Documente Academic
Documente Profesional
Documente Cultură
BANGALORE -560012
In partial fulfilment
Submitted by
CHETHAN J 1KG12ME012
DARSHAN NAIK 1KG12ME014
LAKSHMI KESARI 1KG12ME024
MAHANTHESH S 1KG12ME028
Mr. AKASHDEEP B N
Asst. Professor
Department of Mechanical Engineering
K.S.S.E.M, Bengaluru
Certificate
This is to certify that the project work entitled Design and Fabrication of
Automated Manual Gear Transmission In Motor Bikes is a bonafide work carried
out by
CHETHAN J 1KG12ME012
DARSHAN NAIK 1KG12ME014
LAKSHMI KESARI 1KG12ME024
MAHANTHESH S 1KG12ME028
Declaration
We,
CHETHAN J 1KG12ME012
DARSHAN NAIK 1KG12ME014
LAKSHMI KESARI 1KG12ME024
MAHANTHESH S 1KG12ME028
the students of eight semester BE (Mechanical Engineering) declare that the project
entitled Design and Fabrication of Automated Manual Gear Transmission In
Motor Bikes is carried out by us at K.S. School of Engineering and Management as
a partial fulfilment of academic requirement of BE in Mechanical Engineering
under Visvesvaraya Technological University. The content in the thesis are
original and are free from plagiarism and other academic dishonesty and are not
submitted to any other University either partially or wholly for the award of any
other degree.
1. 1KG12ME012 Chethan J
4. 1KG12ME028 Mahanthesh S
Date: Bangalore
Abstract
The recent survey shows that continuous variable transmission (CVT) are in demand
compared to the gear featured bikes. CVTs do not have the concept of meshing of gears
which enhances a smooth ride, but the fuel efficiency is comparatively lesser when
compared to the gear featured vehicles.
The main objective of our project is to automate the gear transmission in a gear
featured bike to ease the driving and also to maintain the efficiency of the bike. This
mechanism is used in auto-clutch featured bike to smoothen the gear meshing and can be
implemented in clutch featured bike. The aim is to develop of automatic transmission system
which shifts the gears with respect to the speed of the wheel. Simplifying the transmission
and improving the fuel economy are the major objectives of our project. This technology is
implemented in an auto-clutch featured bike which shifts the gears to eliminate the human
interference and results in easy driving. Automation of gears transmission can be achieved
by embedded system. Embedded system is a special purpose computer system. Embedded
system is preferable because it can reduce the number of electrical components and
probability of failure is minimum. It has easy interfacing. Either a microprocessor or a
microcontroller is used in all the embedded systems. Microcontroller Atmel 89S52 is used in
our project. Suitable software is used to write the assembly level language in the
microcontroller. Embedded C Language is written and stored in the ROM of the
microcontroller.
INTRODUCTION ......................................................................................................................1
1.1 Introduction to transportation and transmission.....................................................1
1.2 Types of transmission.............................................................................................2
1.2.1 Manual gear transmission ..................................................................................2
1.2.2 Automatic Transmission .....................................................................................4
1.3 Comparison between Manual and Automatic Transmission..................................6
1.3.1 Manual Transmission .........................................................................................6
1.3.2 Automatic Transmission .....................................................................................6
1.4 Automation of Manual Gear Transmission ............................................................7
1.4.1 Overview .............................................................................................................7
1.4.2 Automation..........................................................................................................7
1.4.3 Embedded System ...............................................................................................7
1.5 Components used in Automated Manual Gear Transmission ................................8
1.5.1 Proximity Sensor.................................................................................................8
1.5.2 LCD Display .......................................................................................................9
1.5.3 Microcontroller.................................................................................................10
1.5.4 Relays................................................................................................................11
1.6 Automatic Transmission Manufacturers ..............................................................12
CHAPTER 2..........................................................................................................................13
CHAPTER 3..........................................................................................................................17
CHAPTER 4..........................................................................................................................38
CHAPTER 5..........................................................................................................................41
P1 Power of motor, kw
T1 Torque of motor, N-m
Chapter 1
Introduction
This chapter consists of general introduction on manual and automatic gear transmission in
two wheelers. The general introduction contains theory, practice involved, important and the
application of this topic. The content of this chapter are derived from journal papers, patents
and other sources. This chapter gives brief information about the different type of
transmissions, their advantages, disadvantages and applications. All different concepts are
compared with each other in terms of their operation, performance and efficiencies.
