“BUTTON OPERATED GEAR SHIFTING MECHANISM” 2018

CHAPTER NO 1
INTRODUCTION
The main objective of our project is to perform an automatic gear change control
apparatus for an automobile and a method of controlling such apparatus. A rotational
output of an internal combustion engine is connected to drive wheels of the automobile
and a load device. 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 coil so that the gear will be
shifted. An automatic gear change control apparatus for an automobile, comprising an
internal combustion engine; an automatic transmission connected to an output rotation
shaft of engine so as to transmit the rotational output of drive wheels through any
selected one of gear ratios; apparatus comprising a load device for applying a load;
means for connecting load device to output rotation shaft of engine and for generating a
gear change control signal for selecting one of gear ratios of automatic transmission in
accordance with one of operational conditions of automobile and said engine; and load
control means for increasing the load of said load device when said gear change signal-
generating means generates the control.

Signal for shifting up the gear in automatic transmission. Increasing demands on

performance, quality and cost are the main challenge for today's automotive industry, in
an environment where every movement, component and every assembly operation must
be immediately and automatically recorded, checked and documented for maximum
efficiency.

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

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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 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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OBJECTIVE
This project is about Design and fabrication of a semiautomatic gear. Shifting
mechanism for a racing car like Go Kart a. This gear shifting mechanism had been
design to overcome issues like–gear shifting. problem while gear shifting, to eliminate
fully manual gear shifting ,so that driver can give more attention to steering, to reduce
the effort and timing of gear shifting which is more important racing basically where
few milliseconds. Make you a winner or a loser. The idea of pneumatic shifter rose when
there was some going on discussion on different mechanism for shifting gear
.Performing some analysis on basic design and on available data design was bought onto
existence.

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1.2COMPONENT LIST
Solenoid

Gear pedal

Battery

Switches and Switch box

Wiring

Bearings

Support Frame

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CHAPTER NO:2
CONSTRUCTION AND WORKING:
This system consist an electromagnetic system which will work on the principle of
electromagnet. An electric current flowing in a wire creates a magnetic field around the
wire. To concentrate the magnetic field of a wire, in an electromagnet the wire is wound
into a coil, with many turns of wire lying side by side. The magnetic field of all the turns
of wire passes through the center of the coil, creating a strong magnetic field there.
Some simple mechanism will be arrange with the electromagnet and will help us to
change the gear as per the desired speed. The two electromagnetic coils are fixed to the
gear shaft of the two ends. One is used to shift the gear in upward direction. Another one
is used to shift the gear in downward direction. These two coil is operated depends upon
the speed of the vehicle this is automatically button operated electromagnetic gear
changer for two wheeler. A rotational output of an internal combustion engine is
connected to drive wheels of the automobile and a load device. When a gear shiftingup
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.

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Fig No:2.1.wiring connections

Fig No 2.2. Button operated electromagnetic gear changer

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The two electro-magnetic coils are fixed to the gear shaft of the two ends. One is used to
shift the gear in upward direction. Another one

is used to shift the gear in downward direction. These two coil is operated depends upon
the speed of the vehicle this is

automatically button operated electromagnetic gear changer for two wheeler.

To perform an automatic gear change control apparatus for an automobile and a method
of controlling such apparatus. A rotational output of an internal combustion engine is
connected to drive wheels of the automobile and a load device. 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.

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CHAPTER NO:3
3.DESCRIPTION OF EQUIPMENTS Solenoid:
Product Detail
Complete security
Simple to introduce
High similarity
Smooth shine
Profoundly effective
Securely stuffed
Continuous execution

3.1 Linear Solenoid Actuator

Another type of electromagnetic actuator that converts an electrical signal into a
magnetic field producing a linear motion is called the Linear Solenoid.

The linear solenoid works on the same basic principal as the electromechanical relay
seen in the previous tutorial and just like relays, they can also be switched and controlled
using transistors or MOSFET’s. A “Linear Solenoid” is an electromagnetic device that
converts electrical energy into a mechanical pushing or pulling force or motion.

