gear 324 Ω
5th Gear 274 Ω
CONCLUSION
 Electronic assisted pneumatic paddle shifter improves the
cornering efficiency and minimize driver fatigue to further
improve the overall performance of our vehicle
 Pneumatic shifters are more efficient than electric solenoid
shifters in terms of cost and market availability.
 The Pneumatic gear shifting mechanism using solenoid valve is
successful with the shift delay of 15 milliseconds.
 Investigation of gear shifts in clutch less automated manual
transmissions and the impact of shift control is determined
THANK YOU