Sri SAIRAM POLYTECHNIC COLLEGE

sAI LEO NAGAR, WEST TAMBARAM, CHENNAI-44

Fabrication of Reverse gear in two wheeler

Guided by: g.mohanraj b.e

 PROJECT MEMBERS
• N.Karthik • 10207994
• S.karthik • 10207995
• A.S.Mohammed Irfan • 10208002
• B.Devandran • 10207982
• S.Vignesh • 10233781
• R.Rajesh • 10208011
 OBJECTIVE
• Physically challenged people finds
difficulties in moving their two
wheelers back. So to overcome this
problem we are implementing the
new concept of reverse gear.
• By using this reverse gear the people
can easily move back without any
difficulties
 ABSTRACT
At present, there is no system available to back the vehicle. At times
when the front wheel gets into a trench it is very difficult to take the
vehicle from parking. Even normal people face much problem to take
the vehicle out of the parking at that time. Incase of the handicapped
people who drive two wheelers with extra support wheels, face much
problem to take the vehicle out of the parking by pushing the vehicle
with legs as we do. In order to take the vehicle out of the parking they
need to seek others help or they should push it out of the parking. As a
help to them we have designed a gear box which will be fit to the
vehicle without altering the existing gear box. The paper deals with the
design of such a gear box and the assembly process of the gear box to
the vehicle. The design deals with the conditions of the gear box
operation, and the design of the gear box based on easy assembly and
easy manufacturing at low cost.
 INTRODUCTION

At present, there is no system available to back the vehicle. At times when the front
wheel gets into a trench it is very difficult to take the vehicle from parking. Even normal
people face much problem to take the vehicle out of the parking at that time. Incase of the
handicapped people who drive two wheelers with extra support wheels, face much
problem to take the vehicle out of the parking by pushing the vehicle with legs as we do. In
order to take the vehicle out of the parking they need to seek others help or they should
push it out of the parking. As a help to them we have designed a gear box which will be fit
to the vehicle. It is fitted to the side of the vehicle and helping in the backing of the
vehicle. When the driver wants to move the vehicle backward what he needs is just to
move the rod in the newly designed gear box in one direction and when the driver wants
the vehicle to move in the forward direction, then the rod is to be moved to the earlier
position. The change of direction of the vehicle is just by the movement of the gear rod.
This project thus gives a detailed view of how an extra gearbox is fitted to the vehicle and
how it is working and how useful in the backing of vehicles. As an additional benefit the
vehicle can also be moved back and forth in heavy traffic. More over the power for this
gear box is taken from the vehicle’s engine itself, so there is no need for any extra motor or
engine. This gear box can be fitted to any vehicle with much ease.
 LIST OF PARTS USED

• BEARINGS
• CHAIN SPROCKET
• GEARS
• SUPPORTIVE WHEELS
• HAND LEVER
 ENGINE
• In this project we are using internal combustion engine.
• In this system petrol is used as fuel.
• It has two stroke single cylinder of cubic capacity of 75 cc.
• Cylinder bore diameter-50mm
• STROKE length-49mm
 ENGINE WORKING
• There are two stroke namely upward stroke (suction and compression) and
downward stroke (expansion and exhaust).
• During upward stroke the piston moves from bottom dead centre to top
dead centre.
• The piston closes the exhaust port closes first and then exhaust port is
closed
• While this stroke the air fuel mixture is compressed in the combustion
chamber and it is ignited with the help of the spark plug.
• The lower edge of the piston opens the inlet port by allowing the fresh
charge.
• During downward stroke the piston moves from tdc to bdc.
• While this stroke the inlet port is closed, the exhaust port is opened and
transfer port opens which admits the fresh charge from the crank case.
• The burnt gases are exhausted to the atmosphere through exhaust port.
 ENGINE TERMINALS
• Cylinder is a space in which the piston makes the
reciprocating motion.
• Piston is a cylindrical component fitted in the cylinder which
transmits the reciprocating motion to the crankshaft.
• Connecting rod is used to connect the piston and crank shaft
to convert the reciprocating motion to rotary motion.
• Crankshaft is the solid component which helps to transfer
the power to the clutch.
• Camshaft is used to control the opening and closing of the
two valves.
• Piston rings provides the tight seal between the piston and
cylinder walls to prevent the leakages of the fuel.
 CHAIN SPROCKET
• This is a cycle chain sprocket. The chain sprocket is coupled
with another generator shaft. The chain converts rotational
power to pulling power, or pulling power to rotational power,
by engaging with the sprocket.
• The sprocket looks like a gear but differs in three important
ways:
• Sprockets have many engaging teeth; gears usually have only
one or two.
• The teeth of a gear touch and slip against each other; there
is basically no slippage in a sprocket.
• The shape of the teeth is different in gears and sprockets.
TYPES OF SPROCKETS
 FLAT BELT DRIVE

•First, let us explain the relationship between flat belts

and pulleys.
•Figure shows a rendition of a flat belt drive. The circle
at the top is a pulley, and the belt hangs down from each
side.
•When the pulley is fixed and the left side of the belt is
loaded with tension (T0), the force needed to pull the belt
down to the right side will be:
T1 = T0 3 eµu
THREE SECTIONS ON THE SPROCKET TOOTH FACE

•Bottom curve of tooth, where the roller falls into place.

