FABRICATION OF AUTOMATIC GEAR SHIFTING SYSTEM

Submitted in the partial fulfillment of the requirement for the award of

DIPLOMA

IN MECHANICAL ENGINEERING

SUBMITTED BY:

1. S. MANIVANNAN 2. G. PUGAZHENDHI 3. S. RAJASEKAR

4. B. RAJKUMAR 5. S. YUVARAJ 6. V. GOPU

Under guidance of Mr. S. JAGADEESAN

MARCH 2009. DEPARTMENT OF MECHANICAL ENGINEERING.

CENTRAL POLYTECHNIC COLLEGE TARAMANI

CENTRAL POLYTECHNIC COLLEGE TARAMANI

BONAFIDE CERTIFICATE
This is to certify that this Project work on

FABRICATION OF AUTOMATIC GEAR SHIFTING SYSTEM

submitted by . Reg. No. in partial fulfillment for the award of DIPLOMA IN MECHANICAL ENGINEERING This is the bonafide record of work carried out by him under our supervision during the year 2009 Submitted for the Viva-voce exam held on ..

PROJECT GUIDE

INTERNAL EXAMINER

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the Principal Mr. ------------------------------- encouragement and valuable advice.

we thank our Esquired Head of Department Mr . -------------------- for presenting his felicitations on us. We are grateful on our Entourages Mr. ---------------------for guiding in various aspects of the project making it a grand success. We also owe our sincere thanks to all staff members of the Mechanical Department.

Ultimately, we extend our thanks to all who had rendered their cooperation for the success of the project.

CONTENTS

CONTENTS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

INTRODUCTION SYNOPSIS CONSTRUCTION DETAILS WORKING PRINCIPLE PNEUMATIC COMPONENTS DETAILS SPARE PARTS DRAWING APPLICATION ADVANTAGES AND DISADVANTAGES FEATURES OF THIS PROJECT SAFTY,CARE AND MAINTENANCE PAINTING AND FINISHING COST ESTIMATION CONCLUSION

14. 15.

BIBLIOGRAPHY PHOTO VIEW

INTRODUCTION

INTRODUCTION
This is a self assessment test on the part of the students to assess his competency in creativity. During the course of study, the student is put on a sound theoretical foundation of various mechanical engineering subjects and of course, to a satisfactory extent. Opportunities are made available to him to work on different kinds of machines, so that he is exposed to various kinds of manufacturing process.

As a students learn more and more his hold on production technology becomes stronger. He attains a stage of perfection, when he himself is able to design and fabricate a device. This is the project work. That is the testimony for the strenuous training, which the student had in the institute. This assures that he is no more a student, he is an engineer. This report discuses the necessity of the project and various aspects of planning , design, selection of materials, fabrication, erection, estimation and testing.

SYNOPSIS

SYNOPSIS
To increase the productivity and to overcome skilled labor shortage. Most of the manufacturing industries are going for automation. The main arm for us to select the project work is to acquire practical knowledge in the field of vehicle automation using PNEUMATIC SYSTEM.

We selected AUTOMATIC PNEUMATIC GEAR CHANGER as our project work and we used principles of Mechatronics in developing this project work, the standing mechanism is achieved by reciprocating the double acting cylinders which controlled by single solenoid operated 5/2 way Directional control valve. This is actuated through the dashboard panel in front of the driver. The operating pressure required for this system is 5 to 6 bar. The maintenance required for this system is less than the other systems. It is used to reducing the gear shifting time without losing the break power and the efficiency is improved, the main advantages of our project are elimination of wear and tear, simple in operation, fast movement in control and less space by elimination of linkages.

CONSTRUCTION

CONSTRUCTION
This unit consists of 1) Gear box unit 2) Pneumatic control system GEAR BOX UNIT; in this project the gear drives are arranged in a M.S. sheet fabricated square shaped box. The gears are arranged in three steps .the gear changer unit is kept in middle and it is shifted by the control of pneumatic cylinder. The pneumatic cylinder is actuated through the 5/2way lever operated directional control valve.

