CHAPTER 1

INTRODUCTION
Now a day’s all the two wheeler industries have improved their
technologies and designs the two wheeler like engine design body modification
and automation etc. By analyzing the above mentioned problems, we replaced
the manual gear shifting mechanism by automatic cam operated based gear
shifting gear box. The gear engagement and disengagement are controlled by
cam. In advance to apply the project for any type and any old model or new
model two wheeler gear boxes. We are not able to change one vehicle spare
parts to other vehicle spare parts. That is the problem to convert the old model
two wheeler of manual transmission to newly modernized type of two wheeler
1.1 INTRODUCTION TO TRANSPORTATION AND TRANSMISSION
Transportation decisions impact many aspects of urban life. Young and
old alike are affected by the viability and relative ease of travelling to
destinations on foot, by bike, transit, or reliance on private vehicles.
Transportation investments are arguably the single largest shaper of urban
spaces and of development patterns. The safety, speed, and comfort for a
particular mode of travel are a function of the investments that have been made
in specific types of travel options. Regions, and parts of regions, vary
considerably in terms of their supportiveness of travelling in ways that are
health promoting (active) and environmentally sustainable.
Transmission system transmits mechanical power from the engine to give
kinetic energy to the wheels. It is an interconnected system of gears, shafts, and
other electrical gadgets that form a bridge to transfer power and energy from the
engine to the wheels. The complete set up of the system helps to maintain the
cruising speed of the vehicle without any disturbance to the performance. The
oldest variant of the transmission system in India is the manual transmission

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that has undergone various modifications and alterations to form the present day
automatic transmission.
A transmission or gearbox provides speed and torque conversions from a
rotating power source to another device using different gear ratios. The
transmission reduces the higher engine speed to the slower wheel speed,
increasing torque in the process. A transmission will have multiple gear ratios
with the ability to switch between them as speed varies. This switching may be
done manually or automatically. Directional control may also be provided, such
as forward and reverse gears.
In motor vehicle applications, the transmission will generally be
connected to the crankshaft of the engine. The output of the transmission is
transmitted through chain drive, which in turn gives motion the rear wheel.
Most modern gearboxes are used to increase torque while reducing the
speed of a prime mover output shaft. This means that the output shaft of a
gearbox will rotate at slower rate than the input shaft, and this reduction in
speed will produce a mechanical advantage, causing an increase in torque.
1.2 TYPES OF TRANSMISSION
There are two major types of transmission, namely manual gear
transmission and automatic gear transmission
1.2.1 Manual Gear Transmission
A manual transmission is a type of transmission used in motor vehicle
applications. It uses a driver-operated clutch engaged and disengaged by a foot
pedal or hand lever, for regulating torque transfer from the engine to the
transmission; and a gear selector operated by hand or by foot.
Manual transmissions often feature a driver-operated clutch and a
movable gear pedal. Most automobile manual transmissions allow the driver to
select any forward gear ratio at any time, but some, such as those commonly
mounted on motorcycles and some types of racing cars, only allow the driver to
select the next-higher or next-lower gear. This type of transmission is

2
sometimes called a sequential manual transmission.
In a manual transmission, the flywheel is attached to the engine's
crankshaft and spins along with it. The clutch disk is in between the pressure
plate and the flywheel, and is held against the flywheel under pressure from the
pressure plate. When the engine is running and the clutch is engaged, the
flywheel spins the clutch plate and hence the transmission. As the clutch is
depressed, the throw out bearing is activated, which causes the pressure plate to
stop applying pressure to the clutch disk. This makes the clutch plate stop
receiving power from the engine, so that the gear can be shifted without
damaging the transmission. When the clutch pedal is released, the throw out
bearing is deactivated, and the clutch disk is again held against the flywheel,
allowing it to start receiving power from the engine.
There are two basic types of manual transmissions. The sliding-gear type
and the constant mesh design. With the basic and now obsolete sliding-gear
type, nothing is turning inside the transmission case except the main drive gear
and cluster gear when the transmission is in neutral. In order to mesh the gears,
apply engine power to move the vehicle.

Fig 1.1 Sliding Gear Transmission

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 All modern transmissions are of the constant-mesh type, which still uses
a similar gear arrangement as the sliding-gear type. This is possible because the
gears on the main shaft are not splinted to the shaft, but are free to rotate on it.
With a constant-mesh gearbox, the main drive gear, cluster gear and all the
main shaft gears are always turning, even when the transmission is in neutral.

