CHENDHURAN

POLYTECHNIC COLLEGE
PUDUKKOTTAI – 622507

AUTOMATIC GEAR SHIFTING MECHANISM FOR

TWO WHEELERS
PROJECT WORK 2023-2024

Done by

NAME REG NO

Report Submitted in partial fulfillment for the award of the

“Diploma in Automobile Engineering” of the
Directorate of technical education,
Government of TamilNadu

Under the Guidance of

Mr.S.SUSHANTH B.E.,
LECTURER

DEPARTMENT OF AUTOMOBILE ENGINEERING

CHENDHURAN POLYTECHNIC COLLEGE

PUDUKKOTTAI – 622507
 BONAFIDE CERTIFICATE

This is to certify that the report titled

AUTOMATIC GEAR SHIFTING MECHANISM FOR TWO

WHEELERS
is a Bonafide record of work done by

Register Number: of the Department of

Automobile Engineering in partial fulfillment for the Directorate of Technical

Education, Government of Tamil Nadu during the academic year 2022-2023

PROJECT GUIDE HEAD OF THE DEPARTMENT

Dr.SG.SHELVARAJ, M.E, Ph.D.,

(LECTURER/AUTO) HOD/AUTO and PRINCIPAL

Submitted for the Board Examination held on

Internal Examiner External Examiner

 ACKNOWLEDGEMENT

At the outset, we express our thanks to our esteemed chairman. Thiru

AVM SELVARAJ and beloved CEO Dr. AVM.S.KARTHICK B.E.,MBA., Ph.D
for their dynamic role and for elevation of our institution to greater heights by
providing us with all the infrastructure and other essential facilities.

Also we would like to extend our thanks to our principal & also HOD of
Mechanical Engineering Department Dr. S.G.SHELVARAJ M.E.,Ph.D for his
constant effort in helping us by providing the necessary equipment and materials
that were used to build the project.

Not the more formality but from the depth of our heart, we extend our
sincere thanks to our project guide lecturer in Department
of Mechanical Engineering for his valuable suggestions, motivation, and constant
support.

We are really indebted to our parents, faculty members and our friends for
their timely help, and for the mental and moral support. Along with their blessing
of the almighty, we will continue to feel the success.

We would like to submit our special thanks to our Department Staff

Members and Lab Instructors and other non teaching staff for their valuable
suggestions to improve the content and quality of the project.

We also exhibit our thanks to one and all who had constantly supported us
either directly or indirectly to complete in completing this project successfully.
 CONTENTS
CHAPTER
TITLE PAGE NO
NO

ABSTRACT

I INTRODUCTION

II LITERATURE REVIEW

III SELECTION OF MATERIALS

IV METHODOLOGY

V COMPONENTS DESCRIPTION

VI WORKING PRINCIPLE

VII DIAGRAM

VII COST ESTIMATION

VIII FEATURES

IX CONCLUSION

X REFERENCES
 ABSTRACT

Motorcycles are widely used around the world particularly in INDIA. The gear
shifting system of the motor-cycle is conventionally manual. This report covers
development of an indigenous gear shifting /changing system for the standard
motorcycle. By this system the manual mechanical gear- shifting will remain
unchanged because an additional electromechanical system is placed on the top
of the lever to shift the gear and automatically control the clutch. So the system
has both the option manual as well as automatic. The system uses low cost
microcontrollers to make the accurate decision for shifting the gear up and
down by observing the speed, and it controls the clutch transmission where
necessary. The complete hardware and software has been tested and the
functioning of the automatic gear shifting system is verified. System is flexible
and can be used with any motorcycle ranging from 50 to 200 cc.