Transmission system transmits mechanical power from the engine to give kinetic
energy to the wheels. It is an interconnected system of gears, shafts, and other electrical
gadgets that form a bridge to transfer power and energy from the engine to the wheels. The
complete set up of the system helps to maintain the cruising speed of the vehicle without any
disturbance to the performance. The oldest variant of the transmission system in India is the
manual transmission that has undergone various modifications and alterations to form the
present day automatic transmission.
Most modern gearboxes are used to increase torque while reducing the speed of a
prime mover output shaft. This means that the output shaft of a gearbox will rotate at slower
rate than the input shaft, and this reduction in speed will produce a mechanical advantage,
causing an increase in torque.
There are two basic types of manual transmissions. The sliding-gear type and the constant
mesh design. With the basic and now obsolete sliding-gear type, nothing is turning inside the
transmission case except the main drive gear and cluster gear when the transmission is in
neutral. In order to mesh the gears, apply engine power to move the vehicle. One of the basic
methods is shown in Figure 1-1: Sliding Gear Transmission.
All modern transmissions are of the constant-mesh type, which still uses a similar
gear arrangement as the sliding-gear type. However, all the main shaft gears are in constant
mesh with the cluster gears as shown in Figure 1-2: Constant Mesh Transmission. This is
possible because the gears on the main shaft are not splinted to the shaft, but are free to
rotate on it. With a constant-mesh gearbox, the main drive gear, cluster gear and all the main
shaft gears are always turning, even when the transmission is in neutral.
(Courtesy: www.nptel.ac.in)
(Courtesy: www.nptel.ac.in)
Besides the traditional hydraulic automatic transmissions, there are also other types of
automated transmissions, such as Figure 1-3: Constant Variable Transmission Low and High
Gear Ratio transmission system. That free from the driver from having to shift gears
manually, by using the transmission's computer to change gear, if for example the driver
were redlining the engine. Despite superficial similarity to other transmissions, traditional
automatic transmissions differ significantly in internal operation and driver's feel from semi-
automatics and CVTs. In contrast to conventional automatic transmissions, a CVT uses a
belt or other torque transmission scheme to allow an "infinite" number of gear ratios instead
of a fixed number of gear ratios. A semi-automatic retains a clutch like a manual
transmission, but controls the clutch through electro hydraulic. The ability to shift gears
manually, often via paddle shifters, can also be found on certain automated transmissions
semi-automatics and CVTs.
Figure 1-3: Constant Variable Transmission Low and High Gear Ratio
(Courtesy: www.nptel.ac.in)
1. The manual transmission locks and unlocks different sets of gears to the output shaft to
achieve the various gear ratios, while in an automatic transmission; the same set of gears
produces all of the different gear ratios.
2. Automatic vehicles are easier to use, especially for the inexperienced driver. Manual
system requires better driving skills, whereas with an automatic, the clever system does it
all on its own. This holds a greater advantage for new and inexperienced drivers and also
helps during congested traffic situations where it becomes difficult to change gears every
second.
3. Automatic transmission requires less attention and concentration from the driver because
the automatic gears start functioning as soon as the system feels the need of a gear
change. For vehicles with manual gear shifts, the driver has to be more alert while
driving and better coordinated.
4. There is no clutch pedal and gear shift in an automatic transmission car. Once you put
the transmission into drive, everything else is automatic.
5. Automatic vehicles have better ability to control traction when approaching steep hills or
engine braking during descents. Manual gears are difficult to operate on steep climbs.