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Fig No 3.1 Linear solenoid Actuator

Linear Solenoid

Linear solenoid’s basically consist of an electrical coil wound around a cylindrical tube
with a ferro-magnetic actuator or “plunger” that is free to move or slide “IN” and
“OUT” of the coils body. Solenoids can be used to electrically open doors and latches,
open or close valves, move and operate robotic limbs and mechanisms, and even actuate
electrical switches just by energising its coil.

Solenoids are available in a variety of formats with the morecommon types being the
linear solenoid also known as the linear electromechanical actuator, (LEMA) and the
rotarysolenoid.

Both types of solenoid, linear and rotational are available as either a holding
(continuously energised) or as a latching type (ON-OFF pulse) with the latching types
being used in either energised or power-off applications. Linear solenoids can also be
designed for proportional motion control were the plunger position is proportional to the
power input.

When electrical current flows through a conductor it generates a magnetic field, and the
direction of this magnetic field with regards to its North and South Poles is determined
by the direction of the current flow within the wire. This coil of wire becomes an
“Electromagnet” with its
own north and south poles exactly the same as that for a permanent type magnet.

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The strength of this magnetic field can be increased or decreased by either controlling
the amount of current flowing through the coil or by changing the number of turns or
loops that the coil has. An example of an “Electromagnet” is given below.

Magnetic Field produced by a Coil

When an electrical current is passed through the coils windings, it behaves like an
electromagnet and the plunger, which is located inside the coil, is attracted towards the
centre of the coil by the magnetic flux setup within the coils body, which in turn
compresses a small spring attached to one end of the plunger. The force and speed of the
plungers movement is determined by the strength of the magnetic flux generated within
thWhen the supply current is turned “OFF” (de-energised) the electromagnetic field
generated previously by the coil collapses and the energy stored in the compressed
spring forces the plunger back out to its original rest position. This back and forth
movement of the plunger is known as the solenoids “Stroke”, in other words the
maximum distance the plunger can travel in either an “IN” or an “OUT” direction, for
example, 0 – 30mm.

Linear Solenoid Construction

This type of solenoid is generally called a LinearSolenoiddue to the linear directional

movement and actionof the plunger. Linear solenoids are available in two basic
configurations called a “Pull-type” as it pulls the connected load towards itself when
energised, and the “Push-type” that act in the opposite direction pushing it away from
itself when energised. Both push and pull types are generally constructed the same with
the difference being in the location of the return spring and design of the plunger.

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Pull-type Linear Solenoid Construction

Linear solenoids are useful in many applications that require an open or closed (in or
out) type motion such as electronically activated door locks, pneumatic or hydraulic
control valves, robotics, automotive engine management, irrigation valves to water the
garden and even the “Ding-Dong” door bell has one. They are available as open frame,
closed frame or sealed tubular types.

Solenoid Switching
Generally solenoids either linear or rotary operate with the application of a DC voltage,
but they can also be used with AC sinusoidal voltages by using full wave bridge
rectifiers to rectify the supply which then can be used to switch the DC solenoid. Small
DC type solenoids can be easilycontrolled using Transistor or MOSFET switches and
are ideal for use in robotic applications.

However, as we saw previously with electromechanical relays, linear solenoids are

“inductive” devices so some form of electrical protection is required across the solenoid
coil to prevent high back emf voltages from damaging the semiconductor switching
device. In this case the standard “Flywheel Diode” is used, but you could equally use a
zener diode or small value varistor.

Switching Solenoids using a Transistor

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Reducing Energy Consumption

One of the main disadvantages of solenoids and especially the linear solenoid is that
they are “inductive devices” made from coils of wire. This means that the solenoid coil
converts some of the electrical energy used to operate them into “HEAT” due to the
resistance of the wire.

In other words when connected for long periods of time to an electrical supply they get
hot!, and the longer the time that the power is applied to a solenoid coil, the hotter the
coil will become. Also as the coil heats up, its electrical resistance also changes allowing
more current to flow increasing its temperature.

With a continuous voltage input applied to the coil, the solenoids coil does not have the
opportunity to cool downbecause the input power is always on. In order to reduce this
self generated heating effect it is necessary to reduce either the amount of time the coil is
energised or reduce the amount of current flowing through it.