Fig 1.2 Constant Mesh Transmissions

1.2.2 Automatic Transmission
An automatic transmission, also called as self-shifting transmission, is a
type of motor vehicle transmission that can automatically change gear ratios as
the vehicle moves, freeing the driver from having to shift gears manually. Like
other transmission systems on vehicles, it allows an internal combustion engine,
best suited to run at a relatively high rotational speed, to provide a range of
speed and torque outputs necessary for vehicular travel.
The most popular type found in automobiles is hydraulic automatic
transmission. Similar but larger devices are also used for heavy-duty

4
commercial and industrial vehicles and equipment. This system uses a fluid
coupling in place of a friction clutch, and accomplishes gear changes by
hydraulically locking and unlocking a system of planetary gears. These systems
have a defined set of gear ranges, often with a parking pawl that locks the
output shaft of the transmission to keep the vehicle from rolling either forward
or backward. Some machines with limited speed ranges or fixed engine speeds,
such as some forklifts and lawn mowers, only use a torque converter to provide
a variable gearing of the engine to the wheels.

Fig 1.3 Constant Variable Transmission Low and High Gear Ratio
Besides the traditional hydraulic automatic transmissions, there are also
other types of automated transmissions that free from the driver from having to
shift gears manually, by using the transmission's computer to change gear, if for

5
example the driver were redlining the engine. Despite superficial similarity to
other transmissions, traditional automatic transmissions differ significantly in
internal operation and driver's feel from semiautomatics and CVT’s. In contrast
to conventional automatic transmissions, a CVT uses a belt or other torque
transmission scheme to allow an "infinite" number of gear ratios instead of a
fixed number of gear ratios. A semi-automatic retains a clutch like a manual
transmission, but controls the clutch through electro hydraulic. The ability to
shift gears manually, often via paddle shifters, can also be found on certain
automated transmissions semi-automatics and CVT’s.
1.3 COMPARISON BETWEEN MANUAL AND AUTOMATIC
TRANSMISSION
1.3.1 Manual Transmission
 It is easier to build a strong manual transmission than an automatic one.
This is because a manual system has one clutch to operate, whereas an
automatic system has a number of clutch packs that function in harmony
with each other.
 Manual transmissions normally do not require active cooling, because not
much power is dissipated as heat through the transmission.
 Manual gearshifts are more fuel efficient as compared to their automatic
counterpart. Torque convertor used to engage and disengage automatic
gears may lose power and reduce acceleration as well as fuel economy.
 Manual transmissions generally require less maintenance than automatic
transmissions. An automatic transmission is made up of several
components and a breakdown of even a single component can stall the car
completely.

1.3.2 Automatic Transmission
 The manual transmission locks and unlocks different sets of gears to the
output shaft to achieve the various gear ratios, while in an automatic

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 transmission; the same set of gears produces all of the different gear
ratios.
 Automatic vehicles are easier to use, especially for the inexperienced
driver. Manual system requires better driving skills, whereas with an
automatic, the clever system does it all on its own. This holds a greater
advantage for new and inexperienced drivers and also helps during
congested traffic situations where it becomes difficult to change gears
every second.
 Automatic transmission requires less attention and concentration from the
driver because the automatic gears start functioning as soon as the system
feels the need of a gear change. For vehicles with manual gear shifts, the
driver has to be more alert while driving and better coordinated.
 There is no clutch pedal and gear shift in an automatic transmission car.
Once you put the transmission into drive, everything else is automatic.
 Automatic vehicles have better ability to control traction when
approaching steep hills or engine braking during descents. Manual gears
are difficult to operate on steep climbs.
1.4 AUTOMATION OF MANUAL GEAR TRANSMISSION
1.4.1 Overview
The topic of our project is to develop an automatic transmission system
with has finite number of gearshifts, which transmits the power automatically
with respect to speed of the vehicle. Gearshifts in automatic transmissions
involve a change in the power flow path through the transmission. Advantages
of these automatic transmissions include simplicity of mechanical design and
savings in transmission weight and size, which are beneficial in terms of fuel
economy and production costs. This enables gain in fuel economy while
meeting drivability and performance goals, these savings become more
significant.
The designed automatic transmission is done in an auto-clutch featured