•Working curve, where the roller and the sprocket are working together.

•Where the tooth can guide the roller but can't transmit tension. If the roller, which should

transmit tension, only engages with C, it causes jumped sprocket teeth.

THE ENGAGEMENT BETWEEN A SPROCKET AND
AN ELONGATED CHAIN

We can sort chains into five types:

•Cast iron chain.
•Cast steel chain.
•Forged chain.
• Steel chain.
• Plastic chain.
BASIC STRUCTURE OF POWER TRANSMISSION CHAIN

A typical configuration for RS60-type chain is shown in

Figure
 BEARING
• Here we are using ball type bearing.

• Ball bearing type is 6202.

• Outer Diameter of Bearing (D) = 35 mm

• Thickness of Bearing (B) = 12 mm

• Inner Diameter of the Bearing (d) = 15 mm

 •r₁ = Corner radii on shaft and housing

•r₁ = 1(From design data book)

•Maximum Speed = 14,000 rpm(From design data

book).

•Mean Diameter (dm) = (D + d) / 2

 
= (35 + 15) / 2
 
dm = 25 mm
 
 
 WAHL STRESS FACTOR

• Ks = 4C – 1 + 0.65
4C – 4 C

= (4 X 2.3) -1 + 0.65
(4 X 2.3 )-4 2.3
• Ks = 1.85
 GEARS
• Gears are commonly used to transmit rotational motion
between machinery shafts.
TYPES OF GEARS
EXTERNAL SPUR GEAR
• The spur gears, which are designed to transmit motion and
power between parallel shafts.
APPLICATION
• Material handling
• Feed drives
• Machine tools
INTERNAL SPUR GEAR

•The internal gears are spur gears turned "inside out."

• In other words, the teeth are cut into the inside diameter while
the outside diameter is kept smooth

APPLICATIONS:
•Light duty applications
•Timing
•Positioning
•Rollers
•Indexing
 WORM GEAR
•Worm gears are made up of two parts: the pinion and the worm gear.
• The pinion has a small number of teeth, usually one to four.
•Worm gears can provide a high angular velocity reduction between
nonintersecting shafts at right angles.
•They are capable of transmitting high tooth loads but the
disadvantage is the high sliding velocities across the teeth.

APPLICATIONS:
•Packaging machinery
•Material handling
•Shrink wrapping
•Conveyors
•Pallet loaders
•Machine tools
•Indexing equipment
•Food processing
BEVEL GEAR:

•The bevel gears are specifically designed for the efficient

transmission of power and motion between intersecting shafts at a
right angle (90°).
• Miter gears are a special type of bevel gear designed to
operate in pairs with identical numbers of teeth and diametric
pitches, and a 1:1 ratio.

APPLICATIONS:
•Printing
•Agriculture
•Bottling
•Material handling
•Steering
 WORKING PRINCIPLE
A method of controlling a reverse gear change of an automobile, said
automobile comprising an internal combustion engine; an automatic
transmission connected to an output rotation shaft of said engine so as to
transmit the rotational output of said engine to drive wheels of said automobile
through any selected one of a plurality of gear ratios; a load device selectively
connectable to said output rotation shaft of said engine via selectively-
connecting means; and means for generating a gear change control signal for
selecting one of said gear ratios of said automatic transmission in accordance
with one of operational conditions of said automobile and said engine said
method comprising the steps of controlling said selectively-connecting means
when said gear change signal-generating means generates the control signal for
reverse up the gear in said automatic transmission, in such a manner that said
selectively-connecting means connects said load device to said output rotation
shaft of said engine. Battery is giving the microcontroller unit. The proximity
sensor is used to detect the wheel speed and this signal is given to the
microcontroller unit. The 1st gear is done by manually press the button and the
succeeding gears all are down automatically by the microcontroller unit.
DIAGRAM
ADVANTAGES
•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.
•Easily turning

APPLICATIONS
•It is very much useful for Car Owners & Auto-garages.
•Thus it can be useful for the two wheeler application

DISADVANTAGES
•Initial cost is required.
THANK YOU