1
INTRODUCTION

2
 CHAPTER I

INTRODUCTION

There are already some inventions done of gear box for motorcycle for
transmitting the torque from engine crankshaft to the rear wheel of the
motorcycle. The gear box is used to vary the torque as per the different driving
conditions. The gearbox increases the required torque for start the ride and put
the motorcycle in to motion. After the start or the running of the motorcycle
there is no need of high torque, so now gear box will transmit the optimum
torque to the rear wheel at high speed. For the operation of gearbox and shifting
the gear there is need of some effort of driver of motorcycle. A foot lever is
used to shift the gears in a motorcycle. Also, a clutch is placed between the
engine and the transmission in order to engage and disengage the flywheel with
the transmission. So for smooth driving of motorcycle there is need to time
these two operations perfectly. This gear shifting becomes a tiresome process
for most new drivers. This can also help in reducing accidents.

Therefore we propose the development of an automated system which

can change the gears automatically with the help of speed. This automated
system which we propose will also be beneficial in terms of fuel economy and
production costs. In our developed system , both the gear and the clutch are
controlled electro- mechanically by a micro controlled based computer system.
This system does not require any modification to the engine. The equipment is
mounted externally on the body of the motorcycle. This system shifts the gear
up and down electro-mechanically like the human rider by sensing the speed of
the vehicle, but the system shifts the gear at exactly the correct speed, which
produces the smooth gear changing sequence. The engine runs smoothly
without any knocking , which increases the engine life. This proposal is
different from the one used in cars as it uses electromechanical actuators.

3
 1) Sensors and Actuators A device which detects or measures a physical
property and records, indicates, or otherwise responds to it. An actuator is a
component of a machine that is responsible for moving or controlling a
mechanism or system.

2) Servo Motor and Linear Punching Actuator A servo motor is a rotary

actuator or linear actuator that allows for precise control of angular or linear
position, velocity and acceleration. It includes a DC motor with a sensor for
position feedback. A linear punching actuator uses it’s to and fro motion for
precise control of angular or linear position, velocity and acceleration.

3) Manual Transmission in Bikes There are three basic controls to operate

when it comes to shifting a motorcycle:

a) The throttle

b) The clutch, and

c) The gear selector.

The throttle controls the engine speed, the function of clutch is to engage
and disengage the transmission, and the gear selector selects the gear. Pull the
clutch towards you using your left hand, and revolution of the engine with
certain r.p.m will be there without moving the bike forward. Releasing of the
clutch while the transmission is "in gear" (ie, not in neutral), and you'll move
the bike forward.

4) Automatic Transmission of Bikes An electronic gear-shifting system is

a method of changing gears on a bike, which enables riders to shift with
electronic switches instead of using conventional control levers and mechanical
cables. The switches have been connected by wires or wirelessly to a battery
pack and to a small electric motor that drives the derailleur, switching the chain
from cog to cog. Use of an electronic system is to change gears faster, and

4
because the system does not use Bowden cables and can calibrate itself, it may
require less maintenance.

In every vehicle, the transmission system transmits the mechanical power

from the engine to give kinetic energy to the wheels. The Gear box in the
system is responsible to vary the torque according to the driving conditions by
shifting the gears manually. Bad shifting is also one of the reasons for the
motorcycle accidents. In case of manual gear shifting, the foot lever is used for
gear shifting in motorcycle and the clutch operation makes it difficult. The
Auto-clutch bikes is used in the project. So, while accelerating the bike, the
clutch plates will not wear, performing the smooth operation. Therefore, we
purpose automated system which uses embedded system to shift gears. As this
embedded system arrangement installed outside, there is no need for
modification inside the engine of the bike. The working of the automated
system is based on the speed of the wheel. As the rpm of the wheel increases,
the proximity sensor counts the rpm and sends the signal to microcontroller
(MCU). The microcontroller then sends the signal to DC Stepper motor to step
up. This process also follows the same with the deceleration of the wheel, as the
speed decreases, the Stepper motor will step down the gear. The engine life is
also increased as the engine runs smoothly without ‘knocking’. This embedded
system can also be used in any auto-clutch motorcycle ranging from 50cc to
200cc.