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bike which can be applied effectively and efficiently in a clutch featured bike
with suitable control techniques. The ultimate goal of our project is to transmit
the gears without the human interference and to attain efficient, safe and easy
driving in cost effective way.
1.4.2 Automation
Automation is the use of control system to control a process replacing the
human operators. It is a step beyond mechanization, where human operators are
provided with the physical requirements of work.
Automation is now often applied primarily to reduce the human effort
thereby to attain desired operation. Another major shift in automation is the
increased emphasis on flexibility and convertibility in different process.
One safety issue with automation is that it is often viewed as a way to
minimize human error in the system, increasing the degree and the levels of
automation also increase the sequence of error that accidently created in
automated systems. Different types of automation tools that exist in today’s
environment are Programmable logic controller, Microcontroller, SCADA, etc.
1.4.3 Embedded System
All embedded system uses either a microprocessor or microcontroller.
The software for the embedded system is called firmware. The firmware will be
written in assembly language using higher level languages life ‘C’ or
‘Embedded C’. The software will be simulated using micro code simulation for
the target processor. Since they are supposed to perform only specific tasks, the
programs are stored in ROM.
An embedded system is some combination of computer hardware and
software, either fixed in capability or programmable, that is specifically
designed for a particular function. Industrial machines, automobiles, medical
equipment, cameras, household appliances, airplanes, vending machines and
toys are among the myriad possible hosts of an embedded system. Embedded
systems that are programmable are provided with programming interfaces, and

8
embedded system programming is a specialized occupation.
An Embedded system is a special-purpose computer system, which is
completely encapsulated by the device controls. It has specific requirements and
performs pre-defined tasks, unlike a general purpose personal computer.
 Avoids lots of Electronic components.
 Build in with rich features.
 Probability of failure is reduced.
 Easy interface.

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 CHAPTER 2
LITERATURE REVIEW
Vishnu P Ra, Vishnu R et al, “Pneumatic Gear Transmission for Two
Wheeler” The present automatic transmission is fully mechanically controlled
and costs very high. In this study, 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, two pneumatic double acting
cylinders, Programmable Logic Controller (PLC), an electrical motor, limit
switches, push buttons, bulbs, a table (holder) and power supply. According to
suggested gear shifting method the control unit chooses optimum gear shifting
ratio for an automobile without operating it manually (using relays). Using this
method leaves to the driver the excitement of choosing the shifting moment.
Urbana, Illinois “Design and Evaluation of an Automatic Gear-Shifting
System for Manual Wheelchairs” Just like shifting gears on a bicycle, multiple
gears on a manual wheelchair can make it easier to complete many tasks of
daily living. We developed an automatic gear-shifting system (AGS) for
manually propelled wheelchairs. The AGS has three speeds – first gear: for
ascending slopes or traversing compliant surfaces, second gear: traditional
direct-drive for everyday situations, and third gear: for improved ergonomics
during fast propulsion. The AGS is packaged as an add-on set of two wheelchair
wheels (each with its own 3-speed transmission connecting the hand rim and
tire) and onboard electronics for gear shifting.
A previous gear shifting design for manual wheelchairs (Magic Wheels,
Magic Wheels, Inc.; Seattle, Washington), required the user to stop completely
and manually shift gears, whereas the AGS can shift on the fly automatically.

10
The Magic Wheels device was shown to significantly reduce the level of
shoulder pain when used for long periods of time, so it is likely that the AGS
can provide the same benefit but with increased usability. A prototype of the
AGS was constructed and tested over the course of a year. Although many
mechanical and electrical components experienced a number of issues, each was
analyzed and redesigned. At the very least, clear guidelines were provided for
future development. Additionally, a study was done to evaluate the AGS’s
usability by assessing user perception of the AGS ability to reduce the effort of
propelling a wheelchair.
Prashant Vavhal, Prof.Sateesha Patil et al, “Improve Gear Shifting
Process Using Devices as Auto Pneumatic Gear Shifter” In this study, 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,
two pneumatic double acting cylinders, Programmable Logic Controller (PLC),
an electrical motor, limit switches, push buttons, bulbs, a table (holder) and
power supply. According to suggested gear shifting method the control unit
chooses optimum gear shifting ratio for an automobile without operating it
manually (using relays). Using this method leaves to the driver the excitement
of choosing the shifting moment.
Mankar N.A., Mr. Keshar S. D et al, “Electro-pneumatic Gear Shifting
Mechanism” In this paper, a gear shifting mechanism was designed and applied
to make the shifting process more expeditious and less destructible for the
driver. The incipient contrivance must be reliable, has a diminutive dimensions,
low construction and maintenance cost. This paper aims to gear shifting process
utilizing contrivances as: a manual four speed gear box, two pneumatic double
acting cylinders, an electrical motor, limit switches, buttons, a table (holder) and
power supply. According to suggested gear shifting mechanism the control unit