PNEUMATIC CONTROL SYSTEM; The sliding gear unit is shifted by the pneumatic cylinder of 20 mm dia and 70mm stroke length. This pneumatic cylinder is actuated through the 5/2 way lever operated directional control valve. The valve is actuated through a lever by hand.

PNEUMATIC CIRCUIT DIAGRAM

AIR CYLINDER

FLOW CONTROL VALVE

4 2

5/2 WAY SOLENOID OPERATED DC VALVE

5 1 3

FRL UNIT

WORKING PRINCIPLE

WORKING PRINCIPLE

The gear shifting operation is start when lever is turned in the controlvalve. When the hand lever is turned, the 5/2 way directional controlled solenoid valve supplies pressurised air to the air cylinder in the pneumatic cylinder unit.. the pneumatic circuit is shown in below figure.

PNEUMATIC CIRCUIT DIAGRAM

AIR CYLINDER

FLOW CONTROL VALVE

4 2

5/2 WAY SOLENOID OPERATED DC VALVE

5 1 3

FRL UNIT

The piston rod pushes the yoke in the gear changer .thus gear drive changes to next speed. The cylinder in conncects the A- (MINUS) position the middle gear

bottom shaft gears and in A+ position the middle gear

connects the top shaft gears.

COMPONENTS USED FOR PNEUMATIC GEAR SHIFTER

COMPONENTS USED FOR PNEUMATIC GEAR SHIFTER

S.NO COMPONENTS

USED

MATERIAL

SIZE

QUANTITY

M.S.FABRICATED MILD STEEL STAND

200X150X100 1 MM (WXHXD) 25X50 MM 1/8 INCH 1 1

DOUBLE ACTING STEEL CYLINDER 5/2 WAY LEVER OPERATED DIRECTIONAL CONTROL VALVE ALUMINIUM CASTING

4 FLOW CONTROL VALVE 5 6 PLASTIC TUBE VALVE CONNECTOR SPUR GEAR 7 ALUMINIUM 1/8 INCH 1

POLYURETHANE 8X6MM STEEL ALLOY STEEL 1/4INCH 8/6 HOLE 70,60,50mm and 60mm,40mm Dia meter gears

5 METER 5 1 set

METAL PRIMER

PAINT

LITRE

PNEUMATIC CIRCUIT DESIGN

PNEUMATIC CIRCUIT DESIGN

PRESSURE = FORCE
AREA

OPERATING PRESSURE = 6 Kg/cm2 Force required for clamping= 50kg Then diameter of the cylinder is found out as follows; 6 kg /cm2-= 50 Pi x d2/4 50 x 4 D2----= -----------------3.14 x 6

diameter of the cylinder is --------= 32 MM

DESCRIPTION OF PNEUMATIC COMPONENTS

INTRODUCTION TO PNEUMATICS
In engineering field may Machines make use of a fluid or compressed air to develop a force to move or hold an object

A system which is operated by compressed air is known as Pneumatic System. It is most widely used the work Piece turning drilling sawing etc.

By the use of Pneumatic System the risk of explosion on fire with compressed air is minimum high working speed and simple in construction.

PNEUMATIC COMPONENTS

In engineering field, many machines make use of fluid for developing a force to move or hold an object. A number of fluid can be used in devices and system. Two commonly used fluids are oil and compressed air. A system which is operated by compressed air. A system which is operated by compressed air is know as pneumatic system.

AIR COMPRESSOR Compressor is a device which gets air fro the atmosphere and compresses it for increasing the pressure of air. Thus the compressed air. Thus the compressed air used for many application.

The compression process requires work in put. Hence a compressor is driven by a prime mover. Generally an electric motor is used as prime mover. The compressed air from compressor is stored in vessel called reservoir. Fro reservoir it be conveyed to the desired place through pipe lines.

2. FLTER In pneumatic system, an air filter is used to remove all foreign matter. An air filter dry clean air to flow without resistance various materials are used for the filter element. The air may be passed thorugh a piece metal, a pours stone felt resin impregnated paper. In some filters centrifugal action or cyclone action is used to remove foreign matters.

