``

2013

PROJECT ON SEMI AUTO PNUEMETIC GEAR SHIFTER

This study describes in detail in an understandable way to how to convert the traditional manually gear shifting mechanism to a semi-automated gear shifting mechanism. 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.

SISTec-e ,Ratibad,Bhopal 4/12/2013

SAGAR INSTITUTE OF SCIENCE,TECHNOLOGY & ENGINEERING ----------BHOPAL M.P.----------

Major project report on semi auto Pnuemetic gear shifter

CERTIFICATE

This is to certify that CHIRAG GAUSWAMI,JITENDRA KUMAR KUSHWAHA,SURAJ YADAV,PANKAJ KUMAR,JANMEJAY MISHRA, MD.KAIF is the student of B.E. final-year,7thSemester (MECHANICAL ENGINEERING) has completed the dissertation titled,

semi auto Pnuemetic gear shifter

during the academic session 2013-14 under my guidance & supervision.

I approve the project for submission as required for partial fulfillment for completion of the engineering degree in Department of Mechanical Engineering.

GUIDED BY: Prof. Raghvendra Khedle ________________ Prof. Santosh Vishwakarma __________________

ACKNOWLEDGEMENT

The completion of this project work could have been possible with continued & dedicated efforts and guidance of large number of faculty & staff members of the Institute. We acknowledge our gratitude to all of them. The acknowledgement however will be incomplete without specifics mentioned as follows: We express our profound sense of gratitude to our project incharge Mr.Santosh Vishwakarma Prof., ME-Dept. for his continued encouragement and guidance during the project period. We also express our sincere thanks to Mr.Raghvendra khedle, H.O.D. , ME-Dept. for his encouragement and providing all the facilities in the department. We would like to extend our gratitude to Dr. Dinesh Kumar Rajoriya Principal, SISTec-E, Bhopal and Dr. N S Sundarmurti Dean,SISTec-E, Bhopal for their valuable encouragement and approval of the project work. Last but not the least; I would also like to thank our parents and those persons specially Ganesh kinage ,who helped me directly or indirectly in completion of the project.

SUBMITTED BY: Chirag Guswami(0536ME113D01) Jitendra kumar kushwaha(0536ME101042) Suraj yadav(0536ME101105) Janmejay mishra(0536ME101040) Pankaj kumar(0536ME101066) Md. Kaif (0536ME101058)

INTRODUCTION

This study describes in detail in an understandable way to how to convert the traditional manually gear shifting mechanism to a semiautomated gear shifting mechanism. 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. This design helps the driver to increase his focusing on the road. Also reduces the time needed to engage the required reduction ratio, which increases the vehicles' response. This design may be considered as an educational model for gear shifting mechanism. so, we pointed to the following: The suitable dimensions for the main components holder. Keeping in mind the addition of other parts for enhancement and development. A manual, 4-frontal speed gear box is used automobile drive is chosen for this design because it is easier to modify.

 An electrical motor is used to create mechanical power instead of an internal combustion engine, which is difficult to be placed there. It is also used to make the engagement process easier .Motor is variable speed (0 to 9000 rpm) A couple of pullies and a belt are used to transmit power from the electrical motor to the gear box.

To avoid binding in the input shaft caused by the radial force, we used a bearing fixed on the holder. . We used two pneumatic, double acting cylinders ,per pair of gar shifting. Two(five ways, two positions) directional control solenoid valves are used to change the compressed air direction. Every directional valve has 230V ac solenoid that converts electrical power to magnetic power, which attracts the spool inside the valve; this action changes the compressed air direction

