Developing Automatic Gear Shifting Mechanism in Two Wheelers - Career Episode 1

Career Episode 1 describes the development of an automatic gear shifting mechanism in two wheelers. The project objectives included developing the design of the automatic transmission system, calculating the magnet's dimensions, programming the Adruino program, delivering analysis on the designed mechanism, and testing and fabricating the designed mechanism. The author's area of work included mathematical calculations related to the research and design program. The project was successful in allowing automation within the motor bikes for gear shifting and automatic clutch operations.

COMPETENCY
DEMONSTRATION REPORT
Career Episode 1

CE 1.1 Project Information
Name of the project: Developing Automatic Gear Shifting Mechanism in Two Wheelers
Location of the project: [PLEASE FILL]
Project Duration: [PLEASE FILL]
Organization: [PLEASE FILL]
Role and Designation during the time: Team Member
CE 1.2 Project Background
CE 1.2.1 Characteristics of the project
I was working in a team and our concerning field was the motorcycles those have been
widely used as the mode of transportation in most of the developing countries. Mostly, the gear
shifting control of the motor bikes were conventionally a manual process. We developed a model
that can be helpful in covering development of the indigenous gear changing/shifting system for
most of the standard bikes. We managed to develop a project that will allow automation in the
clutch system without altering the manual gear-shifting system through placing an additional
electromechanical system over the lever in manner to allow the gear shifting. I managed to keep
the budget of the project low as much possible through utilizing low cost microcontroller without
altering the decision-making control mechanism. We delivered the experiment on the motor
bikes ranging between 50 to 200 cc.

CE 1.2.2 Objectives developed for the project
Following objectives were developed by the team leader after asking the decisions of the
different stakeholders:
 To develop the design automatic transmission system
 To mathematically calculate the magnet’s dimensions that is about to be used
align with the gear ratio
 To program the Adruino program for the linear punching actuator and servo
motor in manner to allow the automation within the gear shifting system
 To deliver Analysis on the designed mechanism developed for the proposed
automated system
 To test and fabricate the designed mechanism
CE 1.2.3 My area of work
I had to work within the team in cooperative manner and manage the entire mathematical
calculation related to the ongoing research and design program. I analysed the existing model of
an automated manual transmission system and used the collected information for developing a
new automatic gear selection machine for the automobile. I was assigned to determine the
necessary constraints and measurement for the delivery of the project. I did the following
calculation for calculating the gearing speed range and vehicle:
If we consider the speed for first gear is 0km /h to 20km/h for second 20km/h to 30km/h
for third 30km/h to 45km/h and for greater than 45km/h take for the gear mashing.

I calculated the vehicle speed range in km/hr and thereafter, converting the speed into
rpm in manner to use that in the following equation:
D = tire diameter in m
V = speed in m/s;
D; Where, N = speed in rpm
N = V*60/3.14
Take, D = 0.80 meter tire diameter
Therefore, using the above equation, the identified speed could be converted into rpm for
further calculations.
I have output 9.889 gear reduction

CE 1.2.4 Project Group
CE 1.2.5 My responsibilities throughout the project
The project had phases and I was assigned for the management of the entire project along
with the mathematical calculations an testing phase. I managed the flow of the project in an
efficient and effective manner through analysing the existing arrangements. I managed the
resources for the project and made the activity plan those could be adhered for the efficient and
effective manner for the delivery of the project within estimated timeline and budget. Since,
calculation was also my job hence, I calculated the following results:
Gear Speed of vehicle in Speed on output shaft Speed of vehicle in

arrangement km/hr. of gear box in rpm. rpm.
Higher Higher Lower Lower Higher Lower
1st 12 1166.41 0 0 117.95 0
2nd 24 2332.82 1166.41 12 235.90 117.95
3rd 36 3499.32 2332.82 24 353.86 235.90
4th 50 4860.13 3499.32 36 491.47 353.86
I assigned two different drivers to further perform for the data collection that helped me
in collecting five different patterns from the respective drivers. I collected the average speed
along with the data available in the internet sources.
Driver 1
Gear No. 1st 2nd 3rd 4th 5th
First Iteration - 11 25 34 51
Second Iteration - 13 24 38 48
Third Iteration - 12 26 35 49
Fourth Iteration - 9 23 36 53
Fifth Iteration - 10 22 36 53
DRIVER 2