Nowadays, a manual transmission or sequential type is a type of

transmission used on motorcycles and Two Wheelers, where gears are selected
in order, and direct access to specific gears is not possible. With traditional
manual transmissions, the driver can move from gear to gear, by moving the
shifter to the appropriate position. A clutch must be disengaged before the new
gear is selected, to disengage the running engine from the transmission, thus
stopping all torque transfer. During manual transmission, shifting between gears

5
in order to match acceleration and deceleration needs, drivers have to learn how
to use a clutch, when to shift, and the proper timing required for operating a
manual transmission effectively. So this project is to being thinking automatic
transmission is one type of motor vehicle transmission that can automatically
change gear ratios as the vehicle moves, freeing the driver from having to shift
gears manually and to achieve efficient driving which reduces human efforts
and fear while driving. In manual transmissions, the driver can move from gear
to gear, by moving the shifter to the appropriate position. A clutch must be
disengaged before the new gear is selected,to disengage the running engine
from the transmission, which is very confusing and fearable. So for avoiding
this we have design and develop such a system which can be installed in any
two wheeler vehicles that run on roads so that it can overcome drawback of
manual transmission. This is the new innovative model mainly used for the
vehicles to control the vehicle without human efforts. The main objective of this
concept is used to apply the gear by using automation system in automobile
vehicles. This is the new innovative model mainly used for the vehicles to
control the vehicle. Here we are concentrating to design the automatic gear
changing mechanism in two wheeler vehicles by using the electronic devices.
This is very useful for the gear changing mechanism in automobile vehicles. By
using this we can easily control the vehicle and improve the performance of the
vehicle also we can avoid the wear and tear of the gear.

6
LITERATURE SURVEY

7
 CHAPTER II

LITERATURE SURVEY

1) Automated Transmission System: [1] Automated Transmission is a clutch-

less (without clutch pedal) manual transmission system which uses electronic
sensors, processors and actuators (hydraulic or electro mechanical) to do clutch
actuation and gear shifts as per command of the driver. Automated
Transmission system uses a conventional manual transmission, actuators and
control unit to automate the whole process. The system consists of three
sections of sensors, processors and Actuators.

2) Gear Selecting Mechanism: Conventional way of gear selection was been

using a gear speeder to detect nicks on transmission gear teeth. However,
measurement over balls, runout and tooth-to-tooth composite error could not be
measured by the gear speeder and skilled workers were always needed to
operate the gear speeder. Efficiency of these highly mechanized processes
appreciably depends on the reliability of work of tooth gearings of machine
drives.

3) Impulsive responses in geared systems with multiple clearances are studied

when the mean torque excitation and system load change abruptly, with
application to a vehicle driveline with an automatic transmission.

A. Reason for Topic Selection

1) Changing gears manually is a gruesome task which has also been very
disturbing for the riders.

2) However, switching to automatic transmission can help us overcome all such

situations.

8
3) Abrupt stopping of the engine in traffic due to poor handling of clutches can
be avoided.

B. Aims and Objectives of Research

1) To design the system for automatic transmission.

2) To calculate the dimensions of the magnet to be used and gear ratios being
used

3) To code the required arduino program for the servo motor and the linear
punching actuator.

4) Analysis of designed mechanism.

5) Fabrication and testing of designed mechanism.

Haj Fraj et al had proposed an optimal control approach for gear shift
operations in automatic transmissions. Starting from a verified model of a
typical power train with an automatic transmission a performance measure for
evaluating the gear shift process in terms of passengers comfort and control
expenditure is developed. The gear shift operation is stated as a multistage
decision process by making use of the dynamic programming method

Paul D. Walker et al Presents original research on the response of DCT

equipped power trains to synchronizer mechanism engagement process with and
without engine harmonic induced vibration. The integral design and operation
of dual clutch transmissions exposes synchronizer mechanisms to new sources
of vibration during actuation. Traditional manual transmissions release the
clutch before synchronization begins, isolating the synchronizer from forced
engine vibration.