1.4.1 Overview
The topic of our project is to develop a automatic transmission system with has finite
number of gearshifts, which transmits the power automatically with respect to speed of the
vehicle. Gearshifts in automatic transmissions involve a change in the power flow path
through the transmission. Advantages of these automatic transmissions include simplicity of
mechanical design and savings in transmission weight and size, which are beneficial in terms
of fuel economy and production costs. This enables gain in fuel economy while meeting
drivability and performance goals, these savings become more significant.
1.4.2 Automation
Automation is the use of control system to control a process replacing the human operators.
It is a step beyond mechanization, where human operators are provided with the physical
requirements of work.
Automation is now often applied primarily to reduce the human effort thereby to
attain desired operation. Another major shift in automation is the increased emphasis on
flexibility and convertibility in different process.
One safety issue with automation is that it is often viewed as a way to minimize
human error in the system, increasing the degree and the levels of automation also increase
the sequence of error that accidently created in automated systems. Different types of
automation tools that exist in todays environment are Programmable logic controller,
Microcontroller, SCADA, etc.
An embedded system is some combination of computer hardware and software, either fixed
in capability or programmable, that is specifically designed for a particular function.
Industrial machines, automobiles, medical equipment, cameras, household appliances,
airplanes, vending machines and toys are among the myriad possible hosts of an embedded
system. Embedded systems that are programmable are provided with programming
interfaces, and embedded system programming is a specialized occupation.
A proximity sensor is a device which detects the presence of nearby objects without any
physical contact. It often emits an electromagnetic field or a beam of electromagnetic
radiation (infrared), and looks for changes in the field or return signal. The object being
sensed is often referred to as the proximity sensor's target as shown in Figure 1-4: Proximity
Sensor that senses metal objects. Different proximity sensor targets demand different
sensors. For example, an inductive proximity sensor always requires a metal target.
The maximum distance that this sensor can detect is defined "nominal range". Some sensors
have adjustments of the nominal range or means to report a graduated detection distance.
Proximity sensors can have a high reliability and long functional life because of the absence
of mechanical parts and lack of physical contact between sensor and the sensed object.
(Courtesy: www.learningaboutelectronics.com)
LCDs are available to display arbitrary images or fixed images with low information
content, which can be displayed or hidden, such as preset words, digits, and 7-
segment displays as in a digital clock. They use the same basic technology, except that
arbitrary images are made up of a large number of small pixels, while other displays have
larger elements.
(Courtesy: www.engineersgarage.com)
1.5.3 Microcontroller
A microcontroller is a small computer on a single integrated circuit containing a processor
core, memory, and programmable input/output peripherals. Program memory in the form
of Ferroelectric RAM is also often included on chip, as well as a typically small amount
of RAM. Microcontrollers are designed for embedded applications, in contrast to the
microprocessors used in personal computers or other general purpose applications consisting
of various discrete chips.
1.5.4 Relays
A relay is an electromagnetic switch. Many relays use an electromagnet to mechanically
operate a switch, but other operating principles are also used, such assolid-state relays.
Relays are used where it is necessary to control a circuit by a low-power signal or where
several circuits must be controlled by one signal. The first relays were used in long
distance telegraph circuits as amplifiers: they repeated the signal coming in from one circuit
and re-transmitted it on another circuit. Relays were used extensively in telephone exchanges
and early computers to perform logical operations.
A type of relay that can handle the high power required to directly control an electric
motor or other loads is called a contactor. Solid-state relays control power circuits with
no moving parts, instead using a semiconductor device to perform switching. Relays with
calibrated operating characteristics and sometimes multiple operating coils are used to
protect electrical circuits from overload or faults; in modern electric power systems these
functions are performed by digital instruments still called "protective relays".
Relays require one pulse of coil power to move their contacts in one direction, and another,
redirected pulse to move them back. Repeated pulses from the same input have no effect.
Relays are useful in applications where interrupted power should not be able to transition the
contacts. The circuit arrangement can be understood by the Figure 1-7 attached below.