3. PRESSURE REGULATOR Constant pressure level is required for the trouble free operation of a pneumatic control., A pressure regulator is fitted downstream of the

compressed air filter. It provides a constant set pressure at the outlet of the outlet of the regulator. The pressure regulator is also called as pressure reducing valve or pressure regulating valve.

4. LUBRICATOR The purpose of an air lubricator is to provide the pneumatic components with sufficient lubricant. These lubricants must reduce the wear of the moving parts reduce frictional forces and protect the equipment from corrosion.

Care should be taken to ensure that sufficient lubrication is provided. But excessive lubrication should be avoided.

. 5. FLR Package (or) FRL Package The air service unit is a combination of following units. 1. Compressed air filter 2. Compressed air regulator 3. Compressed air lubricator

Air Filter, regulator and lubricator are connected together with close nipples as one package. lubricator.) This unit is know as FLR (Filter, regulator,

6. PRESSURE CONTROL VALVE : Each hydraulic system is used to operate in a certain pressure range. Higher pressure causes damage of components. control valves are fitted in the circuits. 7. Direction control valve : Directional control valves are used to control the direction of flow. The design principle is a major factor with regard to service life actuating force switching times etc. To avoid this pressure

8. Piston and Cylinder single acting pneumatic cylinder;

PNEUMATIC CITCUIT SYMBOL FOR SINGLE ACTING PNEUMATIC

CYLINDER;

Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices which produce force, often in combination with movement, and are powered by compressed gas (typically air).

To perform their function, pneumatic cylinders impart a force by converting the potential energy of compressed gas into kinetic energy. This is achieved by the compressed gas being able to expand, without external energy input, which itself occurs due to the pressure gradient established by the compressed gas being at a greater pressure than the atmospheric pressure. This air expansion forces a piston to move in the desired direction. The piston is a disc or cylinder, and the piston rod transfers the force it develops to the object to be moved. When selecting a pneumatic cylinder, you must pay attention to:

how far the piston extends when activated, known as "stroke" surface area of the piston face, known as "bore size" action type pressure rating, such as "50 PSI" type of connection to each port, such as "1/4" NPT" must be rated for compressed air use mounting method

Types
Although pneumatic cylinders will vary in appearance, size and function, they generally fall into one of the specific categories shown below. However there are also numerous other types of pneumatic cylinder available, many of which are designed to fulfill specific and specialised functions. Single acting cylinders Single acting cylinders (SAC) use the pressure imparted by compressed air to create a driving force in one direction (usually out), and a spring to return to the "home" position

Double acting cylinders Double Acting Cylinders (DAC) use the force of air to move in both extend and retract strokes. They have two ports to allow air in, one for outstroke and one for instroke. Other types Although SACs and DACs are the most common types of pneumatic cylinder, the following types are not particularly rare:

Rotary air cylinders: actuators that use air to impart a rotary motion Rodless air cylinders: These have no piston rod. They are actuators that use a mechanical or magnetic coupling to impart force, typically to a table or other body that moves along the length of the cylinder body, but does not extend beyond it.

Sizes

Air cylinders are available in a variety of sizes and can typically range from a small 2.5 mm air cylinder, which might be used for picking up a small transistor or other electronic component, to 400 mm diameter air cylinders which would impart enough force to lift a car. Some pneumatic cylinders reach 1000 mm in diameter, and are used in place of hydraulic cylinders for special circumstances where leaking hydraulic oil could impose an extreme hazard.

Pressure, radius, area and force relationships

Although the diameter of the piston and the force exerted by a cylinder are related, they are not directly proportional to one another. Additionally, the typical mathematical relationship between the two assumes that the air supply does not become saturated. Due to the effective cross sectional area reduced by the area of the piston rod, the instroke force is less than the outstroke force when both are powered pneumatically and by same supply of compressed gas. The relationship, between force on outstroke, pressure and radius, is as follows:

This is derived from the relationship, between force, pressure and effective cross-sectional area, which is: F = p A\,

With the same symbolic notation of variables as above, but also A represents the effective cross sectional area. On instroke, the same relationship between force exerted, pressure and effective cross sectional area applies as discussed above for outstroke. However, since the cross sectional area is less than the piston area the

relationship between force, pressure and radius is different. The calculation isn't more complicated though, since the effective cross sectional area is merely that of the piston less that of the piston rod. For instroke, therefore, the relationship between force exerted, pressure, radius of the piston, and radius of the piston rod, is as follows:

Where: F represents the force exerted r1 represents the radius of the piston r2 represents the radius of the piston rod is pi, approximately equal to 3.14159. VALVE CONNECTORS;

POLYURETHANE TUBE ; shortly say PUN tube;

Manual operations involving heavy lifting.