9
 Ferran Reverter et al Proposed this paper that analyses the accuracy and
resolution of direct resistive sensor-to-microcontroller interfaces using
theoretical and experimental methods

J. Rafiee a et al Present this paper to introduce an automatic feature

extraction system for gear and bearing fault diagnosis using wavelet-based
signal processing. Vibration signals recorded from two experimental set-ups
were processed for gears and bearing conditions. Four statistical features were
selected: standard deviation, variance, kurtosis, and fourth central moment of
continuous wavelet coefficients of synchronized vibration signals (CWC-SVS).

10
SELECTION OF
MATERIALS

11
 CHAPTER III

SELECTION OF MATERIALS

1.Properties:

The material selected must possess the necessary properties for the proposed
application. The various requirements to be satisfied can be weight, surface
finish, rigidity, ability to withstand environmental attack from chemicals,
service life, reliability etc. The following four types of principle properties of
materials decisively affect their selection

 Physical

 Mechanical

 From manufacturing point of view

 Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity,
electrical conductivity, magnetic purposes etc. The various Mechanical
Properties Concerned are strength in tensile, Compressive shear, bending,
torsional and buckling load, fatigue resistance, impact resistance, elastic limit,
endurance limit, and modulus of elasticity, hardness, wear resistance and sliding
properties. The various properties concerned from the manufacturing point of
view are,

 Cast ability

 Weld ability

 Surface properties

 Shrinkage

12
2. Manufacturing Case

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may
demand the use of special materials.

3. Quality Required

This generally affects the manufacturing process and ultimately the

material. For example, it would never be desirable to go casting of a less
number of components which can be fabricated much more economically by
welding or hand forging the steel.

4. Availability of Material

Some materials may be scarce or in short supply, it then becomes

obligatory for the designer to use some other material which though may not be
a perfect substitute for the material designed. The delivery of materials and the
delivery date of product should also be kept in mind.

5. Space Consideration

Sometimes high strength materials have to be selected because the forces

involved are high and space limitations are there.

6. Cost

As in any other problem, in selection of material the cost of material

plays an important part and should not be ignored. Sometimes factors like scrap
utilization, appearance, and non-maintenance of the designed part are involved
in the selection of proper materials.

13
METHODOLOGY

14
 CHAPTER IV

METHODOLOGY

The study of following research papers are done:

a) Modeling of an automated manual transmission system.

b) Development of a New Automatic Gear Selecting Machine for

Automobile.

c) Tooth wear modeling and prognostication parameters of engagement

of spur gear power transmissions.

d) Impulsive response of an automatic transmission system with multiple

clearances: Formulation, simulation and experiment. 2) Calculations Speed
range of gearing and vehicle Now here we calculate the range of speed of gear
box output power and range of all minimum and maximum rpm of the gear box
shaft in every gear mashing condition… If we consider the speed for first gear is
0km /h to 20km/h for second 20km/h to 30km/h for third 30km/h to 45km/h and
for greater than 45km/h take for the gear mashing. Here, we have the range in
term of speed in km/h now converting the vehicle speed in rpm for that use the
equation , as given below. N=V*60/3.14 D; Where , N=speed in rpm V=speed
in m/s D=tire diameter in m Take, D=0.80 meter tire diameter. Thus by using
this equation we can find the our speedometer speed km/h can convert in
revolution per minute(rpm). We have output gear reduction as 9.889 (calculated
by using the output shaft dia. And the teeth on rear to front sprockets) The gear
torque is shown as below. Gear arrangement Speed of vehicle in km/hr. Speed
of vehicle in rpm. Speed on output shaft of gear box in rpm.