Chapter 2
Literature Review
Introduction
It is very important to realize automatic shift for engineering vehicles, because its poor
working conditions and complicated operation condition. Realizing automatic shift can
improve the performance and fuel economy of vehicles, it can also improve efficiency and
quality of gear shift, lighten the working strength of drivers, etc.
At present, there is not a perfect automatic shift technology for vehicles, they can
only use the automatic shift technology of ordinary vehicle. Engineering vehicles mainly
work on engineering work, so they will consume lots of power of the engine, and the change
range is very large. This is very different from the vehicles used for driving. We cannot
greatly improve the vehicles performance and fuel economy if we implement the existing
gear shift technology. Therefore, studying automatic shift technology of the engineering
vehicle has important theoretical and practical significance.
shifting and downshifting through the transmission gears by pressing pushbuttons mounted
on the handle bar. It is an object of this invention to provide a pushbutton solenoid shifter
that incorporates the use of electronic solenoids to actuate the shifting of gears in manual
transmission of motorcycle. Patent [4]has mentioned that the transmission gears and clutch
shifting apparatus for automatic operation of manual shift mechanism in a automotive
vehicle include gear and clutch actuation mechanisms mounted on bar of vehicle and
coupled by the cables to the control actuation mechanisms mounted off the vehicle board.
The on-board gear shift actuator includes two intersecting movable slots for causing
movement of the shift lever. In this invention electrical control and actuation mechanism are
mounted outside the vehicle. A relatively small gear and clutches is mounted on the vehicle,
cables are used to connect these actuators with each other. The patent [5]has explained that a
multi speed automatic transmission for automobiles having parallel input and output shafts
includes two parallel gear sets and constant meshing gear wheels, which provide two fixed
speed ratios. The first power path uses the first speed ratio which includes a first control
clutch and a second control clutch. The second power path uses the second speed ratio which
is higher than the first speed ratio, which include a third control clutch. This also has a
double planetary gear set, a first and second control brake. Alternatively either the input or
output shafts are in alignment and one the two speed ratios are used. This transmission
features six forward speeds, a braked neutral and a reverse drive.
The journal [6]gives us a brief introduction to shift schedule of gears to save energy
and improve fuel economy. Since there is no perfect automatic shift technology for
engineering vehicles, this theory is implemented to improve the ordinary vehicle
transmission. The author predicts that automatic gear transmission vehicle chooses the best
shift rule based upon drivers information of manipulation .the author also claims that the
rule of shift decision changes the traditional shift mechanism to intelligent shift decision.
Journal [7]has specified that automatic transmission is a key technology to improve the
performance of vehicles. With the synthesized application of mechatronics technology,
computer technology, auto control technology on vehicles, development of modern vehicles
is leading to an intelligent gear shifting mechanism. Gear shifting strategy as explained in
the journal is the core of intelligent control system of automatic transmission that
improvesvehicles performance and fuel efficiency. The gear shift strategy is the rule of
changing the time of automatic shifting between gears with respect to rear wheel revolution.
A journal [8, 5] has provided the solution for power loss in manual gear transmission system.
The main objective is to create a mechanism to reduce inconvenience caused in manual gear
Dept. of Mech. Engineering, K.S.S.E.M Page 14
Literature Review
vehicles. The shifting of gears is done automatically as well as manually. In automatic gear
shifting mechanism the gears are shifted in accordance with the speed of the vehicle. The
wheel revolutions are sensed and the signal is transferred to the microcontroller which shifts
the gear with respect to the implemented C program. The journal [9] has shared an
information, that the production of manual transmission is reduced by fifty percent and
automated manual transmission (AMT) production is increased. The AMTs are used in
racing cars and in modern hybrid electric vehicles.
The literature review clearly indicates the gap in fabrication of the automated manual gear
shifting mechanism in the conventional motor bikes, in order to bridge this gap gear shifting
mechanism is designed and fabricated in the following project work.
