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Project Description

Project Background: The Polaris Outlaw 525 is one of the most high performing race ATV's on the market. With the KTM 525 cc engine and newly designed 5 speed manual transmission, Polaris is moving to the forefront of the ATV race industry. The Automatic Shift Controls project is a 3rd Generation project to build upon current button shift modifications to move toward intelligent shifting for the manual transmission. Traditionally, the manual transmission is more efficient for race conditions however the automatic shift controls would provide the quick, smooth shifting of an automatic transmission with a manual user input interface for button shift racing. The system will need to be functional and practical

Problem Statement: An automatic shift control system with manual override designed for race as well as general use. The system must me light, fast , smooth and add no extra maintenance to racing duty cycles.

Objectives/Scope: 1. Evaluate current design for possible cost and

weight reduction as well as improved performance.

2. Investigate RPM shift points that are safe and efficient for general and race conditions.

3. Create more attractive and functional packaging that has no obstruction to vehicle or driver.

4. Leave project in a manner in which it can be picked up easily by another team or by the people at Polaris.

Deliverables: • Investigate and program new automatic shift

controls. • Integrate current push button control for

manual override function. • Conduct cost and weight analysis.

Expected Project Benefits: • Automatically shifts a manual transmission

which is traditionally more efficient for race conditions

• Shift control does not require user input for shifting, manual override integration gives user the option to input shift change

Core Team Members: • Ashley Shoum- Project Lead • Keith Cobb • Matt Dombovy-Johnson • Jonathan Willistein • Feng Li • Bibhu Shah • Sarah Bicho

Strategy & Approach

Assumptions & Constraints: 1. Current controller is sufficient for testing and

mounting new automatic controls. 2. Current design is sufficient for use as

manual override feature.

Issues & Risks: • Previous phase went out of budget

constraints, cost analysis for manufacturability will need to be carefully reevaluated.

• Electrical/Computer engineer staffing requests not met. Project will require heavy portion of programming and project has only two electrical engineers. Background will need to be assessed.

• Previous phase hardware and software may not be able to be used for new phase in which design may be more intensive than planned and project scope will need to be reevaluated.

Project # Project Name Project Track Project Family

P09310 Automatic Shift Controls for ATV

Systems and Controls

Modular, Scalable, Open Architecture Control Systems

Start Term Team Guide Project Sponsor Doc. Revision

2008-1 Professor George Slack Polaris Industries 2

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General Mode

Shift Dir?

Can we UpShift?

Can we DownShift?

DownUp

Throttle/RPM Input

Bad Shift Indicator

No

LED Indicator

Cut Spark(Disengage clutch)

Yes Yes

Spark Pulldown Signal

Cut Spark(Disengage clutch)

Open Up-solenoid,Close Down-

solenoid for X secs

Close Up-solenoid, Open Down-

solenoid for X secs

Release Spark Pulldown SignalEnable Spark(Engage clutch)

Update Gear In software

CDI

Need to Shift?No

Reset/ Power-onAutocheck RPM/

TPS

X secsX=0.1s

Display

Shift Limits

DisplayGear Signal (R,N,1,2,3,4,5)

Button pressed?No

Yes

Yes

Spark Pulldown Signal

AutoShift On?

Yes

No

RPM 7600

RPM 7600

RPM 7300

RPM 7000

RPM 3000

RPM 9500

Maximum Downshift Speed

[5 to 4]Maximum

Downshift Speed [4 to 3]

Maximum Downshift Speed

[3 to 2]Maximum

Downshift Speed [2 to 1]

Minimum Upshift Speed

Maximum Upshift Speed

Gear Sensor

Gear Sensor

Shift Map(Moderate)

150 in-lbs20 deg rot. Trans.

Microcontroller Schematic

MS

P43

0

RPM(Digital Input)

0 - 0.3V

TPS(Analog Input)

0 - 12V

Gear Sensor

Clutch Signal

3-Position Switch(Race, General, Off)

Gear Indicator(P R N 1 2 3 4 5)

solenoids

Bad Shift Indicator

About-to-shift Indicator

Voltage Regulator(3.6V)

Voltage Divider12 => 3.6V

12V

ADC DAC

12

Spark-Cut Circuit

12V

Driver

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