SHRI VAISHNAV POLYTECHNIC COLLEGE,

INDORE

A PROJECT REPORT ON

Study on Manual Synchromesh Gearbox

THE DISSERTATION SUBMITTED TO

RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA, BHOPAL (M.P)
TOWARDS THE PARTIAL FULFILLMENT OF THREE YEAR DIPLOMA
IN
AUTOMOBILE ENGINEERING
BY
Automobile Students
PROJECT HEAD: SUBMITEDBY:
Er.RAJEEV NAMDEO (INCHARGE) VIKAS MISHRA
PRASHANT TIWARI
TILAK PATIDAR
RITIK SHARMA
TARUN SINGH
PROJECT GUIDE:
Er. RAHUL KHANDE

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Department of Automobile Engineering
January-June2024

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SHRI VAISHNAV POLYTECHNIC COLLEGE, INDORE

DEPARTMENT OF AUTOMOBILE ENGINEERING

2023-24
RECOMMENDATION
We are pleased to recommend the work submitted by, Vikas

Mishra, Prashant Tiwari, Tarun Singh, Tilak Patidar, Ritik

Sharma students of automobile engineering branch entitled “SVP

SYNCHROMESH MANUAL TRANSMISSION SYSTEM 2024”

may be accepted impartial fulfillment of the three year diploma in

Automobile Engineering of Rajiv Gandhi Proudyogiki

Vishwavidyalaya, Bhopal (M.P.)

Project Guide: Project Head:

Er. Rahul Khande Er. Rajeev Namdeo (Incharge)

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SHRI VAISHNAV POLYTECHNIC COLLEGE, INDORE
DEPARTMENT OF AUTOMOBILE ENGINEERING

2023-24

CERTIFICATE

This is to certify that the project work on “ MANUAL

SYNCHROMESH GEARBOX 2024” is submitted by, Vikas

Mishra, Tarun singh, Ritik sharma, Tilak patidar, Prashant

Tiwari students of automobile engineering branch of this

institute in session 2023 – 2024 have prepared the project based

on the syllabus and is approved as a impartial fulfillment for the

record of project based on syllabus and prescribed by Rajiv Gandhi

ProudyogikiVishwavidyalaya (Polytechnic), Bhopal.

Internal Examiner External Examiner

Date-2024/ / Date-2024/ /

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 ACKNOWLEDGMENTS

We would like express our sincere thanks to Er. Rajeev Namdeo, Head
of the department, and automobile engineering branch for giving us this
opportunity to work on this project and to make this project
successful. This is the first time that our group students have worked on
this type of project. This project is very good because it will help junior to
unbiased her knowledge.
It would never be possible for us to take the project to this level
without the innovative ideas of our H.O.D sir and their great support and
encouragement.
We express our thanks to Er. Rahul Khande, Automobile faculty for
guide us in our project and give us suggestions to make this project
successful.
We would like to express our gratitude towards our honorable
principal Dr.Ashok Vyas , for letting us to do creative and explore
our curiosity through the medium of this institute.
We also express our sincere thanks to the teachers of Workshop
assistant superintendent and all the workshop technicians for
facilitating access to the equipment in the workshop and guiding us
whenever in times of need.
Last but not the least we would like to thank all those teachers
students and our friends who directly or indirectly helped me in
completion of this Endeavour and to make this project to that level on
which it works and in future our project will be the guideline and a big
example for the students who will think to make any project like us.

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 Student’s worked on the SVP E-Vehicle 2020

Sr. No. NAME OF STUDENTS ROLL NUMBERS WORK ASSIGNED

01 RITIK SHARMA 21019A03037 MARKETING

02 VIKAS MISHRA 21019A03050 REPORT MAKING

03 TILAK PATIDAR 21019A03045 PAINTING

04 PRASHANT TIWARI 21019A03033 HELPER

05 TARUN SINGH 21019A03044 CUTTING

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 ABSTRACT

All the automobile vehicles available are always set to changing speed and
torque between engine and driving wheels. Torque is not directly changed
but it can be done in the form of power using a suitable device. It is a very
useful method that we adopt, and it is also easily affordable. Many other
alternative, even though more elegant, and appear to be more effective are
not feasible when it comes to transmission.
This project mainly focuses on the design and fabrication of a gear box
that can transmit torque to the maximum and also helps to do some useful
work in automobile where power transmission is a major factor. The
transmission of power is done in six speeds in this project. The setup uses
two shafts and thirteen gears arranged in suitable distances to achieve the
desired torque and speed.