11
select optimum gear shifting ratio for an automobile without operating it
manually (utilizing relays). Utilizing this method leaves to the driver the
exhilaration of selecting the shifting moment.
N.Venkatesh, P.Karthikeyan et al, “Pneumatic Gear Changer for Four
Wheelers” Pneumatic Gear Changer can be used in four wheelers easily because
the availability of compressor is there. So, we don’t need extra support. In this
we used principles of Mechatronics in developing this project work. The
standing mechanism is achieved by reciprocating the double acting cylinders
which controlled by single solenoid operated 5/2 way Directional control valve.
This is actuated through the dashboard panel in front of the driver through the
buttons. The operating pressure required for this system is 5 to 6 bar. The
maintenance required for this system is less than the other systems. It is used to
reducing the gear shifting time without losing the break power and the
efficiency is improved. The main advantages of our project are elimination of
wear and tear, simple in operation, fast movement in control and less space by
elimination of linkages. Our project is a gear changing device, in which gear is
changed using pneumatic power so that it avoids wear and tear.

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 CHAPTER 3
WORKING METHODOLOGY

EXISTING
COMPONENTS

PROPOSED
METHOD

DESIGN

COMPONENTS
SELECTION

ASSEMBLY

WORKING
AND
OUTPUT

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3.1 COMPONENTS USED

 Gear lever

 Cam

 Motor

 Battery

 Frame

3.2 OBJECTIVE

The main objective of this system is to minimize the human errors in

operating the gears with the help of automatic technology. Other objectives

include optimum gear ratios, reducing wear and tear of the gears, shifting the

gear effectively, optimum performance of the gear box, optimum force exerted

by the cams to move the shifting levers.

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 CHAPTER 4
COMPONENTS DESCRIPTIONS
4.1 GEAR LEVER

Fig 4.1 Gear lever

The lever is used to change gears in a motor bike. A manual transmission,
also known as a manual gear box, a standard transmission or colloquially in
some countries as a stick shift, is a type of transmission used in motor vehicle
applications. It uses a driver operated clutch, usually engaged and disengaged
by a foot pedal or hand lever, for regulating torque transfer from the engine to
the transmission and a gear selector that can be operated by hand or foot.
4.2 CAM

Fig 4.2 Rotating cams and cam followers

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 A cam is a rotating or sliding piece in a mechanical linkage used
especially in transforming rotary motion into linear motion or vice-versa. It is
often a part of a rotating wheel (e.g. an eccentric wheel) or shaft (e.g. a cylinder
with an irregular shape) that strikes a lever at one or more points on its circular
path. The cam can be a simple tooth, as is used to deliver pulses of power to
a steam hammer, for example, or an eccentric disc or other shape that produces
a smooth reciprocating (back and forth) motion in the follower, which is a lever
making contact with the cam.

OVERVIEW

The cam can be seen as a device that rotates from circular to

reciprocating (or sometimes oscillating) motion. A common example is
the camshaft of an automobile, which takes the rotary motion of the engine and
translates it into the reciprocating motion necessary to operate the intake and
exhaust valves of the cylinders.

4.2.1 Displacement Diagram

Fig 4.3 Basic displacement diagram

Certain cams can be characterized by their displacement diagrams, which

reflect the changing position a roller follower (a shaft with a rotating wheel at
the end) would make as the cam rotates about an axis. These diagrams relate
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angular position, usually in degrees, to the radial displacement experienced at
that position. Displacement diagrams are traditionally presented as graphs with
non-negative values. A simple displacement diagram illustrates the follower
motion at a constant velocity rise followed by a similar return with a dwell in
between as depicted. The rise is the motion of the follower away from the cam
center.