Gear No. 1st 2nd 3rd 4th 5th
First Iteration - 8 18 35 44
Second - 11 24 36 46
Iteration
Third Iteration - 10 23 36 48
Fourth Iteration - 13 24 34 51
Fifth Iteration - 13 24 38 52
CE 1.3 Distinctive Activity
CE 1.3.1 Comprehending the theory of the project
I used the theoretical knowledge gained during my academics for assuring that the coding
and mechanics being applied could be helpful in allowing the automatic gear change for the
motor bikes. I identified that placing the additional mechanical system on the top of the lever in
manner to allow the automation and gear shifting to the clutch and the gears respectively. I
delivered many experiments for collecting and executing the raw data for the development of this
project in an efficient and effective manner. I calculated the gear torque of the CBZ motor bike at
all the four gears and recorded it in manner to calculate the speed range of gearing and the
vehicle. Actuator selection was another crucial factor that needed to be accomplished and was
delivered through calculating the gear shift force.

CE 1.3.2 Engineering knowledge and skills applied in the project
The project had two sections, first one emphasizing on the coding of microcontroller for
automation in the gear shifting and clutch operating. I used Boolean principle for the gear
shifting, positive signal is transmitted that states the gear shifting. There is null vale for the
instance, when there is no change in the gear. I was solely appointed to the second phase of the
project that emphasizes on developing design of the project. The three major concerning parts of
this phase were the relays, magnetic clutch, and Wipe motor (High Torque Motor). The
manufacturing was delivered using the construction of the proposed project and the electric
connectivity for establishing the smooth automation. I placed the magnets on the rear wheel
along with the r.p.m sensor.
CE 1.3.4 Identified issues and their solutions
1.3.4.1 Issues
I identified that integration of the software and mechanics was crucial for the successful
delivery of the project however, integration was very difficult for the successful and efficient
development of the automation in the gear shifting and automatic clutch management. The entire
project was a complex environment for the entire team and hence, a sophisticated model was
required. Since, we were for different background and so, I identified that communication
between the different team members were the major cause during the management and delivery
of the project.
1.3.4.2 Solutions
I combined with a team the comprise of team members from different backgrounds in
manner to assure that other than the mechanical engineering, rest of the electrical circuit and
coding could be done for the management of the operations related to the successful and efficient

delivery of the project. I used CAD drawing for demonstrating the arrangements necessary for
the implementation of automation in the gear shifting. I established a communication between
the team members that helped in establishing a bond of understanding and trust. Thus, the project
was managed and delivered within the estimated time.
CE 1.3.5 Plan to produce creative and innovative work
I implemented innovation through implementing and installing the Hall Effect sensor that
is helpful for delivering the expected outcome through utilizing the principle of Hall Effect that
will be responsible for generating the voltage. Thus, for the instance, when the magnetic field
will be passing perpendicularly to the field, the voltage will be transferred to the ECU and after
analysing the situation (including the speed and acceleration), the command will be forwarded to
the actuator and allowing the change in the gear whether it is back or forth.
CE 1.3.6 Collaborative work
Every team member made equal contribution in the development and execution of this
project through accomplishing the deliverables of the project those was estimated to be in
different phases. I made sure that the team should be contributing equally in the growth and
development of the project through delivering every possible activities and phases of the project.
CE 1.4 Project Review
CE .4.1 Project Overview and Contribution Made
The developed project was successful and efficient enough in allowing the automation
within the motor bikes for gear shifting and automatic clutch operations. I made sure that the
software and hardware integrate in an efficient and effective manner for allowing the automation

within the existing functioning of the bikes. I kept the construction of the project simple and cost
effective in manner to be applicable within the motor bike industries. The team management was
the major concerning factor in this field and I, along with team leader, contributed in the team
through making better relationship with the team members.