LITERATURE

The most common transmission systems that have been used for the automotive industry are manual transmission, automatic transmission, semi-automatic transmission, and continuouslyvariable transmission (CVT). The first transmission invented was the manual transmission system. The driver needs to disengage the clutch to disconnect the power from the engine first, select the target gear, and engage the clutch again to perform the gear change. This will challenge a new driver. It always takes time for a new driver to get used to this skill. This idea came from the hydraulic brake,

which was first invented in 1927 by Magura lo-cated in Bad Urach, Germany and used for BMW motorcycles. The company also invented the first adjust-on-the-fly clutch in 1968. In 1941, Chrysler introduced the first automatic transmission system, which included a fluid coupling between en-gine and clutch. An automatic transmission uses a fluid-coupling torque converter to replace the clutch to avoid engaging/disengaging clutch during gear change. A completed gear set, called planetary gears, is used to perform gear ratio change instead of selecting gear manually. With the invention of the automatic transmission, a driver no longer needs to worry about gear selection during driving. It makes driving a car much easier, especially for a disabled or new driver.

However, the indirect gear contact of the torque converter causes power loss during power transmission, and the com-plicate planetary gear structure makes the transmission heavy and easily broken

A semi-automatic transmission tries to combine the advantages of the manual and automatic transmission systems, but avoid their disadvantages. However, the complicated design of the semi-automatic transmission is still under development, and the price is not cheap. It is only used for some luxury or sports cars currently.

 CVT has been used for low-powered machinery like scooters for a long time due to its highly efficient gear change. However, it is a challenge to install it on high power machinery because of the strength of the driving belt. With the progress of materials technology, engineers have been successfully installed it on automobiles, making the power transmission efficient.

In 2009, the department of mechanical Engg Faculty of egg. Technology, Al-Balqa Applied University studied that, a gear shifting mechanism was designed and applied to make the shifting process faster and less destructible for the driver. The new device must be reliable, has a small dimensions, low construction and maintenance cost. This paper aims to improve gear shifting process using devices as: a manual four speed gear box, four pneumatic double acting cylinders, four pneumatic two position five ways directional control valves, Programmable Logic Controller (PLC) LOGO unit, an electrical motor, an electrical clutch, a belt, two pulleys, limit switches, push buttons, bulbs, a table (holder) and power supply. According to suggested gear shifting method the driver can select the transmission gear ratio without moving his hands from the steering wheel by putting the gear shifting push buttons on the steering wheel. Using this method leaves to the driver the excitement of choosing the shifting moment.

SYSTEM DEVELOPMENT
Construction The construction of the Automatic gear box comprises of the following parts. 1. Base Frame wThe base frame is an structural element that supports the entire gear box system. The frame carries the drive system at its lower end which comprises of the LH and RH rear bearing housings . The drive motor is mounted on the base frame. 2. Drive system Drive system comprises of the single phase AC commutator motor with following specifications: Single phase AC motor Commutator motor TEFC construction Power = 1/15hp=50 watt Speed= 0-6000 rpm (variable)

3. Pneumatic linear actuator The pneumatic linear actuator is an Standard cylinder DNU-16-25-PPV-A. This cylinder is an double acting cylinder that is operated by an pneumatic valve5/2 way. The valve is supplied compressed air from the compressor by means of an aAGBopriate filter-regulator-lubricator (FRL)unit. This linear actuator is used in the following positions, a. 1st gear b. 2nd gear c. 3rd gear d. 4th gear 4. Shifter mechanism The shifter mechanism is an assemblage of levers actuated by the linear actuator as mentioned above. This shifter is normally in neutral condition , it shifts the gears at start of cycle and releases it at end of cycle. 5. Position control system The position system comprises of the following components; a. 5/2 way solenoid control valves, centre off, detent type b. Pneumatic cylinder DPNC connectors The details of this relay system are given in the circuit diagram of the pneumatic system

semi auto Pnuemetic gear shifter

WORKING
The pneumatic circuit is as shown , the motor is started to drive the main shaft by means of belt and pulley arrangement, initially the gear box is in neutral ie, the output shaft doesnot rotate. When the 5/2 way direction control valve -1 is operated the cylinder -1 operates the piston to move in the right hand direction thereby bringing the 3rd gear into engagement, and thus the output shaft starts to rotate therby transmitting power fron the input ( motor/engine) to the output ( differential).

