“Design and Fabrication of Automated Manual Gear Transmission in Motor Bikes” (Ref no: 39S_BE_1837) A Project sponsored by KARNATAKA STATE COUNCIL FOR SCIENCE AND TECHNOLOGY INDIAN INSTITUTE OF SCIENCE CAMPUS BANGALORE -560012 In partial fulfilment Submitted by CHETHAN J 1KG12ME012 DARSHAN NAIK 1KG12ME014 LAKSHMI KESARI 1KG12ME024 MAHANTHESH S 1KG12ME028 Under the Guidance of Mr. AKASHDEEP B N Asst. Professor Department of Mechanical Engineering K.S.S.E.M, Bengaluru Department of Mechanical Engineering K.S. School of Engineering and Management No. 15, Mallasandra, off Kanakapura Road, Bengaluru-560109 2015-16 K.S. School of Engineering and Management No. 15, Mallasandra, off Kanakapura Road, Bangalore-560109 Department of Mechanical Engineering 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 in partial fulfilment for the award of Bachelor of Engineering in Mechanical Engineering of Visvesvaraya Technological University, Belgaum, during the year 2015-16. It is certified that all the suggestions indicated during internal assessment have been incorporated in the report and this thesis satisfies the academic requirement in respect of project work prescribed for the degree. _________________________ _____________________ _______________ Name and Signature of Internal Head of the Department Principal/ Director Guide K.S. School of Engineering and Management No. 15, Mallasandra, off Kanakapura Road, Bangalore-560109 Department of Mechanical Engineering 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. Sl. No. Reg. No. Name of Student Signature with Date 1. 1KG12ME012 Chethan J 2. 1KG12ME014 Darshan Naik 3. 1KG12ME024 Lakshmi Kesari 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. CVT’s 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. By implementing this system into an auto-clutch feature bike, automatic transmission of gears while driving the motor bike can be achieved. This automated transmission can be controlled by the acceleration, since it is with respect to the speed of the bike. The fuel efficiency can be tested after fabricating the bike according the above mechanism. Contents CHAPTER 1............................................................................................................................1 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 LITERATURE REVIEW ...........................................................................................................13 2.1 Present work on automatic gear shifting ..............................................................13 2.2 Microprocessor explained briefly.........................................................................15 2.3 Review on literature survey..................................................................................15 2.4 Aim, Objectives and Methodology ......................................................................16 2.5 Methodology: .......................................................................................................16 CHAPTER 3..........................................................................................................................17 DESIGN AND FABRICATION ..................................................................................................17 3.1 Selection of bike...................................................................................................17 3.1.1 Specifications of the bike ..................................................................................18 3.2 Design...................................................................................................................19 3.2.1 Torque Calculation...........................................................................................19 3.2.2 Designing the gear shifting mechanism............................................................20 3.3 Fabrication............................................................................................................22 3.3.1 Geared DC Motor or Starter Motor .................................................................22 3.3.2 Electronic circuit ..............................................................................................23 3.3.3 Proximity Sensor...............................................................................................24 3.3.4 Microcontroller.................................................................................................25 3.3.5 LCD Display.....................................................................................................31 3.3.6 Relays................................................................................................................32 3.4 Programming........................................................................................................33 3.4.1 KIEL μ vision ....................................................................................................33 3.4.2 Willar Programmer ..........................................................................................34 3.5 Program Flowchart...............................................................................................35