One method of consuming less current is to apply a suitable high enough voltage to the
solenoid coil so as to provide the necessary electromagnetic field to operate and seat the
plunger but then once activated to reduce the coils supply voltage to a level sufficient to
maintain the plunger in its seated or latched position. One way of achieving this is to
connect a suitable “holding” resistor in series with the solenoids coil, for example:

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Reducing Solenoid Energy Consumption

Here, the switch contacts are closed shorting out the resistance and passing the full
supply current directly to the solenoid coils windings. Once energised the contacts which
can be mechanically connected to the solenoids plunger

action open connecting the holding resistor, RH in series with the solenoids coil. This
effectively connects the resistor in series with the coil.

By using this method, the solenoid can be connected to its voltage supply indefinitely
(continuous duty cycle) as the power consumed by the coil and the heat generated is
greatly reduced, which can be up to 85 to 90% using a suitable power resistor. However,
the power consumed by the resistor will also generate a certain amount of heat, I2R
(Ohm’s Law) and this also needs to be taken into account.

Solenoid Duty Cycle

Another more practical way of reducing the heat generated by the solenoids coil is to use
an “intermittent duty cycle”. An intermittent duty cycle means that the coil is repeatedly
switched “ON” and “OFF” at a suitable frequency so as to activate the plunger
mechanism but not allow it to de-energise during the OFF period of the waveform.
Intermittent duty cycle switching is a very effective way to reduce the total power
consumed by the coil.

The Duty Cycle (%ED) of a solenoid is the portion of the “ON” time that a solenoid is
energised and is the ratio of the “ON” time to the total “ON” and “OFF” time for one
complete cycle of operation. In other words, the cycle time equals theswitched-ON time
plus the switched-OFF time. Duty cycle is expressed as a percentage, for example:

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Then if a solenoid is switched “ON” or energised for 30 seconds and then switched
“OFF” for 90 seconds before being re-energised again, one complete cycle, the total
“ON/OFF” cycle time would be 120 seconds, (30+90) so the solenoids duty cycle would
be calculated as 30/120 secs or 25%. This means that you can determine the solenoids
maximum switch-ON time if you know the values of duty cycle and switch-OFF time.

Fig No3.2: Actual Used solenoids

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3.2 Gear Pedal:

Fig No: 3.3 Gear Pedal

Gear pedal is used for shifting of gear .

It is connected directly to gear box of motorcycle.
It is made up of stainless steel.

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3.3 BATTERY ( 12 V 7.2 AH)

INTRODUCTION

The common battery (dry cell) is a device that changes chemical energy to electrical
energy. Dry cells are widely used in toys, flashlights, portable radios, cameras, hearing
aids, and other devices in common use. A battery consists of an outer case made of zinc
(the negative electrode), a carbon rod in the center of the cell (the positive electrode),
and the space between them is filled with an electrolyte paste. In operation the
electrolyte, consisting of ground carbon,Manganese dioxide, Sal ammoniac, and zinc
chloride, causes the electrons to flow and produce electricity.

WORKING
Electricity is the flow of electrons through a circuit or conductive path like a
wire.Batteries have three parts, an anode (-), a cathode (+), and the electrolyte. The
cathode and anode (the positive andnegative sides at either end of a smaller battery) are
hooked up to an electrical circuit.

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3.4 ELECTRON FLOW

The chemical reaction in the battery causes a buildup of electrons at the anode. This
results in an electrical difference between the anode and the cathode. You can think of
this difference as an unstable build-up of the electrons. The electrons want to rearrange
themselves to get rid of this difference. But they do this in a certain way. Electrons repel
each other and try to go to a place with fewer electrons.
In a battery, the only place to go is to the cathode. But, the electrolyte keeps the
electrons from going straight from the anode to the cathode within the battery. When the
circuit is closed (a wire connects the cathode and the anode) the electrons will be able to
get to the cathode. In this example, the electrons go through the wire, lighting the light
bulb along the way. This is one way of describing how electrical potential causes
electrons to flow through the circuit. However, these electrochemical processes change
the chemicals in anode and cathode to make them stop supplying electrons. So there is a
limited amount of power available in a battery.When a battery is recharged, the
direction of the flow of electrons is changed, theelectrochemical processes happen in
reverse, and the anode and cathode are restored to their original state and can again
provide full power.
Inside the battery, a chemical reaction produces the electrons. The speed of electron
production by this chemical reaction (the battery's internal resistance) controls how
many electrons canflow between the terminals. Electrons flow from the battery into a
wire, and must travel from the negative to the positive terminal for the chemical reaction
to take place. That is why a battery can sit on a shelf for a year and still have plenty of
power - unless electrons are flowing from the negative to the positive terminal, the
chemical reaction does not take place.