However, the most common type is in the valve actuators in internal

combustion engines. Here, the cam profile is commonly symmetric and at
rotational speeds generally met with, very high acceleration forces develop.
Ideally, a convex curve between the onset and maximum position of lift reduces
acceleration, but this requires impractically large shaft diameters relative to lift.
Thus, in practice, the points at which lift begins and ends mean that a tangent to
the base circle appears on the profile. This is continuous with a tangent to the tip
circle. In designing the cam, the lift and the dwell angle   are given. If the
profile is treated as a large base circle and a small tip circle, joined by a
common tangent, giving lift   , the relationship can be calculated, given the

angle   between one tangent and the axis of symmetry (  being ),

while   is the distance between the centres of the circles (required), and   is
the radius of the base (given) and   that of the tip circle (required)

 And 

4.2.2 Plate Cam

The most commonly used cam is the plate cam (also disc cam or radial
cam) which is cut out of a piece of flat metal or plate. Here, the follower moves
in a plane perpendicular to the axis of rotation of the camshaft. Several key
terms are relevant in such a construction of plate cams: base circle, prime circle
(with radius equal to the sum of the follower radius and the base circle radius),
pitch curve which is the radial curve traced out by applying the radial

17
displacements away from the prime circle across all angles, and the lobe
separation angle (LSA - the angle between two adjacent intake and exhaust cam
lobes).

Fig 4.4 Cam profile

The base circle is the smallest circle that can be drawn to the cam profile.

A once common, but now outdated, application of this type of cam was
automatic machine tool programming cams. Each tool movement or operation
was controlled directly by one or more cams. Instructions for producing
programming cams and cam generation data for the most common makes of
machine were included in engineering references well into the modern CNC era.

This type of cam is used in many simple electromechanical

appliance controllers, such as dishwashers and clothes washing machines, to
actuate mechanical switches that control the various parts.

4.2.3 Cylindrical Cam

Fig 4.5 Cylindrical cam

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 Fig 4.6 Barrel Cam

A cylindrical cam or barrel cam is a cam in which the follower rides on

the surface of a cylinder. In the most common type, the follower rides in a
groove cut into the surface of a cylinder. These cams are principally used to
convert rotational motion to linear motion parallel to the rotational axis of the
cylinder. A cylinder may have several grooves cut into the surface and drive
several followers. Cylindrical cams can provide motions that involve more than
a single rotation of the cylinder and generally provide positive positioning,
removing the need for a spring or other provision to keep the follower in contact
with the control surface.

Applications include machine tool drives, such as reciprocating saws, and

shift control barrels in sequential transmissions, such as on most
modern motorcycles.

A special case of this cam is constant lead, where the position of the
follower is linear with rotation, as in a lead screw. The purpose and detail of
implementation influence whether this application is called a cam or a screw
thread, but in some cases, the nomenclature may be ambiguous.

Cylindrical cams may also be used to reference an output to two inputs,

where one input is rotation of the cylinder, and the second is position of the
follower axially along the cam. The output is radial to the cylinder. These were

19
once common for special functions in control systems, such as fire control
mechanisms for guns on naval vessels and mechanical analog computers.

An example of a cylindrical cam with two inputs is provided by a

duplicating lathe, an example of which is the Klotz axe handle lathe, which cuts
an axe handle to a form controlled by a pattern acting as a cam for the lathe
mechanism.

4.2.4 Face Cam

A face cam produces motion by using a follower riding on the face of a

disk. The most common type has the follower ride in a slot so that the captive
follower produces radial motion with positive positioning without the need for a
spring or other mechanism to keep the follower in contact with the control
surface. A face cam of this type generally has only one slot for a follower on
each face. In some applications, a single element, such as a gear, a barrel cam,
or other rotating element with a flat face, may do duty as a face cam in addition
to other purposes.

Face cams may provide repetitive motion with a groove that forms a
closed curve, or may provide function generation with a stopped groove. Cams
used for function generation may have grooves that require several revolutions
to cover the complete function, and in this case, the function generally needs to
be invertible so that the groove does not self intersect, and the function output
value must differ enough at corresponding rotations that there is sufficient
material separating the adjacent groove segments. A common form is the
constant lead cam, where displacement of the follower is linear with rotation,
such as the scroll plate in a scroll chuck. Non-invertible functions, which
require the groove to self-intersect, can be implemented using special follower
designs.