Pushing or pulling

motions can be firing for the operations and can induce a monotony which results in lowered production. Cylinders have been designed to carry out these movements with a pre determined force and stroke and can be fitted to synchronize with operation cycles of many machines it is worth wile to examine the existing plan and methods of movement and to consider the numberous mechanical applications which the range of pneumatic cylinders make possible. Quality is to keynote of air cylinder. Engineer them into

you production setup to get the last ounce of power, speed and efficiency to save time, space and money.

Piston is cylinder part which moves in a cylinder have corresponding hole on it. To make the strokes effective there is no gap between them or with a very tiny gap, part of the micron. The cylinder and its piston have a glazing surface where there is a contact between them for easy motion of piston and avoiding wear and tear of both. The outer side of the cylinder

have mountings consists of plate and studs attached with it. But the of these mountings, the cylinder and piston assembly can fitted on any place of the piston have threads on it for fastening theother parts (or) accessories according the operating performed and the application required. We can fit holding devices, Clamping materials or other metal cutting and forming ports with which can be movable with the piston.

Pneumatics are used practically in every industry for a wide variety of manufacturing process, pneumatics equipments are used for multiple reasons. The best reason is that it is air powered ordinary air turns out to be very excellent as a fluid power components.

Solenoid Valve : In order to automate the air flow in our system we have to provide an electrically controlled valves. Electrical devices can provide more effective

control, less expensive interlocks having many additional safety features and simplified automatic sequencing when a machine must operate in a hazardous area, remote actuation is a desirable. The operator can provide satisfactory control though electrical devices from a remote point with in a safe area, uding a semi automatic system and these electrical flow control devices are also in use in full automation by providing proper action signals.

Push and pull actuation can be priced b solenoids. These movements are used to open and close the pop pet type valves. These actuations are done according to the signals given to the solenoid coil when the decided by the program. The outlet of solenoiud coil when the decided by the program,. The outlet of solenoid valve is connected to a spray gun, which is going to spray the paint.

SOLENOID OPERATED VALVES: Solenoid valves are electromechanical devices like relays and contractors. A solenoid valve is used to obtain mechanical movement in machinery by utilizing fluid or air pressure. The fluid or air pressure is applied to the cylinder piston through a valve operated by a cylindrical electrical coil. The electrical coil along with its frame and plunger is known as the solenoid and the assembly of solenoid and mechanical valve is known as solenoid valve. The solenoid valve is thus another important

electromechanical device used in control of machines. Solenoid valves are of two types, 1. Single solenoid spring return operating valve,(5/2) 2. Double solenoid operating valve.

In fig 1 is shown a single solenoid spring return valve in its de-energized condition. The symbol for the solenoid and the return are also shown. The solenoid valve is shown connected to the cylinder to help readers understand

the solenoid valve action. In the de energized condition, the plunger and the valve spool position as shown in figure 1.

5/2 WAY VALVE

In this position of spool, port P is connected to port A and port B is connected to tank or exhaust (i.e. atmosphere) if air is used. Spring pressure (S) keeps the spool in this condition as long as the coil is de energized. Fluid pressure from port P through port A is applied to the left side of the cylinder piston. Thus the cylinder piston moves in the right direction. Now

when the solenoid coil is energized, plunger is attracted and it pushes the spool against spring pressure. The new position of plunger and spool are shown in fig 2.

In this position of spool, port A gets connected to tank and port P gets connected to port B. Thus pressure is applied to the cylinder piston from right and moves the piston rod to the left. At the same time fluid in the other side is drained out to the tank. When the solenoid coil is again de energized, the spring (S) will move the spool to its original position as shown in figure 1. Thus, normally when the solenoid coil is de energized the piston rod remains extended.