Aim:
To design and fabricate the automated manual gear transmission in motor bikes.
Objectives:
1. To design the gear shifting mechanism and modify the vehicle according to the designed
mechanism.
2. To program the microcontroller according to the needs of the mechanism and build the
electronic circuit.
3. To calibrate the gear shifting mechanism and also to check for the improvements in the
efficiency if any.
2.5 Methodology:
Methodology for objective-1:
The chain drive mechanism between the geared DC motor and gear pedal is designed
using Catia V5 software. The geared DC motor is fitted about the pedal with
calculated offset. A gear is welded on to the pedal of the vehicle. The timing chain is
attached as the driving medium.
Chapter 3
Design and Fabrication
Introduction
In order to reach our goal of making an automatic gear transmission motor bike, different
types of systems and components are used. According to this customization and fabrication
of the components, proper placement and fitting of components is carried out. The details
regarding various components used and the fabrication methods are explained in this
chapter, it helps to have the knowledge of different components and its working.
DESCRIPTION DATA
ENGINE, POWER & TORQUE
Displacement 109.7 cc
Maximum Power 8,4 BHP @ 7500 rpm
Maximum Torque 8.3 Nm @ 5500 rpm
Engine Description 109.7cc, 4-sroke
Cooling Air Cooling
Bore 53.5 mm
Stroke 48.8 mm
Number of Cylinders 1
TRANSMISSION
Gearbox 4 Automatic
Clutch Wet dual clutch
BRAKES
Rear Brake 110mm Drum
Front Brake 130mm Drum
SUSPENSION
Front Suspension Telescopic Forks
Rear Suspension Hydraulic, Coaxial springs
WHEELS & TYRES
Wheel Size 2.75x17 - 3.00x17
Wheel Type Alloys
BATTERY
Battery Type Maintenance Free
DIMENSIONS, WEIGHT & CAPACITY
Overall Length 1975.00 mm
Overall Width 700.00 mm
Overall Height 1060.00 mm
3.2 Design
The design basically consists of a timing chain which fitted to the gear wheel fitted
externally to the gear lever. The driver of this timing chain is the geared DC motor and the
driven is the gear at the gear lever. All data and calculations are briefly explained below.
Data:
60 10 2
=
2 500
= 38.197 N-m
Gear Ratio,
40
= = 3.33
12
= =
38.197
= 3.33
, = 11.47 N-m
The torque necessary to obtain the shifting of gears is about 10 N-m which is less than the
torque at the driven gear which is about 11.47 N-m.
Figure 3-2: Isometric and Front view of the Automated Manual Gear Shifting
Mechanism
RPM: 500
A suitable geared DC motor is used to move the gear pedal. Necessary modifications are
made to the gear pedal to obtain the shifting with respect to the DC motor. The DC motor is
connected to 12V power supply and runs at 500rpm. The DC motor fabricated to the motor
bike is shown in the Figure 3-3. The starter motor is attached above the bike engine. It is
operated by giving the power supply from the motor bike battery.
The geared DC motor or a starter motor is connected to the relays. Relay 1 and 2 are
actuated with respect to the program to rotate the DC motor in anticlockwise (up shift) and
clockwise (down shift) motion. The gear, pitch diameter 25mm, on the DC motor is meshed
with the gear pedal with timing chain. The gear pedal is fitted with spur gear of 80mm pitch
diameter. When the DC motor rotates anticlockwise with 45 inclination, the pedal rotates
with 25. This inclination is sufficient is to push the pedal down to achieve the up shift
during driving. Similarly, the DC motor rotates clockwise with 45 of inclination when relay
is actuated. This enables the gear pedal to move in clockwise direction and the down shift is
achieved.