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 CONTENT

Sr. CONTENTS Pg. no.

no.
1. Abstract 1
2. Introduction
3. Design Calculations & Drawings
4. Gearbox operations
5. Comments and conclusions
6. Appendix
7. Reference
8. Acknowledgement
9.
10.

11.

12. Chapter no. 4

Maintenance 54 – 56
13. Chapter no. 5

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 Calculations and price estimates 57 – 59
14. Chapter no. 6
Conclusion 60
15. Chapter no. 7
Future scope 61
16. Chapter no. 8
References 62
17. Group photo 63

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 LIST OF FIGURES

Fig. No. Title

01. Electric go – Kart
02. Power transmission
03. Battery assembly
04. BEV’s circuit diagram
05. PHEV’s circuit diagram
06. HEV’s circuit diagram
07. Power transmission block diagram
08. Motor of SVP E vehicle 2020
09. Stator of motor
10. Rotor of motor
11. Commutator of motor
12. Brush and terminals of motor
13. DC motor color diagram
14. Line diagram of motor
15. Plates of the battery
16. Separator of the battery
17. Group of elements
18. Elements of battery
19. Battery container
20. Controller of SVP E vehicle 2020
21. Throttle of SVP E vehicle 2020
22. Line diagram of throttle
23. Disc brake of SVP E vehicle 2020
24. SVP E vehicle 2020 chassis diagram
25. SVP E vehicle 2020 frame diagram
26. Steering system of SVP E vehicle 2020
27. Line diagram of worm and roller
28. Steering linkage system line diagram
29. Wheel and tire diagram
30. Rim diagram

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 31. Battery indicator diagram
32. Indicator lights
33. Head lights
34. Tail lights

LIST OF TABLES

Table No. Title

01. Charging time
02. No. of components
03. Price estimates
04. Range / Ah

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 CHAPTER:-1

INTRODUCTION

A gear is a machine element used to transmit motion between rotating

shafts/wheels when the center distance between the shafts is not too large.

They provide a positive drive, maintaining exact velocity ratios between

driving and driven shafts. A transmission is a speed and power changing

device installed at some point between the engine and driving wheels of

the vehicle. It provides a means for changing the ratio between engine rpm

(revolutions per minutes) and driving wheel rpm to best meet each

particular driving situation. Given in order to get smooth starts and have

power to pass and climb hills, a power ratio must be provided to multiply

the torque and turning effort of the engine. Also required is a speed ratio n

to avoid the need for extremely high engine rpm at high road speed. The

transmission is geared to perform these functions. Power transmission

gears are usually made from chromium molybdenum steel which provides

good toughness and resistance to wear. Some (low power) gears are made

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from sintered metal (powered metal). Non-power gears can be made of

almost any material including composites for quieter running non

lubricated arrangements. Most gears are run lubricated either by regular

maintenance lubrication or by being run semi submersed in oil or spray

lubricated.

2.1 Gears usage

It plays an important role in our daily life basis, starting from our
washingmachines in houses till the heavy vehicles in mining and
construction places.Accordingly for each machine or vehicle. Gears are
simply a means of applyingleverage to rotating parts. A modern
transmission provides both speeds and power.The engineer who designed
it selected the gear sizes that would give the best allaround performance. It
is geared to a power ratio that puts the car in motion, andthen it shifts, or it
shifted, to one or more speed ratios that keeps it rolling.

2.2 Types of gearboxes:

Different types of gearbox are used. These types are manual gear,
automatic, semi-automatic, and bicycle gearing. For each gearbox, several
gears are utilized such as spur, helical, bevel, hypoid and worm gears.
Each type of gear is explained briefly below:

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  Spur Gear

This is the most common type of gear tooth shape, and would be fitted in the
accessory gearbox of an engine. The gear can be formed either internally or
externally. An internal gear would be used where a change in speed is
required without changing the axis of drive. External spur gears are used
where a change in speed is required but the shafts lie parallel to each other.
Spur gears may be noisy owing to the impact of the teeth upon each other as
they rotate.