PNEUMATIC FITTING

PNEUMATIC FITTINGS: There are no nuts to tighten the tube to the fittings as in the conventional type of metallic fittings. The tube is connected to the fitting by a simple push ensuring leak proof connection and can be released by pressing the cap and does not require any special tooling like spanner to connect (or) disconnect the tube from the fitting.

SPECIFICATION OF THE FITTING: Body Material Collect/Thread Nipple Seal Fluid Used Max. Operating Pressure - Plastic - Brass - Nitrate Rubber - Air - 7 Bar

Tolerance on OD of the tubes - 1 mm Min. Wall thickness of tubes - 1 mm.

FLEXIBLE HOSES:

The Pneumatic hoses, which is used when pneumatic components such as actuators are subjected to movement. Hose is fabricated in layer of Elastomer or synthetic rubber, which permits operation at high pressure. The standard outside diameter of tubing is 1/16 inch. If the hose is subjected to rubbing, it should be encased in a protective sleeve.

ADVANTAGES AND LIMITATIONS

ADVANTAGES:

 The Pneumatic arm is more efficient in the technical field Quick response is achieved Simple in constructions Easy to maintain and repair Cost of the unit is less when compared to other robotics No fire hazard problem due to over loading Comparatively the operation cost is less The operation of arm is faster because the media to operate is air
Continuous operation is possible without stopping.

LIMITATIONS: High torque cannot be obtained. Load Carrying capacity of this unit is not very high (3 5 kg/s) Silencer may be used, to reduce the noise of compressed air

APPLICATION

1) DISCHARGE OF WORKPIECE: The arm fed has wide application in low cost automation. It can be used in automated assembly lines to pick-up the finished product from workstation and place them in the bins. It can also be used to pick-up the raw material and place them on the conveyor belts and vice versa.

2) JOB CLAMPING: This unit can also be used in clamping operations in certain areas of mass productions where clamping and unclamping have to be done at high speeds. The application of this unit is limited to operations, which involves moderate clamping forces.

3) TRANSFER OF JOBS BETWEEN WORK STATIONS:

The gripping method used in a low cost automation to move the work piece from one workstation to another. The combination of an angular rotary motion is the principle behind this method. The gripper holds the work rigidly. The to and fro motion is achieved by means of the actuating cylinder.

4) TOOL CHANGING APPLICATION: When the pneumatic arms are made smaller in size they can be used in automatic tool changer in CNC turning and drilling machines, by attaching suitable tool holding device to the rotary cylinder.

SPARE PARTS AND ASSEMBLY DRAWING

PNEUMATIC

CIRCUIT

DIAGRAM

PNEUMATIC CIRCUIT DIAGRAM

AIR CYLINDER

FLOW CONTROL VALVE

4 2

5/2 WAY SOLENOID OPERATED DC VALVE

5 1 3

FRL UNIT

ADVANTAGES

ADVANTAGES

It requires simple maintenance cares.

The moving parts of this system are cooled by the oil itself used. Thus this project does not require any cooling arrangements.

The safety system for automobile.

Checking and cleaning are easy because of the main parts are screwed

 Easy to Handle.

DISADVANTAGES

DISADVANTAGES

Initial cost is high

High maintenance cost

APPLICATION

APPLICATIONS

It is very much useful for care Owners & Auto-garages.

This automatic

gear shiftingsystem is used for smooth engagement of gear selecting for the vehicles. Thus it can be usedful for the following type of vehicles.

1) MARUTHI 2) AMBASSADOR 3) FIAT 4) MAHINDRA 5) TATA

PAINTING AND FINISHING

FINISHING AND PAINTING

JOB PREPARATION
Before welding, remove any bend in the L angle with the sludge hammer on the anvil block. Then it is cut to the required length with the hacksaw blade and fabricated to required dimensional shape with arc welding.

FINISHING OPERATION BEFORE PAINTING

After welding, any slag on the welded area is removed with the chipping hammer and cleaned with the metal wire brush. Then all the surfaces are rubbed with the emery sheet.