(4)
(5)
Component Particulars
no
1 Voltage regulator 12v DC to 5v DC
3 Microcontroller AT 89s52
Microcontroller Atmel 89S52 as shown in Figure 3-6 is used in our project. It is a 8K byte of
In-system reprogrammable flash memory microcontroller with 40 pins. It is programmed by
using Embedded C program which is written using Keil V5 software. The program consists
of the gear positioning codes with respect to the pulse range obtained from the proximity
sensor. By combining a versatile 8-bit CPU with in-system programmable Flash on a
monolithic chip, the Atmel AT89S52 is a powerful microcontroller which provides a highly-
flexible and cost-effective solution to many embedded control applications. The AT89S52
provides the following standard features: 8K bytes of Flash, 256 bytes of RAM, 32 I/O lines,
Watchdog timer, two data pointers, three 16-bit timer/counters, a six-vector two-level
interrupt architecture, a full duplex serial port, on-chip oscillator, and clock circuitry. In
addition, the AT89S52 is designed with static logic for operation down to zero frequency
and supports two software selectable power saving modes. The Idle Mode stops the CPU
while allowing the RAM, timer/counters, serial port, and interrupt system to continue
functioning. The Power-down mode saves the RAM con-tents but freezes the oscillator,
disabling all other chip functions until the next interrupt or hardware reset.
The microcontroller board is used to mount the device to connections to LCD display, relays
and the power source. The pin configuration of the microcontroller is shown on the board to
give the necessary wire connection.
GND: Ground.
Port 0: Port 0 is an 8-bit open drain bidirectional I/O port. As an output port, each
pin can sink eight TTL inputs. When 1s are written to port 0 pins, the pins can
be used as high-impedance inputs.
Port 1: Port 1 is an 8-bit bidirectional I/O port with internal pull-ups. The Port 1 output
buffers can sink/source four TTL inputs. When 1s are written to Port 1 pins, they are
pulled high by the internal pull-ups and can be used as inputs. As inputs, Port 1 pins
that are externally being pulled low will source current (IIL) because of the internal
pull-ups.
In addition, P1.0 and P1.1 can be configured to be the timer/counter 2 external count
input (P1.0/T2) and the timer/counter 2 trigger input (P1.1/T2EX), respectively, as
shown in the following table. Port 1 also receives the low-order address bytes during
Flash programming and verification.
Port 2: Port 2 is an 8-bit bidirectional I/O port with internal pull-ups. The Port 2 output
buffers can sink/source four TTL inputs. When 1s are written to Port 2 pins, they are
pulled high by the internal pull-ups and can be used as inputs. As inputs, Port 2 pins
that are externally being pulled low will source current (IIL) because of the internal
pull-ups.
Port 2 emits the high-order address byte during fetches from external program
memory and during accesses to external data memory that uses 16-bit addresses
(MOVX @ DPTR). In this application, Port 2 uses strong internal pull-ups when
emitting 1s. During accesses to external data memory that uses 8-bit addresses
(MOVX @ RI), Port 2 emits the contents of the P2 Special Function Register. Port 2
also receives the high-order address bits and some control signals during Flash
programming and verification.
Port 3: Port 3 is an 8-bit bidirectional I/O port with internal pull-ups. The Port 3 output
buffers can sink/source four TTL inputs. When 1s are written to Port 3 pins, they are
pulled high by the internal pull-ups and can be used as inputs. As inputs, Port 3 pins
that are externally being pulled low will source current (IIL) because of the pull-ups.
Port 3 receives some control signals for Flash programming and verification.
RST: Reset input. A high on this pin for two machine cycles while the oscillator is running
resets the device. This pin drives high for 98 oscillator periods after the Watchdog
times out. The DISRTO bit in SFR AUXR (address 8EH) can be used to disable this
feature. In the default state of bit DISRTO, the RESET HIGH out feature is enabled.
Memory Organization: MCS-51 devices have a separate address space for Program and
Data Memory. Up to 64K bytes each of external Program and Data Memory can be
addressed.
Program Memory: If the EA pin is connected to GND, all program fetches are directed to
external memory. On the AT89S52, if EA is connected to VCC, program fetches to
addresses 0000H through 1FFFH are directed to internal memory and fetches to
addresses 2000H through FFFFH are to external memory.