15
COMPONENT
DESCRIPTION

16
 CHAPTER V

COMPONENT DESCRIPTION

Sensor

A proximity sensor is a non-contact device that senses the presence of an

object. According to the application, proximity sensors are classified into
different types. In this project, inductive type proximity sensor is used. This
sensor detects only metallic object placed next to it. This sensor works under the
electrical principal of inductance, the fluctuating current indices induces the
EMF (electromotive force) in a target object. The cost of this sensor is
comparatively low and operating distance is less than 50mm

Relay circuit

Relays are the switches which operates electromagnetically. It focuses on

closing and opening of the circuit contacts in electronic circuit. The schematic
diagram in the figure 2 shows the components inside the relays. There are two
switches of 5V and 10A are used for shifting the gears. The first relay is used to
shift the gear up and second for shifting the gear down. The NPN transistor
“BC547” is used to control the relays. The transistor works on logic circuit,
when the input is logic “1” in the port pin it is driven into saturation (turned
ON). When the input is logic “0”, the relays are turned OFF. A diode is
connected to the relays, to avoid the damage to the transistor due to back EMF
generated in the relays when transistor is OFF. The LED displays whether the
relays are ON or OFF.

DC Stepper Motor

A DC Stepper motor or stepping motor is the type of brushless DC motor

which rotates in steps to complete its full rotation. The steps of the motor are
controlled by microcontroller according to gear to shift. The stepper motor is

17
connected to the gear pedal. Necessary modification is done on the gear pedal.
The motor is connected to 12v power supply and runs at 500 rpm. The geared
DC stepper motor of model “VJT253” is used for high torque output. Relays are
provided to control the power supply to the motor. Relay 1 is actuated to rotate
the motor in clockwise direction and relay 2 for anticlockwise direction. The
pitch diameter of the gear on the dc motor is 25mm meshes with the gear pedal
which is fitted with spur gear of pitch diameter of 80mm. When the output shaft
DC motor rotates at 45° (anticlockwise), the pedal rotates at 25° which is
sufficient to shift the lever down and the gear shifts up of motorcycle. The same
condition follows with gear down. Fig -4: DC Stepper Motor 2.4

Microcontroller

A microcontroller is a device which is used as a computer in embedded

system. The microcontroller includes processor, memory and input/output (I/O)
peripherals. There are different types of microcontroller available based on the
applications. The “ATMEGA328”microcontroller (8-bit AVR with 32kb flash
program memory) with read-while write capabilities, 1kb EEPROM, 2kb
SRAM, 23 general purpose I/O, 32 general purpose working registers. The
device can be operated between 1.8 – 5.5 volts. Embedded “C program is burnt
into the microcontroller using “proteus software”. Since it is reprogrammable, it
can be burnt until a program with necessary pulses ranges is implemented to it.
The Table 1 shows the input feed in the microcontroller which shifts the gear
according to the pulses.

18
WORKING PRINCIPLE

19
 CHAPTER VI

WORKING PRINCIPLE

The control unit is nothing but the microcontroller is a small chip, its
already programmed and feed in the chip for working of our project. One of the
gun is used to apply the gear and another one for reducing the gears. The gears
are applied on the vehicle depending up on the speed of the vehicle. The speed
sensors are placed near the wheel the sensor sense the signal and give the output
signal to the control unit. Depending up on the signal the clutch and gears will
automatically changed with the help of the control unit. When the vehicle speed
increasing automatically the clutch and the gear will change in the vehicles. In
our project, we used Regulator as Accelerator to control speed and D.C.Motor
as Flywheel to store energy.

We have provided a specific limit of speed for each gear so that when we
accelerate the regulator the speed of D.C. Motor increases at that time the speed
sensor sense the range of speed which is mounted near the dc motor. And the
signal of speed increase sense by speed sensor is given to microcontroller. In
microcontroller, the program is already feed for that speed range, the
microcontroller checks the speed and for that specific speed range the output
signal is send to the D.C. Gun through relay circuit due to which D.C. Gun
strikes on gear changing pedal and gear increase takes place. Simultaneously the
clutch is operated automatically by D.C. Gun which is also operated by
microcontroller through relay. And similarly, when we deaccelerate the
regulator the speed of dc motor decreases and another dc gun is operated which
is mounted on other end of gear changing pedal to decrease the gear. And thus
through this mechanism the gear change can be done automatically.