 Helical Gear

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This is a smoother, less noisy running gear than the spur gear, the teeth are
cut on a curve or helix, which produces a sliding engagement of the teeth,
and more than one tooth is in engagement at any one time. A disadvantage
of this gear for is that it produces a heavy axial load. This disadvantage
can be eliminated by using double helical gears, with the teeth being cut in
an opposite helix. An advantage of this type of gear is that it can accept
and transmit a higher loading than a spur gear of the same size. Helical
gears might be fitted in the reduction gearbox of a turboprop engine or in
the gearbox of an ordinary car.

 Bevel Gear
This type of gear is used when the drive is required to be transmitted
through an angle; in this case the gear teeth can be straight cut or in a
helical form, when the axis of the shafts intersect. An example of use
would be for the transmission of drive from the main rotating assembly on
a gas turbine to the accessory gearbox, or the tail rotor gearbox on a
helicopter.

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  Worm Gear

This gear form is used where there is a large resistance to

turning,and a large reduction in speed is required. The worm
teeth aresimilar to a multi start thread, and are cut at an angle or

on theskew, in which case the gear may be called a skew gear.

 Automatic gear box

An automatic transmission (also called automaticgearbox) is a type of

motor vehicle transmissionthat can automaticallychangegear ratiosas the
vehicle moves, freeing the driver from having toshift gears manually. Most
automatic transmissions have a defined set ofgear ranges, often with a
parking pawlfeature that locks the output shaft ofthe transmission stroke
face to keep the vehicle from rolling either forwardor backward. [2]

 A semi-automatic transmission
(SAT) (also known as a clutch-less manualtransmission, automated manual
transmission, flappy-paddle gearbox,or paddle-shift gearbox) is an
automobile transmissionthat does not changegears automatically, but rather
facilitates manual gear changes by dispensingwith the need to press a
clutchpedal at the same time as changing gears. Ituses electronic sensors,

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pneumatics, processors and actuatorstoexecute gear shiftson the command
of the driveror by a computer. Thisremoves the need for a clutchpedal
which the driver otherwise needs todepress before making a gear change,
since the clutch itself is actuated byelectronic equipment which can
synchronize the timing and torque requiredto make quick, smooth gear
shifts. The system was designed by automobilemanufacturersto provide a
better driving experience through fast overtakingmaneuvers on highways

 Bicycle gearing :
Bicyclesusually have a system for selecting different gearratios. There are
two main types: derailleur gearsand hub gears. Thederailleur type is the
most common, and the most visible,using sprocketgears. Typically there are
several gears available on the rear sprocket assembly, attached to the rear
wheel. A few more sprockets areusually added to the front assembly as
well. Multiplying the number ofsprocket gears in front by the number to the
rear gives the number of gearratios, often called "speeds".The type of
gearbox used in this project is a manual Nissan car gearbox. The
mainspecification of the gear box we selected consists of main shaft,
counter shaft, andhousing. Gears are placed in the main shaft and counter
shaft to transmit themotion, whereas bearings to hold and support the shafts
inside the housing. Theselected gearbox has specifications of helical and
spur gearings. Gearboximportance appears in transmitting the work output
from the pistons to the carwheels. Owing to the gear ratios, gears such as
reverse gear, low gear, second gear,high gear, & overdrive rotate in
different rotational speeds. For example in high gear,the gear ratio is 1 to 1,
thus the output shaft turns at the same speed as thecrankshaft.The objective
of this project is to illustrate how a gearbox works and show thefunction of
each component inside it.