Data Memory: The AT89S52 implements 256 bytes of on-chip RAM. The upper 128 bytes
occupy a parallel address space to the Special Function Registers. This means that the
Interrupts: The AT89S52 has a total of six interrupt vectors: two external interrupts (INT0
and INT1), three timer interrupts (Timers 0, 1, and 2), and the serial port interrupt.
Each of these interrupt sources can be individually enabled or disabled by setting or
clearing a bit in Special Function Register IE. IE also contains a global disable bit,
EA, which disables all interrupts at once. User software should not write a 1 to this
bit position, since it may be used in future AT89 products.
Timer 2 interrupt is generated by the logical OR of bits TF2 and EXF2 in register
T2CON. Neither of these flags is cleared by hardware when the service routine is
vectored to. In fact, the service routine may have to determine whether it was TF2 or
EXF2 that generated the interrupt, and that bit will have to be cleared in software.
Oscillator Characteristics: XTAL1 and XTAL2 are the input and output, respectively, of
an inverting amplifier that can be configured for use as an on-chip oscillator. Either a
quartz crystal or ceramic resonator may be used. To drive the device from an external
clock source, XTAL2 should be left unconnected while XTAL1 is drive. There are no
requirements on the duty cycle of the external clock signal, since the input to the
internal clocking circuitry is through a divide-by-two flip-flop, but minimum and
maximum voltage high and low time specifications must be observed.
Programming the Flash Serial Mode: The Code memory array can be programmed
using the serial ISP interface while RST is pulled to VCC. The serial interface
consists of pins SCK, MOSI (input) and MISO (output). After RST is set high, the
Programming Enable instruction needs to be executed first before other operations
can be executed. Before a reprogramming sequence can occur, a Chip Erase
10 1st gear
10 to 25 2nd gear
25 to 35 3rd gear
The pulses ranges mentioned in the table 3.2 were obtained by trial and error method
according to the city traffic conditions. The Embedded C program is burnt into the
microcontroller using Willar software. Since the microcontroller is reprogrammable, it can
be burnt until a program with necessary pulses range is implemented into it.
LCD display as shown in Figure 3-8 used in the circuit visualises the pulses, timing and the
gear position. 162 type with 14 pins LCD display is used in our project. The up and down
shift of the gears in the vehicle is displayed in the LCD. The output from the microcontroller
is given to the relays for further shifting mechanism. The LCD display is used to show the
pulse, timer, gear position and the action to be taken to shift the gear.
Relays come in various configurations for their switch contacts, as well as different DC
voltages to operate their coils. They may be as simple as an on/off switch or as complex as
integrating several switches into one unit. They are classified under electromagnetic
switches. Two relays of 5V and 10A are used in our gear shifting mechanism
Figure 3-9. The first relay is used for up shift of gear and the second relay is used for down
shift of the gears. Relays are devices which allow low power circuits to switch a relatively
high current and voltage ON/OFF. For a relay to operate a suitable pull-in and holding
current should be passed through its coil. Generally relay coils are designed to operate from
a particular voltage at 5V or 12V. The NPN transistor BC547 is used to control the relay.
The transistor is driven into saturation (turned ON) when logic 1 is written on the port pin
thus turning ON the relay. The relay is turned OFF by writing logic 0 on the port pin. A
diode is connected across the relay coil to protect the transistor damage due to back EMF
generated in the relays inductive coil when the transistor is turned OFF. The LED is used to
indicate that the relay is turned ON or OFF.
Compilers are programs used to convert a High Level Language to object code. Desktop
compilers produce an output object code for the underlying microprocessor, but not for other
microprocessors. I.E the programs written in one of the HLL like C will compile the code
to run on the system for a particular processor like x86 (underlying microprocessor in the
computer). For example compilers for Dos platform is different from the Compilers for
UNIX platform So if one wants to define a compiler then compiler is a program that
translates source code into object code. The compiler derives its name from the way it
works, looking at the entire piece of source code and collecting and reorganizing the
instruction. See there is a bit little difference between compiler and an interpreter. Interpreter
just interprets whole program at a time while compiler analyses and execute each line of
source code in succession, without looking at the entire program.