The flow control valve in the circuit governs the pressure which is of the order of 1.5 to 2 bar, hence the governed pressure causes the gradual push provided to the piston rod which brings about gradual engagement of the gears hence, (effect of gradual clutch release for smooth engagement is not required).

When the 5/2 way direction control valve -2 is operated the cylinder -2 operates towards left as the piston rod is locked for movement left , hence first the fork shifter moves towards left bringing on the neutral position and then slides farther left to bring the 1st gear into engament . Note : If both the valves ie , 5/2 way direction control valve -1&2 are operated simultaneously, the system is arranged such that neutral position will be achieved, hence the system beacomes fool proof,

 Similarly the circuit works for the 2nd and 4th gear.

SR NO. 1 2 3 4 5 6

PART CODE

DESCRIPTION

QTY

MATERIAL

AGB -1 AGB -2 AGB -3 AGB -4 AGB -5 AGB -6

MOTOR REDUCTION PULLEY BELT MAIN SHAFT COUNTER SHAFT GEAR COUNTER SHAFT LOW (35T) GEAR MAIN SHAFT SECOND (17T) GEAR COUNTER SHAFT SSECOND(29T) GEAR MAIN SHAFT THIRD

01 01 01 01 01 01

STD MS STD EN24 EN24 EN24

AGB -7

01

EN24

AGB 8

01

EN24

AGB 9

01

EN24

(22T) Bill of Materials 10 AGB 10 GEAR COUNTER SHAFT THIRD(26T) GEAR MAIN SHAFT FOURTH (24T) GEAR COUNTER SHAFT FOURTH(22T) LH BRG HSG RH BRG HSG CYL- DNU-16-25-PPV-A. CYL- DNU-16-25-PPV-A. SHIFTER MECHANISM 5/2WAYSOLENOID FLOWCONTROL VALVES 01 EN24

11 AGB 11

01

EN24

12 AGB 12

01

EN24

13 AGB 13 14 AGB 14 15 AGB 15 16 AGB 21 17 AGB 22 18 AGB 24 19 AGB 25

01 01 01 01 01 02 O1

EN9 EN9 STD STD MS STD STD

Material Procurement

Material is procured as per raw material specification and part quantity. Part process planning is done to decide the process of manufacture and aAGBopriate machine for the same. General Material Used En24- Alloy Steel En9- Plain Carbon Steel Ms-Mild Steel Std-Standard Parts Selected From Psg Design Data/Manufacturer Catalogue

Raw Material Cost

The total raw material cost as per the individual materials and their corresponding rates per kg is as follows, Total raw material cost = Rs 1200/-

PUCHASING COST:-

SR DESCRIPTION NO 1 2 3 4 5 6 7 MOTOR CYL- DNU-16-25-PPV-A GEAR BOX 5/2 WAY SOLENOID VALVES FLOW CONTROL VALVE CONNECTORS & TUBE EL. SPEED REGULATOR

QTY

COST

01 02 01 02 01 01

1550 2360 5150 1620 395 670 380

Miscellaneous Costs

OPERATION GAS CUTTER FABRICATION TOTAL

COST(Rs) 100 320 420

Machining Cost

OPERATION

RATE Rs /HR

TOTAL TIME HRS 8 6 2

TOTAL COST Rs/640 540 120 1300

LATHE MILLING DRILLING TOTAL

80 90 60

CONCLUSION
Advantages 1. Semi-automated gear shifting mechanism. 2. Gear shifting mechanism is easy to use and workable, these demands are very important especially for small cars used by special needs people. 3. Gearbox becomes much smoother and produces less noise. 4. Gear shifting less confusing. 5. Easy to choose the right reduction ratio and engaging it at the right time. 6. This design helps the driver to increase his focusing on the road. 7. It reduces the time needed to engage the required reduction ratio, which increases the vehicles' response.

Application This is specially use for vehicles such as large buses or dump trucks, where engine may be further away from the driver than in most vehicles

 FUTURE SCOPE Now, this project we made for two gears, but it will use for four gears also. This concept continuously improve in advance in the place of pneumatic, it will works on electromagnetically also.