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    Dynamic Analysis of Gear Shifting Mechanism

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    Mr. S. Thiyagu Asst Prof MECH
    The document analyzes the dynamic shifting mechanism of a two-wheeler gearbox using ADAMS simulation software. It studies how parameters like the cam inertia, weight, friction, and stopper spring stiffness affect the shift effort and time. The gearbox model is created in ProE and imported into ADAMS to apply constraints and simulate motions. Minimum torque required to rotate the cam and engagement time are measured from the ADAMS output for different parameter values to understand their impact on shift quality. The goal is to advance shift quality and future gearbox design.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Dynamic Analysis of Gear Shifting Mechanism

    Uploaded by

    Mr. S. Thiyagu Asst Prof MECH
    77 views4 pages
    The document analyzes the dynamic shifting mechanism of a two-wheeler gearbox using ADAMS simulation software. It studies how parameters like the cam inertia, weight, friction, and stopper spring stiffness affect the shift effort and time. The gearbox model is created in ProE and imported into ADAMS to apply constraints and simulate motions. Minimum torque required to rotate the cam and engagement time are measured from the ADAMS output for different parameter values to understand their impact on shift quality. The goal is to advance shift quality and future gearbox design.

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    DYNAMIC ANALYSIS OF GEAR SHIFTING MECHANISM

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    The document analyzes the dynamic shifting mechanism of a two-wheeler gearbox using ADAMS simulation software. It studies how parameters like the cam inertia, weight, friction, and stopper spring stiffness affect the shift effort and time. The gearbox model is created in ProE and imported into ADAMS to apply constraints and simulate motions. Minimum torque required to rotate the cam and engagement time are measured from the ADAMS output for different parameter values to understand their impact on shift quality. The goal is to advance shift quality and future gearbox design.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    77 views4 pages

    Dynamic Analysis of Gear Shifting Mechanism

    Uploaded by

    Mr. S. Thiyagu Asst Prof MECH
    The document analyzes the dynamic shifting mechanism of a two-wheeler gearbox using ADAMS simulation software. It studies how parameters like the cam inertia, weight, friction, and stopper spring stiffness affect the shift effort and time. The gearbox model is created in ProE and imported into ADAMS to apply constraints and simulate motions. Minimum torque required to rotate the cam and engagement time are measured from the ADAMS output for different parameter values to understand their impact on shift quality. The goal is to advance shift quality and future gearbox design.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    DYNAMIC ANALYSIS OF GEAR SHIFTING MECHANISM

    P. NARASIMMAN*** P. Senthilnathan* G. GNAKOTTAIA**


    *** Asst, Prof, Dept. of Mechanical Engg., A.C College of Engg & Tech,. Karaikudi- 4.
    [email protected]
    * Final year, ME-CAD, A.C. College of Engg & Tech., Karaikudi-4. [email protected]
    ** Manager, R&D, TVS Motor Company, Hosur

    ABSTRACT
    In Automotive transmissions, the problem of shift effort and corresponding shift time are complex
    ones. High shift effort and more shift time are recognized as a basic performance malfunction that takes
    place during shifting. In this paper, the shifting mechanism of two-wheeler gearbox is analyzed using
    ADAMS. The shift effort and shift time are analyzed with different parameters and using the results, the
    mathematical model is formed using SPSS software. The transmission requires discrete ratio change shifts,
    which perturb vehicle acceleration and engine speed. Therefore shift disturbances are important aspect of
    the customer’s perception of overall quality.
    The purpose of this study is to understand the fundamental effects of these parameters to make further
    advancement in the area of shift quality and future developments in the design of linkages.
    Keywords: shift effort, shift time, shift quality

    INTRODUTION in this narrow rpm range while rear wheel’s


    For motorcycles equipped with manual rotating speed varies greatly.
    transmissions, the ‘Shift feeling’ is very In this study, the motorcycle engine
    important. But it is based on customer’s runs at 8000 rpm and develops maximum torque
    perception. The customer’s perception in general of 12.3Nm at 6000 rpm and develops maximum
    depends on expectation, sense and environment. power of 9.95Kw at 8500 rpm.
    The customer expects shifting to be done with At 38KPH, the rear tires are only turning about
    lesser shift effort and achieves the required speed 335rpm, while the engine is revolving about
    at a shorter time. 10000rpm. The primary pair provides part of this
    Shift effort is the amount of force that is reduction and other gear reductions are handled
    to be applied on the shifting lever to achieve the by the transmission that allows the rider to select
    each gear shifting. This depends upon the 5 different ratios.
    leverage of the mechanism and stiffness of the
    springs used to return of the shift lever and in the
    TRANSMISSION
    stopper roller, mass and inertia of all the parts,
    friction between the contact pairs. Shift time is The transmission consists of two
    the time required for engagement of dogs. Dog parallel shafts upon which the gears are
    engagement time varies according to shifting mounted. These shafts called as counter shaft
    speed, clutch drag torque, gear rpm, and dog and drive shaft. Each shaft carries 5 different
    engagement angle. sized gears. Each gear meshes with a
    corresponding gear on the other shaft. To obtain
    GEAR BOX each of the different ratios, constant mesh type of
    The motorcycle engine is wonderful transmission is used.
    piece of engineering. It is light, compact and In constant mesh transmission, Gear
    efficient and develops tremendous power for its shifting is accomplished by forks that fit in to
    size. It is one draw back in IC engines, is that it circumferential grooves in the hubs of the gears.
    is only really efficient over a relatively narrow There are three forks in this gearbox. Each gear
    range of rpm. At low rpm, it does not develop is splined to it’s shaft, so it can slide, but not
    much power, while at high rpm, it wears out rotate independently. These sliding gears have
    quickly. These characteristics of the engine ‘Lugs’ on their side faces that protrude to engage
    require that a multi speed transmission be used to slots on adjacent gears. Each adjacent gear is
    allow the engine to operate in its efficiency constantly in mesh with a companion gear on the
    range. The transmission allows the engine to run other shaft, but it spins freely until it is engaged
    by a sliding gear, which locks the gear to the • Creating the Parts of the Model
    shaft. Even though all the gears are meshed • Adding Constraints and Motions to
    simultaneously, only one gear set will be Mandate Part Movements
    • Adding Forces that Induce or Resist
    Part Movements