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3.5 Switches and Switch box

Type of switch used:

Three Way Switch

Fig No: 3.4 Three Way Switch

The controlled load is often a lamp, but multiway switching is used to control other
electrical loads, such as an electrical outlet, fans, pumps, heaters or other appliances.
The electrical load may be permanently hard-wired, or plugged into a switched
receptacle.

Three-way and four-way switches make it possible to control a light from multiple
locations, such as the top and bottom of a stairway, either end of a long hallway, or
multiple doorways into a large room. These switches appear externally similar to single
pole, singlethrow(SPST)switches, but have extra connections whichallow a circuit to be
controlled from multiple locations. Toggling the switch disconnects one "traveler"
terminal and connects the other.
Electrically, a typical "3-way" switch is a single pole, doublethrow(SPDT)switch.By
correctly connecting two of theseswitches together, toggling either switch changes the
state of the load from off to on, or vice versa. The switches may be arranged so that they
are in the same orientation for off, and contrasting orientations for on.

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Fig.No: 3.5 switch and switch box

3.6 Bearings and Rod

Fig No: 3.6Ball Bearing

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Ball bearing

A bearing is a machine elementthat constrains relative motion to only the

desired motion, and reduces frictionbetweenmoving parts. The design of the bearing
may, for example, provide for free linearmovement of the moving part or for free
rotation around a fixed axis;
or, it may prevent a motion by controlling the vectorsofnormal forcesthat bear on the
moving parts. Most bearings facilitate the desired motion by minimizing friction.
Bearings are classified broadly according to the type of operation, the motions allowed,
or to the directions of the loads (forces) applied to the parts.

Rotary bearings hold rotating components such as shaftsoraxleswithinmechanical

systems,
andtransferaxial and radial loads from the source of the load to the structure supporting
it.
The simplest form of bearing, the plain bearing, consists of a shaft rotating in a hole.
Lubricationis often used to reduce friction. In the ballbearingandrollerbearing,to
prevent
sliding friction, rollingelements such as rollers or balls with a circular cross-section are
located between the races or journals of the bearing assembly. A wide variety of bearing
designs exists to allow the demands of the application to be correctly met for maximum
efficiency, reliability, durability and performance

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3.7 Support Frame

Frame is made from cast iron.

It is made in fabrication shop by welding process.
After welding finishing is also done.

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CHAPTER NO 4

COSTING
Sr No Name Of Component Quantity Rate
1 SOLENOID MECHANISM 1 500/-
2 GEAR PEDAL 1 600/-
3 SWITCHES 1 800/-
4 BEARING 2 600/-
5 FRAME 1 800/-
TOTAL 3300/-

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CHAPTER NO 5

ADVANTAGES:
Easy way of shifting gear

Reduces human effort

Makes driving simple

LIMITATIONS

Electric Current Is Required For Their Application.

Comparatively large space is required.

The initial cost of the system is quite hig

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CHAPTER NO 6
CONCLUSION

This Button operated gear shifting mechanism is very flexible due to its reaction time.
This system having quick response due to its simple mechanism and it is comfortable for
physically handicapped people and also from women’s point of view.

Due to its simple mechanism and quick response it has very good performance in gear
shifting.

It is very easier to operate over feet operated gear shifting.

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CHAPTER NO 7
FUTURE SCOPE

However more further scope to button operated gear shifter, we recommend to society to
use this project.

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REFERENCES

www.google.com/solenod

www.google.com/threeway_switches

www.google.com/battery

www.google.com/ball_bearing

Mechatronics

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ANNEXURE

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