The advantage of interpreters is that they can execute a program immediately. Secondly
programs produced by compilers run much faster than the same programs executed by an
interpreter. However compilers require some time before an executable program emerges.
Now as compilers translate source code into object code, which is unique for each type of
computer, many compilers are available for the same language.
Later when the gear transmission was automated again the same test was conducted with 100
ml of petrol which was better compared to manual mode as it increased to about 5.9kms.
Chapter 4
Results and Discussions
Introduction
Its important to check the performance of the vehicle after implementing the new
technology, which can shift the gears without human interference as shown in Figure 4-1.
The gear shifting was observed while riding the bike. The gears changed with respect to the
wheel speed. As soon as the bike was brought to first gear manually, from neutral, the
proximity sensor sensed the speed of the wheel. As the bike was accelerated, the sensor
transferred to the higher input pulses to the microcontroller. The pulses per 8 seconds were
counted and decision the position of the gear. At higher speed, the relay 1 was actuated and
the dc gear motor rotated. This resulted in the up shift of the gear automatically. We were
able to reach the top gear position (4th) as we accelerated the bike. There was no much
vibration produced during the gear change. By maintaining constant speed of the bike, we
could maintain a constant gear ratio which was a major factor for fuel efficient ride.
As the speed of the bike was reduced uniformly, the gear shifted down with a delay
time. There is a delay time in between each gear position to smoothen the gear down
mechanism. Once the acceleration was brought down to zero, the dc geared motor was
successful in bring the gear position to the first gear.
Automatic up shift of gear was observed without any interference other than
accelerating.
Delay time was observed between each gear positions.
The ride was smooth during traffic condition since the gear shifting was dependent
upon the wheel speed.
Chapter 5
Conclusion and Future work
5.1 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.
[9] Luigi Glielmo, Gearshift Control for Automated Manual Transmissions, IEEE
/ASME, vol. 1, p. 11, 2006.
[10] Y. Huang, Hybrid intelligent gearshift control of technical vehicles based on AGA-
NN, International Journal of Control and Automation, vol. 6, no. 4, p. 14, 2013.
Annexure A
Automated Manual Gear Transmission in Motor Bikes
Mr. Akashdeep B N1
Asst. Professor Dept. of Mechanical Engineering, K .S .School of Engineering and Management, Bengaluru
email:bndeep@gmail.com
Abstract
The main theme of this paper is to design and fabricate automated manual gear transmission
in motor bikes. The gear shifting technology is designed and fabricated on the tmatic clutch
featured bike for smooth gear transmission. The RPM from the rear wheel is sensed by
proximity sensor and it is taken as the input for the microcontroller. Embedded C program
selects the gear position according to the wheel RPM range set. Relays are activated to shift
the gear up and down. A DC geared motor actuates the gear lever by means of chain
mechanism. A smooth and efficient drive can be achieved from this technology.
Keywords: Proximity Sensor, Atmel89S52 Microcontroller, Relays, DC geared motor.
important component of the complete 5V and 10A are used in our gear shifting
circuit used for this mechanism. mechanism. The first relay is used for up
Microcontroller Atmel89S52 is used in shift of gear and the second relay is used
our project. It is a 8K byte of In-system for down shift of the gears.
reprogrammable flash memory
microcontroller with 40 pins. It is
programmed by using Embedded C
program which is written using Keil V5
software. The program consists of the gear
positioning codes with respect to the pulse
range obtained from the proximity sensor.
Annexure B
K.S. School of Engineering and Management
Bachelor of Engineering (Mechanical Engineering)
Chethan J 1KG12ME012
DarshanNaik 1KG12ME014
Lakshmi Kesari 1KG12ME024
Mahanthesh S 1KG12ME028
Guide:
Mr.Akashdeep B N, AP, MED, KSSEM.