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 Fig 4.7 Traditional cam

A variant of the face cam provides motion parallel to the axis of cam
rotation. A common example is the traditional sash window lock, where the cam
is mounted to the top of the lower sash, and the follower is the hook on the
upper sash. In this application, the cam is used to provide mechanical advantage
in forcing the window shut, and also provides a self-locking action, like
some worm gears, due to friction.

Face cams may also be used to reference a single output to two inputs,
typically where one input is rotation of the cam and the other is radial position
of the follower. The output is parallel to the axis of the cam. These were once
common is mechanical computation and special functions in control systems.

A face cam that implements three outputs for a single rotational input is
the stereo phonograph, where a relatively constant lead groove guides the stylus
and tone arm unit, acting as either a rocker-type (tone arm) or linear (linear
tracking turntable) follower, and the stylus alone acting as the follower for
two orthogonal outputs to representing the audio signals. These motions are in a
plane radial to the rotation of the record and at angles of 45 degrees to the plane
of the disk (normal to the groove faces). The position of the tone arm was used
by some turntables as a control input, such as to turn the unit off or to load the
next disk in a stack, but was ignored in simple units.

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4.2.5 Linear Cam

A linear cam is one in which the cam element moves in a straight line
rather than rotates. The cam element is often a plate or block, but may be any
cross section. The key feature is that the input is a linear motion rather than
rotational. The cam profile may be cut into one or more edges of a plate or
block, may be one or more slots or grooves in the face of an element, or may
even be a surface profile for a cam with more than one input. The development
of a linear cam is similar to, but not identical to, that of a rotating cam.

Fig 4.8 Left hand holder

The original key (mounted in the left hand holder) acts as a linear cam to
control the cut depth for the duplicate.

A common example of a linear cam is a key for a pin tumbler lock. The
pins act as the followers. This behavior is exemplified when the key is
duplicated in a key duplication machine, where the original key acts as a control
cam for cutting the new key.

4.2.6 Cam Shaft

A cam is a mechanical member for transmitting a desired motion to a
follower by direct contact. The driver is called the cam, and the driven member
is called the follower. The cam, may remain stationary, or translate oscillate or
rotate whereas the follower may translate or oscillate.

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4.3 MOTOR
An electric motor is an electrical machine that converts electrical
energy into mechanical energy. The reverse of this is the conversion of
mechanical energy into electrical energy and is done by an electric generator,
which has much in common with a motor.
There are types of motors,
AC motor
DC motor
In this course, we are going to focus on DC motors only because of high torque
production.
4.3.1 DC Motor
A DC motor is any of a class of rotary electrical machines that converts

direct current electrical energy into mechanical energy. This system

demonstrates efficient gearless transmission of power at right angles. This saves
gear manufacturing time and costs along with teeth matching and gear
placement issues. The elbow mechanism is an efficient design of gearless
transmission technique and the kinematic system that allows for efficient
power/motion transmission at right angles.
This mechanism allows for motion transmission at 90 degree angles
between the driver and the driven shafts. We use mounts to mount a DC motor
with shaft coupled to it. We then use 90 degree bent rods to link driver shaft
with the driven shaft. We use accurate drilling with relatively spaced and
diameter holes to attach the connection rods with precision. We then use mounts
to hold the driven rod in precise position. Now the motor can be powered using
12V battery supply and can be used to lift the heavy weight material or 360 0
rotation.

23
 Fig 4.9 DC Motor
4.3.2 Principles of Operation of DC Motor

In any electric motor, operation is based on simple electromagnetism. A

current-carrying conductor generates a magnetic field; when this is then placed
in an external magnetic field, it will experience a force proportional to the
current in the conductor, and to the strength of the external magnetic field. As
you are well aware of from playing with magnets as a kid, opposite (North and
South) polarities attract, while like polarities (North and North, South and
South) repel. The internal configuration of a DC motor is designed to harness
the magnetic interaction between a current-carrying conductor and an external
magnetic field to generate rotational motion.
Let's start by looking at a simple 2-pole DC electric motor (here red
represents a magnet or winding with a "North" polarization, while green
represents a magnet or winding with a "South" polarization).

