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 BATCH MEMBERS
AJAI.P.S [97607114005]
AJITH.G [97607114006]
ARUN.A [97607114013]
SUJITH.S[97607114308]

UNDER THE GUIDANCE OF

Mr. SANKAR KUMAR.
(H.O.D. Mechanical dept.)

ABSTRACT
The objective of the project is to automate the gear
changing mechanism in two wheelers.
In this project the manually operated gear shifting
mechanism by using leg into button operated gear
shifting mechanism by using wiper motor and a control
circuit.
A password system is also implemented in this project.
The gear shifting can be done by two buttons.
Both the gear shifting and password system is
controlled by the microcontroller.

WORKING PRINCIPLE

Two buttons are used for shifting the gear.

One button is for forward motion and another button is for

reverse motion.

A wiper motor is coupled to the gear arrangement , the shaft

of the gear arrangement is connected to the lever of the gear
box

The speed ratio between the wiper motor and the gear
arrangement is 20:1.

The password system is installed in the microcontroller , the

microcontroller is connected to the ignition coil .If we enter
the correct password the microcontroller will trigger the
ignition coil , then only the bike will start.

BLOCK DIAGRAM
LCD

Keypad
Micro
Controll
er

Driver
Circuit

Ignition
Coil

Driver

Wiper

Circuits

Motor

COMPONENTS USED

HERO HONDA CD 100

WIPER MOTOR
GEAR ARRANGEMENT
CONTROL CIRCUIT
LCD DISPLAY
KEY PAD
BUTTON (UP&DOWN)
BATTERY

HERO HONDA
SPECIFICATION
Engine
: 4-stroke, single cylinder,
air-cooled
Displacement : 97.2cc
Clutch type
: Manual
Clutch
: Secondary Multi-plate
wet
Transmission : 4-speed constant mesh
Ignition
: Electronic
Max Power
: 7.0 PS @ 8000 rpm

CUT SECTION OF WIPER MOTOR

WIPER MOTOR
A normal windscreen wiper motor is
used in this project.
The speed of the motor is 76 rpm.
It requires 12 voltage and 4.5 amps
current.
A worm gear arrangement is present
inside the wiper motor.
It will pull and push the gear shifting
lever with a force of .214 N

MICROCONTROLLER
A Microcontroller is a single IC chip.
Microcontrollers are used in many
application.
For the project a program is feed in the IC
chip.
The microcontroller controls both the gear
shifting mechanism and the password
system.

2D DIAGRAM
GEAR ARRANGEMENT
CRANK
CONNECTING ROD
GEAR ARRANGEMENT

GEAR
SHIFTING
LEVER

WIPER MOTOR

BIKE GEAR BOX

VIPER MOTOR
ARRANGEMENT

MICROCONTROLLER KIT

BUTTON AND KEYPAD

PHOTOGRAPHY OF PROJECT

DESIGN CALCULATION
Calculation of pulling force exerted by motor
Length of connecting rod = 145mm
Speed of wiper motor = 76rpm
Voltage
= 12V
Current
= 4.5 amps

STANDARD VALUE FOR HERO HONDA TWO WHEELER

Maximum speed of vehicle
= 85km/h
Wheel base
= 1210mm
Diameter of the wheel
= 600mm
MOTOR POWER
P = Power
P = V*I
= 12*4.5
= 54W
= 0.054KW
MOTOR TORQUE
P = 2*3.14*N*T/60
P = 2*3.14*76*T/60
0.054 = 2*3.14*76*T/60
-3

Length of the crank

= 75mm
Length of the connecting rod
= 145mm
Length of the two fixed end= 145mm
Length of the gear leaver
= 95mm

FOUR BAR MECHANISM :

For diagram
AD two fixed end
BC connecting rod
AB crank
CD gear lever
speed of motor

= 76 rpm

wBA = 2*3.14*(76/60)
= 7.958 rad/sec
vBA = wBA * AB
= 7.958*0.075m
vB = vBA
=0.596 m/sec
Length of vCD & vBC is show the velocity diagram
vCD = 0.54 m/s
vBC = 0.1 m/s

Acceleration diagram:
aBA

= (vBA)^2/AB
= (0.596)^2/0.075
= 4.736 m/s^2

aBC

= (vBC)^2/BC
= (0.1)^2/0.145
= 0.068 m/s^2

aCD

= (vCD)^2/CD
= (0.54)^2/0.095
= 3.069 m/s^2

The mass of the connecting rod= 102g

= 0.102kg
Force acting on the connecting rod = mass * acceleration
The acceleration of connecting rod = 2.1 m/s^2
Thus the pulling force exerted by the motor
= 0.102*2.1

ADVANTAGES

Easy to operate the gear.

Maintenance is easy.
It is used for Handicapped person.
It can be easily handled by ladies.

Cost analysis
Hero Honda bike

Rs.6,000.00

Battery (12v)

Rs.1,800.00

Wiper motor

Rs.3,500.00

Gear arrangement

Rs.1,000.00

Micro controller

Rs.5,000.00

Switch board & wire

Rs.700.00

Labour charge

RS.2,000.00

Total

Rs.20,000.00

CONCLUSION
Thus changing manually operated gear shifting
into electrically operated gear shifting
A password system is also incorporated with the
project.
The components used are two buttons, wiper
motor, gear arrangement, control circuit and
batteries.
Both the gear shifting and the password system
were controlled by a microcontroller.
Therefore the gears can be changed by using the
buttons and ignition coil will be triggered by using
password system.

U
O
Y
K
THAN