    The complete gearbox modeling is done using


    ProE Wildfire and the models are imported in
    ADAMS. The required type of constraints like
    translational, rotational constraints applied on the
    model. Each part’s mass, center of gravity and
    inertia data are given and simulated.

    transmitting power. The other pairs of gears all


    have one gear spinning freely. When the
    transmission is in neutral, none of the sliding
    gears are engaged with adjacent gears, so the
    output shaft doesn’t turn with any force.
    A drum cam controls the shift forks.
    The function of the cam is to convert the rotating
    motion of the cam to move the sliding gears in to
    and out of engagement. The lateral movement
    and position of the forks are controlled by slots
    in the drum cam.
    The end of the cam has a set of pins that work in
    conjunction with pawl and levers to rotate the
    drum the proper amount each time, the gear shift
    lever is moved. An index star is mounted over
    the pins to control the indexing amount of drum
    cam during shifting. A spring loaded stopper arm
    and roller holds the star to lock the drum cam in
    each gear position.

    ANALYSIS
    The shift characteristics analysis is done using
    ADAMS. ADAMS is mechanical system
    simulation software. It enables users to produce
    virtual prototypes, realistically simulating the
    full-motion behavior of complex mechanical From the ADAMS post processor, minimum
    systems on their computers and quickly force required to rotate the cam with stopper
    analyzing multiple design variations until an roller alone and time required to engage are
    optimal design is achieved. measured.
    Steps in ADAMS
    Minimum torque required to rotate the drum cam against the stopper roller is tried with various parameters.
    Neutral to first gear

    Friction between cam and


    Inertia of the cam (Kg mm2)
    CCase Torque required to
    Weight of the Stopper Spring
    rotate
    cam stiffness
    ( Nmm ) (From
    ( Kg ) (N mm)
    ADAMS )
    Ixx Iyy Izz Static Dynamic

    0.40643518 71.048363 402.62321 404.33029 0.5 0.3 566.4 275

    0.38 71.048363 402.62321 404.33029 0.5 0.3 566.4 272

    0.36 71.048363 402.62321 404.33029 0.5 0.3 566.4 268

    0.34 71.048363 402.62321 404.33029 0.5 0.3 566.4 266

    0.32 71.048363 402.62321 404.33029 0.5 0.3 566.4 265

    0.3 71.048363 402.62321 404.33029 0.5 0.3 566.4 265

    WITHOUT FRICTION BETWN CAM & CCASE

    0.4064351 71.048363 402.62321 404.33029 0 0 566.4 228

    0.38 71.048363 402.62321 404.33029 0 0 566.4 226

    0.36 71.048363 402.62321 404.33029 0 0 566.4 225

    0.34 71.048363 402.62321 404.33029 0 0 566.4 223

    0.32 71.048363 402.62321 404.33029 0 0 566.4 220

    0.3 71.048363 402.62321 404.33029 0 0 566.4 220

    INERTIA (Izz)

    0.4064351 71.048363 402.62321 404.33029 0 0 566.4 228

    0.4064351 71.048363 402.62321 375 0 0 566.4 222

    0.4064351 71.048363 402.62321 350 0 0 566.4 220

    Spring stiffness

    0.4064351 71.048363 402.62321 404.33029 0 0 550 220


    0.4064351 71.048363 402.62321 404.33029 0 0 525 222
    0.4064351 71.048363 402.62321 404.33029 0 0 500 215
    WITHOUT FRICTION BETWN STAR & ROLLER
    0.4064351 71.048363 402.62321 404.33029 0 0 550 218
    0.4064351 71.048363 402.62321 404.33029 0 0 525 216
    0.4064351 71.048363 402.62321 404.33029 0 0 500 214
    CONCLUSION

    1. A model of power transmission system


    focused on the manual transmission was
    proposed. The whole system is divided in to
    subassemblies and each subassembly is analyzed
    separately for shift smoothness.
    2. As ADAMS/View simulates the model and it
    displays the calculated results as frames of an
    animation. The animation helps us to graphically
    view the overall behavior of your model and
    pinpoint specific problems, such as improper
    connectivity or misapplied motions or forces.
    ADAMS/View can display this information in
    strip charts for more in-depth investigation and
    manipulation.
    3. The mathematical model obtained from the
    SPSS software shows good correlation with the
    simulation data.
    4. This provides an effective verification
    methodology to find out the impact of design
    change in the final shift effort and time.

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