24
 Fig 4.10 Sectional view of DC motor
Every DC motor has six basic parts: axle, rotor (a.k.a., armature), stator,
commutator, field magnet(s), and brushes. In most common DC motors (and all
that Beamers will see), the external magnetic field is produced by high-strength
permanent magnets. The stator is the stationary part of the motor, this includes
the motor casing, as well as two or more permanent magnet pole pieces. The
rotors (together with the axle and attached commutator) rotate with respect to
the stator. The rotor consists of windings (generally on a core), the windings
being electrically connected to the commutator. The above diagram shows a
common motor layout with the rotor inside the stator (field) magnets.
The geometry of the brushes, commutator contacts, and rotor windings
are such that when power is applied, the polarities of the energized winding and
the stator magnet(s) are misaligned, and the rotor will rotate until it is almost
aligned with the stator's field magnets. As the rotor reaches alignment, the
brushes move to the next commutator contacts, and energize the next winding.
Given our example two-pole motor, the rotation reverses the direction of current
through the rotor winding, leading to a "flip" of the rotor's magnetic field,
driving it to continue rotating.

25
 The DC Motor or Direct Current Motor to give it its full title, is the most
commonly used actuator for producing continuous movement and whose speed
of rotation can easily be controlled, making them ideal for use in applications
were speed control, servo type control, and/or positioning is required. A DC
motor consists of two parts, a "Stator" which is the stationary part and a "Rotor"
which is the rotating part. The result is that there are basically three types of DC
Motor available.
BRUSHED MOTOR
This type of motor produces a magnetic field in a wound rotor (the part
that rotates) by passing an electrical current through a commutator and carbon
brush assembly, hence the term "Brushed". The stators (the stationary part)
magnetic field is produced by using either a wound stator field winding or by
permanent magnets. Generally brushed DC motors are cheap, small and easily
controlled.
BRUSHLESS MOTOR
This type of motor produce a magnetic field in the rotor by using
permanent magnets attached to it and commutation is achieved electronically.
They are generally smaller but more expensive than conventional brushed type
DC motors because they use "Hall effect" switches in the stator to produce the
required stator field rotational sequence but they have better torque/speed
characteristics, are more efficient and have a longer operating life than
equivalent brushed types.
SERVO MOTOR
This type of motor is basically a brushed DC motor with some form of
positional feedback control connected to the rotor shaft. They are connected to
and controlled by a PWM type controller and are mainly used in positional
control systems and radio controlled models.

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 Normal DC motors have almost linear characteristics with their speed of
rotation being determined by the applied DC voltage and their output torque
being determined by the current flowing through the motor windings. The speed
of rotation of any DC motor can be varied from a few revolutions per minute
(rpm) to many thousands of revolutions per minute making them suitable for
electronic, automotive or robotic applications. By connecting them to gearboxes
or gear-trains their output speed can be decreased while at the same time
increasing the torque output of the motor at a high speed.
4.4 BATTERY
Common examples are the alkaline battery used for flashlights and a
multitude of portable devices. Secondary (rechargeable) batteries can be
discharged and recharged multiple times; the original composition of the
electrodes can be restored by reverse current.

Fig 4.11 Battery

A standard car battery is used for its deep cycle charging characteristics,
allowing for frequent and large inward and outward passages of charge. US
standards have a nominal voltage of 12.6V yet range from 11.8 to 14.4V based
on internal charge level. The typical amp-hours of a car battery are 40Ah. Under
these conditions the system could draw maximum output power from the car
battery alone for 4.2 hours. When not loaded and the generator operating at
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continuous duty maximum current it would take 5.3 hours to full charge a
completely depleted battery.
4.4.1 TYPES OF BATTERIES
Batteries can be divided into two major categories, primary batteries and
secondary batteries. A primary battery is a disposable kind of battery. Once
used, it cannot be recharged. Secondary batteries are rechargeable batteries.
Once empty, it can be recharged again. This charging and discharging can
happen many times depending on the battery type. Alkaline batteries, Mercury
batteries, Silver-Oxide batteries, and Zinc carbon batteries are examples of
primary batteries whereas Lead-Acid batteries and Lithium batteries fall into the
secondary battery's category.
A primary cell or battery is one that cannot easily be recharged after one
use, and are discarded following discharge. Most primary cells utilize
electrolytes that are contained within absorbent material or a separator (i.e. no
free or liquid electrolyte), and are thus termed dry cells.
A secondary cell or battery is one that can be electrically recharged after
use to their original pre-discharge condition, by passing current through the
circuit in the opposite direction to the current during discharge. The following
graphic evidences the recharging process.