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 5.2 PRICE ESTIMATES:

NO. NAME OF COMPONENTS QUANTIT COST (Rs)

Y

1. Motor 01 3000
2. Battery 04 3600
3. Controller 01 2000
4. Throttle 01 500
5. Chain 01 80
6. Calliper 01 500
7. Disc 01 300
8. Tube 04 1000
9. Battery meter 01 200
10. lubrication 01 200

Total 11280

Table no. 3: Price estimates

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 CHAPTER: - 6

CONCLUSION

Through this project, we have cleared maximum of our doubts related to

an electric vehicle and as well as we understood that how can we simplify
our planning, and learned how face the difficulty’s come while preparing
the SVP E Vehicle 2020 or any other project which could be made by us.
Our team made this project so that our juniors can clear there doubts
related to any electric vehicle. We are thankful of over adviser to guide us
in all possible way and we can now successful run our vehicle. Through
his guidance we have solved all our problems faced while building SVP E
vehicle 2020.

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 CHAPTER: - 7

FUTURE SCOPE

The future scope of this project is that as we have seen the disadvantages
of an electric vehicle so in future we have to try to reduce those not all but
maximum of the disadvantages. And this project is not actually made as
an electric vehicle but our team as tried to cover the best, so as it is not
accurate so in future we can upgrade this vehicle through the
specifications of an electric vehicle.
As we know that this vehicle is an battery operated vehicle and the battery
makes the land pollution which indirectly harms our environment so we
can decrease the use of battery in this vehicle and can use the solar plates
as the power source, so the use of the battery would be reduced through
this because currently in this vehicle we are using the 4 battery, and if we
use the solar plates so it will be directly reduced to a single battery,
because at that time we are using the battery as a storage on a current and
the main power source will be our solar plates. This can be a best
upgradation in the future on this vehicle.

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And the other main upgrade can be done on this vehicle should be the by
changing its power transmission system currently we are using the chain
and sprocket to run the vehicle. But in upgradation we can do it a gear
drive this can be done by replacing the sprocket through the gear. And
fixing another gear on the motor this can save the vehicle from power lose
and increase the efficiency of the vehicle.

CHAPTER: - 8

REFERENCES

9.1 REFERENCES:

1. History of e-vehicle: https://en.wikipedia.org/wiki/Electric_car#History

2. Types of EVs:https://www.evgo.com/why-evs/types-of-electric-vehicles/
3. Levels of charging:https://en.wikipedia.org/wiki/Charging_station
4. Component - motor: https://sciencing.com/basic-parts-dc-generator-6760185.html
5. Working of motor: https://www.electricaleasy.com/2014/01/basic-working-of-dc-motor.html
6. Work of controller in e – cars: https://www.electricvehiclesmalta.eu/e-driving/how-do-electric-vehicles-work
7. Working and components of throttle:https://en.wikipedia.org/wiki/Electronic_throttle_control
8. Working principle of the brake : https://www.quora.com/What-is-the-principle-of-disc-brakes
9. Chassis function and components:https://en.wikipedia.org/wiki/Chassis
10. Functions of frame:https://en.wikipedia.org/wiki/Vehicle_frame
11. Loads act on frame: https://autokeeda.wordpress.com/2015/03/28/various-loads-acting-on-frame/
12. Functions of frame: http://www.differencebetween.net/miscellaneous/difference-between-frame-and-chassis/
13. Brief of worm and roller: http://constructionmanuals.tpub.com/14273/css/Worm-and-Roller-311.htm
14. Types of steering system: https://www.bluestar.com/get_informed/article/the-power-steering-system-steering-gear/
15. Components of steering system: https://en.wikipedia.org/wiki/Steering_system
16. Types of wheel:https://medium.com/@popularrightnow/difdifferent-types-of-wheels-2ea522142967
17. Components of wheels: https://en.wikipedia.org/wiki/Wheel

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18. Battery indicator and its uses: https://en.wikipedia.org/wiki/Battery_indicator#Automobiles
19. Working principle of battery indicator: https://www.electronicshub.org/battery-level-indicator/
20. Advantages and disadvantages of e vehicles: https://freedomgeneral.com/blog/10-advantages-and-disadvantages-of-electric-cars/
21. Maintenance of e vehicle: https://www.energy.gov/eere/electricvehicles/electric-car-safety-maintenance-and-battery-life
22. Maintenance of tesla cars: https://www.tesla.com/support/car-maintenance?redirect=no
23. Ackermann Steering geometry: https://www.quora.com/What-is-Ackermann-steering

Group photo:

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