Metal primer is applied on the surfaces with the brush. After drying the metal primer, the second coating is applied with the paint.

SAFETY,CARE AND MAINTENANCE

SAFETY,CARE AND MAINTENANCE

Before starting the operation, some of the points to be noted for safety purpose, 1. Before starting the operation, check the following items (1) (2) (3) Check the pressurecondition for proper operation . Check the alignment of gear engagelever in the system Dont insert the any material or object between the during operation (4) (5) Check the shifting alignment and engagement in the system Check the leakage in the gear shifting system.

FEATURES OF THIS PROJECT

It can installed easily LOW electrical power consumption It can be utilized It is simple in construction Low cost Less weight and easy to handle Life of system increased It is simple in operation..

COST ESTIMATION

COST ESTIMATION

1.5/2 way solenoid operated DC Valve 2. Double acting cylinder 3. Valve connectors 5nos

1600,00 1200.00 200.00 1000.00 1600.00 100.00 200.00

4.M.S. Fabricated housing unit 5. gear box unit 6. Painting cost 7. transport cost TOTAL COST

5900.00

CONCLUSION

CONCLUSION
We make this project entirely different from other projects. Since concepts involved in our project is entirely different that a single unit is used to various purposes, which is not developed by any of other team members. By doing this project we gained the knowledge of fabrication work and how the welding is doing and material selection for particular components etc., It is concluded that any fabrication work can be done with the help of welding. We have successfully completed the project work on using welding work at our Institute.

Once again we express our sincere thanks to our staff members.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. WORKSHOP TECHNOLOGY 2. PRODUCTION TECHNOLOGY 3. MACHINE SHOP TECHNOLOGY 4. JIG AND FIXTURE DESIGN 5.FLUID POWER BY

-HAJRA CHOWDRY -R.S. KHURMI -S.S.MANIAN - R.K.JAIN -E.SUNDRAMOORTHY

PHOTO VIEW

PHOTO VIEW

PNEUMATIC GEAR SHIFTER

OBJECTIVE;
To change the gear speed through the remote operation and to reduce the mechanical linkages.

DEFINITION OF PROBLEM;
In two wheeler and four wheeler lady driving, the speed changing lever is difficult to operate while controlling the steering mechanism. moreover the gear shifting mechanical lever linkage should be nearer to the gearbox and the driver.to overcome such difficulty , this pneumatic system is introduced.

SCOPE OF THE PROJECT;

The outstanding advantage of pneumatic system is the control valve which consistently applies a specified load with minimum effort. Simple construction than the mechanical linkages. Operation is very smooth and in this system we can get more output by applying less effort.

ADVANTAGES ;
It can be modified to any extend to bring out the required effort. Its outcome can be utilized properly in the extensive mechanical field. Multiple cylinder systems can be put into action according to the need of different speeds effort. Compared to hydraulic and mechanical ,pneumatic system economical. No extra skill is required for operating this system. Operation is very smooth and in this system we can get more output by applying less effort. This system can be effectively used for automobile gear box system. It requires simple maintenance cares The safety system for automobile. is

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.

DISADVANTAGES;

Initial cost is high.

 The system is complicated one. APPLICATIONS

It is very much useful for Car Owners & Auto-garages.

Thus it can be useful for the two wheeler application

COMPONENTS USED FOR PNEUMATIC GEAR SHIFTER

S.NO COMPONENTS

USED

MATERIAL

SIZE

QUANTITY

M.S.FABRICATED MILD STEEL STAND

200X150X100 1 MM (WXHXD) 25X25 MM 1

DOUBLE ACTING STEEL

CYLINDER

5/2 WAY LEVER OPERATED DIRECTIONAL CONTROL VALVE

ALUMINIUM CASTING

1/8 INCH

4 FLOW CONTROL VALVE 5 6 PLASTIC TUBE VALVE CONNECTOR SPUR GEAR 7 ALUMINIUM 1/8 INCH 1

POLYURETHANE 8X6MM STEEL ALLOY STEEL 1/4INCH 8/6 HOLE 70,60,50mm and 60mm,40mm Dia meter gears

5 METER 5 1 set

METAL PRIMER

PAINT

LITRE

1.