Fig 4.12 Recharging cell

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Secondary batteries fall into two sub-categories depending on their intended
applications.
 Cells that are utilized as energy storage devices, delivering energy on
demand. Such cells are typically connected to primary power sources
so as to be fully charged on demand. Examples of these type of
secondary cells include emergency no-fail and standby power sources,
aircraft systems and stationary energy storage systems for load-
leveling.
 Cells that are essentially utilized as primary cells, but are recharged
after use rather than being discarded. Examples of these types of
secondary cells primarily include portable consumer electronics and
electric vehicles.
4.5 FRAME
A frame is often a structural system that supports other components of a
physical construction and/or steel frame that limits the construction's extent.
Framing, in construction, is the fitting together of pieces to give a structure
support and shape. Framing materials are usually wood, engineered wood, or
structural steel. The alternative to framed construction is generally called mass
wall construction, where horizontal layers of stacked materials such as log
building, masonry, rammed earth, adobe, etc. are used without framing.

Fig 4.13 Frame

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 Building framing is divided into two broad categories, heavy-frame
construction (heavy framing) if the vertical supports are few and heavy such as
in timber framing, pole building framing, or steel framing; or light-frame
construction (light-framing) if the supports are more numerous and smaller
called light-frame construction, for example balloon, platform and light-steel
framing. Light-frame construction using standardized dimensional lumber has
become the dominant construction method in North America and Australia due
to the economy of the method; use of minimal structural material allows
builders to enclose a large area at minimal cost while achieving a wide variety
of architectural styles.

Fig 4.14 Heavy-frame

4.5.1 CHARACTERISTICS OF STRUCTURAL STEEL
Structural steel differs from concrete in its attributed compressive
strength as well as tensile strength.

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Strength - Having high strength, stiffness, toughness, and ductile properties,
structural steel is one of the most commonly used materials in commercial and
industrial building construction.
Constructability - Structural steel can be developed into nearly any shape,
which are either bolted or welded together in construction. Structural steel can
be erected as soon as the materials are delivered on site, whereas concrete must
be cured at least 1–2 weeks after pouring before construction can continue,
making steel a schedule-friendly construction material.
Fire resistance - Steel is inherently a noncombustible material. However, when
heated to temperatures seen in a fire scenario, the strength and stiffness of the
material is significantly reduced. The International Building Code requires steel
be enveloped in sufficient fire-resistant materials, increasing overall cost of
steel structure buildings.
Corrosion - Steel, when in contact with water, can corrode, creating a
potentially dangerous structure. Measures must be taken in structural steel
construction to prevent any lifetime corrosion. The steel can be painted,
providing water resistance. Also, the fire resistance material used to envelope
steel is commonly water resistant.
Mold - Steel provides a less suitable surface environment for mold to grow than
wood.

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 CHAPTER 5
WORKING PRINICIPLE

 In our project is gear changing mechanism operated by D.C. motor, it’s

consists of battery, motor, cam, gear lever and frame setup.

 The gear lever’s each end is cam mechanism is connected, it’s operated

up and down movement of gear lever.

 The motor is rotating and that time cam mechanism is actuated to produce

linear motion. To motor operating with help of battery.

 The cam should be rotating automatically gear will be changing with help

of gear lever.

 Its cam operated mechanism is a continuous process, and it's very useful

to the automobile sector.

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 CHAPTER 6
ADVANTAGES AND APPLICATIONS
6.1 ADVANTAGE

 It requires simple maintenance cares.

 The safety system for automobile.

 Checking and cleaning are easy, because of the main parts are

screwed.

 Easy to Handle.

 Low cost automation Project

 Repairing is easy.

 Replacement of parts is easy.

6.2 APPLICATION

 These using four wheelers and two wheelers,

 Industrial application, etc.,

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 CHAPTER 7
CONCLUSION
The project carried out by us made an impressing task in the field of

automobile department. It is very useful for driver while drive the vehicle at any

places without any tension.

It is a new idea in the transmission system of a vehicle. By implementing

this smart gear shifter in cars, we can achieve more space, smooth operation,

and more user friendly, less effort to change the gear.

This project is very useful for drivers which who interested to drive two

wheelers, it is very differ from gearless motor bikes which this system is very

useful for rough driving and increase the performance and torque of the two

wheeler. This can be also applied in feature for four wheeler and also heavy

vehicles to improve the driving and avoid fear while driving.

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