DESIGN AND FABRICATION OF POWER CLUTCH FOR TWO WHEELERS

A PROJECT REPORT

Submitted by

P.VELRAJ

V.S.YAVANARAJ

S.SRIDHAR

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

INSTITUTE OF ROAD AND TRANSPORT TECHNOLOGY

ERODE-638316.

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2009

1
DESIGN AND FABRICATION OF POWER CLUTCH FOR TWO WHEELERS

A PROJECT REPORT

Submitted by

P.VELRAJ

V.S.YAVANARAJ

S.SRIDHAR

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

INSTITUTE OF ROAD AND TRANSPORT TECHNOLOGY

ERODE-638316.

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2009

2
 ANNA UNIVERSITY: 600 025

BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF POWER

CLUTCH FOR TWO WHEELERS” is the bonafide work of

P.VELRAJ (70906114055)

V.S.YAVANARAJ (70906114060)

S.SRIDHAR (70906114039)

Who carried out the project work under my supervision

SIGNATURE SIGNATURE

Dr.K.MAYILSAMY., Ph.D., Mr.A.SENDHIL KUMAR., M.E., M.B.A.,

HEAD OF THE DEPARTMENT, SUPERVISOR,
Dept. of Mechanical Engineering, Selection Grade Lecturer,
I.R.T.T, Dept. of Mechanical Engineering,
Erode-638316. I.R.T.T,
Erode-638316.

3
 CERTIFICATE OF EVALUATION

College Name: Institute of Road and Transport Technology

Branch/Semester: Mechanical Engineering/ VI Semester

Name of the
Title of the Project Name of the Supervisor with Designation
Students

P.Velraj
Design and Fabrication of
Power Clutch for Two Mr.A.SENDHILKUMAR.,M.E.,M.B.A.,
V.S.Yavanaraj
Wheelers Selection Grade Lecturer

S.Sridhar

Submitted for the university practical on 27.04.2009

INTERNAL EXAMINER EXTERNAL EXAMINER

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2009

4
 ACKNOWLEDGEMENT

We wish to express sincere thanks to our college principal

Prof.Mr.L.PETER STANLY BEBINGTAN.,M.Sc., Institute of Road and
Transport Technology, Erode-638 316 to give an opportunity to conduct our
project.

We extend our gratitude to Dr.K.MAYILSAMY., Ph.D., The Head

of the Department of Mechanical Engineering for providing valuable
suggestions and support given throughout the study. We express our graceful
thanks to Mr.A.SENDHILKUMAR., M.E., M.B.A., for his valuable
technical guidance to our project.

We thank our staff members, skilled assistants of our department for

helping in our project work.

Heartfelt thanks to our parents, brothers and friends for their

blessing to bring out this project.

Finally we wish to thank our classmates and all who have directly or
indirectly contributed for the success of our project.

TABLE OF CONTENTS
5
CHAPTER
TITLE PAGE NO
NO

1) INTODUCTION 7

2) OUTLINE 8

3) REASON FOR SELECTION 9

4) OPERATION 10

5) MECHANICAL COMPONENTS 12

6) ELECTRONIC COMPONENTS 13

7) FABRICATION PROCEDURE 15

8) COST ESTIMATION 16

9) SNAPSHOTS 17

10) CONCLUSION 18

11) BIBLIOGRAPHY 19

CHAPTER 1

6
 INTRODUCTION

Project work enables to increase the practical experience of the

student by doing the project work. We are getting chances to improve
knowledge, skills and work experience in machines. Project work also
increases the coordination with peoples. It has given us to show our own
innovation.

The following were considered in implementation of our project work

The objective of the project is to evoke technical and induce the

student to make an ordinary performance in the existing situation, at hand so
as to reach at definite conclusion.

It provides through knowledge of material cost, labour cost, machine

cost, work study, routing, scheduling, etc., thus providing a better future for
the students.

CHAPTER 2

7
 OUTLINE

There are many people those who feel riding a bike is tedious. The
main problem that they face is frequent changing of gears and frequent usage
of clutch lever. This project helps them a lot in providing power for engaging
and disengaging the clutch. This project reduces the strain of the riders and
provides power to operate the clutch with a soft touch button.

In this project there is a DC Wiper motor with a built in worm and

wheel arrangement which provides the required power to operate the clutch
and a lever arrangement. This motion operates the clutch.

CHAPTER 3

8
 REASON FOR SELECTION

In the recent worlds trend it is the work of an engineer to provide

safety and comfort for the end-users. In case of riding a two wheeler the
operation of the gear and the clutch is a tiresome process. So as a beginning
in this project the operation of the clutch lever has been made ease. This
project will increase the fame of two wheelers among those who feel riding a
two wheeler a tedious process.