20
DIAGRAM

21
CHAPTER VIII

DIAGRAM

22
COST ESTIMATION

23
 CHAPTER VIII

COST ESTIMATION

S.No Component Qty Price

1 Motor 1 Rs.400

2 Sensor 1 Rs.500

3 Microcontroller 1 Rs.1300

4 Relay 1 Rs.600

5 Transformer 1 RS.800

Total Rs.3600

LABOUR COST

 Welding

 Grinding

 Power hacksaw

 gas cutting cost

OVERHEAD CHARGES:

24
The overhead charges are arrived by ”manufacturing cost”

Manufacturing Cost =Material Cost +Labour Cost

= Rs. 3600 + Rs. 1200

= Rs. 4800

Overhead Charges = 20% of the manufacturing cost

= Rs. 1000

TOTAL COST

Total cost = Material Cost +Labour Cost +Overhead Charges

= 3600 + 1200 + 1000

= Rs. 5800 /-

Total cost for this project = Rs. 5800 /-

25
FEATURES

CHAPTER IX

26
 FEATURES

 Ease of use

Automatic bikes are easy to operate, especially in stop-and-go traffic, and don't
require any practice before riding.

 Faster acceleration

Automatic transmissions shift faster and more accurately than manual

transmissions.

 Better fuel efficiency

Automatic bikes are typically faster than manual bikes due to less fuel
consumption and power generation per kilometer.

 Safer to operate

Automatic motorcycles can stop quickly in confined areas and don't stall
because the computer shifts gears on its own.

 Ideal for beginners

Automatic bikes are ideal for beginners or those who want an easy-to-operate
bike for congested traffic conditions

27
CONCLUSION

CHAPTER X

28
 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. The
programmed embedded ‘C’ codes, in the microcontroller, were optimized and
were the key source for changing gears in city limits as well as highways.
Maintaining aproper pulse range, as in the program, or a constant speed of the
vehicle resulted in better fuel efficiency. Fuel efficiency has been improved by
2km to 4km. After implementing this technology we have come to a conclusion
that no human operation is necessary, other than accelerating, to ride the motor
bike.

29
REFERENCES

CHAPTER XI

30
 REFERENCES

[1] R. Hembree, “SEMI-AUTOMATIC ELECTRIC GEAR SHIFTING

APPARATUS FOR A MOTORCYCLE”. United States 15 July 1975.

[2] U. M. Friedrich Raff, “SHIFTING ARRANGEMENT‘FOR AN

AUTOMATIC TRANSMISSION OF A MOTOR VEHICLE”. United States 3
Sep 1991.

[3] David G. Funk, “PUSHBUTTON SOLENOID SHIFTER”. United States of

America Patent 6070485, 6 Jun 2000.

[4] P. Alexander M.E, “AUTOMATIC GEAR TRANSMISSION IN TWO

WHEELERS,” vol. 3, no. 2, 2012.

[5] Oliver J. Tysver, “AUTOMATIC GEAR SHIFTING MECHANISM FOR

MULTISPEED MANUALLY POWERED VEHICLES”. United States 28 Dec
1999.

[6] Francis G. King, “AUTOMATED MANUAL TRANSMISSION SHIFTER

WITH ELECTRONIC CONTROL ACTUATORS EXTERNAL OF THE
VEHICLE”. United States of America Patent 4554824, 26 nov 1985.

[7] Robert E. LaWrie, “AUTOMATED MANUAL TRANSMISSION SHIFT

SEQUENCE CONTROLLER”. United States 1 Feb 2000.

[8 ] Pierre A. G. Lepelletier, “MULTISPEED AUTOMATIC TRANSMISSION

FOR AUTOMOBILE VEHICLES”. United States 21 April 1992.

[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.
31