CHAPTER 4

9
 OPERATION

COMPONENTS USED:-

The main components used in this project are

 DC Wiper motor
 Clutch wire
 Electronic circuits to operate the motor

WORKING PRINCIPLE:-

A lever is mounted to the shaft of the wiper motor. A built in worm

wheel arrangement is also available in the wiper motor this stops the rotation
of the wiper motor in the opposite direction. The clutch wire is fixed to a
point on the lever.

When we push the button mounted on the hand bar the motor rotates
for some degrees in the clock wise direction and stops. The supply to the
motor is also stopped. So the lever rotates then the wire displaces. An
opposite force from the clutch spring acts on the lever this makes the lever to
rotate in the opposite direction. This opposite force is stopped with the help
of the worm and wheel arrangement in the wiper motor. This disengages the
clutch. During engagement of the clutch the button is left so the motor starts
to rotate in the opposite direction and stops. This makes the wound wire to
release and then the clutch is engaged.

The power to the motor is given from the battery already available in
the vehicle. The wire is connected on the fixed point available on the lever
with the help of a slot as already available in a clutch lever. The whole setup
can be mounted anywhere in the place near the engine.

10
 The electronics circuit consists of a microprocessor which controls the
whole arrangement. The electronics circuit is so small that it can be mounted
anywhere in the vehicle. The circuit is designed and programmed for the
operation of the motor. Relay circuits are used for the operation of the motor.

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 CHAPTER 5

MECHANICAL COMPONENTS

The force required to engage is given by the axial force of the spring.
The force required to disengage is given by the clutch lever in normal case.
But in this project the operation is made with a motor. So the axial force
must be calculated.

CALCULATION OF AXIAL FORCE

The clutch used in Two Wheeler is multiplate wet type clutch.

Inner radius (r1) = 70 mm

Outer radius (r2) = 45 mm

Friction coefficient (µ) = 0.3

Max torque (T) = 10.5 Nm @ 6500 rpm

No. of friction surface (n) =6

2T
W=
μ . n . ( r 1 +r 2 )

2∗10.5
¿
0.3∗6∗( 0.07+0.045 )

W = 101.5 N

CHAPTER 6
12
 ELECTRONIC COMPONENTS

The electronic components consists of the following things

 DC Wiper motor
 Microprocessor
 Relay coil
 LED
 Push button

DC WIPER MOTOR

A motor is a machine that converts electrical energy into

mechanical energy. The DC shunt motor receives the electrical energy from
a DC source and converts into mechanical energy.

DC motor consists of three main parts

 Armature
 Commutator
 Brush
DESIGN OF THE MOTOR:-

The force required to disengage the clutch is = 101.5 N

Torque required for the rotation of the lever is = 2.53 Nm

The RPM of the motor is = 80 rpm

The rating of the motor is given by

2 πNT
W=
60

2 π∗80∗2.53
¿
60

13
 = 21.19 Watt

The required rating of the motor is 21.19 Watts

MICROPROCESSOR

A microprocessor is an electronic device which can be used to do a

specified work with a help of in built programs. The type of microprocessor
used in this project is PIC16F77A

RELAY COIL

A relay is an electromechanical device that is actuated by an electric

current. It contains a sensing unit, the electrical coil that powered by AC or
DC current. When the applied current or voltage exceeds a threshold value
the coil activated the armature which operates either close or open contacts
or vice versa. It is used in many applications throughout the industries.

In this project we are using the electromechanical relay. There is a

general purpose relay is rated by the amount of current its switch handle.
Most version of this relay has 1-8 poles and can be single or double throw.

LED

LEDs are used in this project to sense the position of the relay coil

PUSH BUTTON

Push button is used for the operation of the clutch. It is mounted near
the left side hand bar

CHAPTER 7

14
 FABRICATION PROCEDURE

The motor can be assembled anywhere on the engine. In this project

the fabrication of the motor has been made on the butterfly. It is connected
with a help of a clamps, standard nuts and bolts. One side of the clutch wire
has a cylindrical projection which can be inserted in the slot provided on the
lever the other side is connected to the clutch.

The electronic circuit is also placed on the engine. The power for the
motor and the circuit is given from the battery which is already available.
The soft switch is placed near the hand bar.

CHAPTER 8
15
 COST ESTIMATION

SL.
COMPONENTS COST (Rs)
NO.

1) DC wiper motor 900

2) Electronic circuits 1000

3) Clutch wire 20

4) Fabrication 250

5) Push button 10

6) Miscellaneous 100

Total 2280

CHAPTER 9

16
SNAPSHOTS

17
 CHAPTER 10

CONCLUSION

This project makes riding two wheelers ease. The fame

of the two wheelers will increase a lot among old peoples. This project does
not make a large change in the efficiency of the vehicle. The component is
very small that it can be placed anywhere in the vehicle. This project will
decrease the strain created in the rider during frequent gear and clutch
disengagement.

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 CHAPTER 11

BIBLIOGRAPHY

 “Design of machine elements” - R.S. Khurmi

 “Mechatronics” - HMT publications
 “Automobile engineering” - R.B.Gupta

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