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 4. B. RAJKUMAR 2. G. PUGAZHENDHI 5. S. YUVARAJ 3. S. RAJASEKAR 6. V. GOPU

Under guidance of

Mr. S. JAGADEESAN

MARCH 2009.

DEPARTMENT OF MECHANICAL ENGINEERING.

CENTRAL POLYTECHNIC COLLEGETARAMANI

CENTRAL POLYTECHNIC COLLEGETARAMANI

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 co-

operation for the success of the project.

CONTENTS

CONTENTS

1. INTRODUCTION

2. SYNOPSIS

3. CONSTRUCTION DETAILS

4. WORKING PRINCIPLE

5. PNEUMATIC COMPONENTS DETAILS

6. SPARE PARTS DRAWING

7. APPLICATION

8. ADVANTAGES AND DISADVANTAGES

9. FEATURES OF THIS PROJECT

10. SAFTY,CARE AND MAINTENANCE

11. PAINTING AND FINISHING

12. COST ESTIMATION

13. CONCLUSION

14. BIBLIOGRAPHY

15. 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.

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.

The piston rod pushes the yoke in the gear changer .thus gear drive changes

to next speed. The cylinder in ‘A- (MINUS) position the middle gear

conncects the bottom shaft gears and in A+ position the middle gear

connects the top shaft gears.

DESCRIPTION OF PNEUMATIC

COMPONENTS

DESCRIPTION OF PNEUMATIC COMPONENTS

1. Double acting air cylinder with piston arrangement.

2. Spool valve (2 position 5 ports valve)

3. Pneumatic fittings

a. Bulk head union

b. Flexible hoses

c. Air compressors

DOUBLE ACTING AIR CYLINDER WITH PISTON ARRANGEMENT:

It consists of a piston inside a cylindrical housing called a barrel.

Attached to one end of the piston is a rod which the rod end has one port.

This rod end port is used for entrance of air and extends outside one end of

the cylinder. At another end is a port for exit of air.

Double acting cylinder can be extended and retracted pneumatically.

The smallest bore size of a double acting cylinder is 1 1/8 inch. The piston,

which is made of ductile Iron, contains u-cup packing to seal against leakage

between the piston and barrel. The ports are located in the end caps, which

are secured to the barrel by bolts and nuts.

SPOOL VALVE:

The spool is rod in 5/2 values, so that 5/2 valve is called “spool

valve”. It used to change the path of flow of air.

DIRECTING CONTROL VALVES:

A direction control valve is used to change the direction of airflow as

and when required by the system for reversing the machine tool devices. A

direction control valve may be classified, according to the construction of

the internal moving parts, as

1. Rotary spool Type.

2. Sliding Spool Type.

3. Solenoid operated valves

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.

PNEUMATICFITTING

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 - Plastic

Collect/Thread Nipple - Brass

Seal - Nitrate Rubber

Fluid Used - Air

Max. Operating Pressure - 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

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) Check the pressure condition for proper operation .

(2) Check the alignment of gear engage lever in the system

(3) Don’t insert the any material or object between the during

operation

(4) Check the shifting alignment and engagement in the system

(5) 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 1600,00

2. Double acting cylinder 1200.00

3. Valve connectors 5nos 200.00

4.M.S. Fabricated housing unit 1000.00

5. gear box unit 1600.00

6. Painting cost 100.00

7. transport cost 200.00

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 -HAJRA CHOWDRY

2. PRODUCTION TECHNOLOGY -R.S. KHURMI

3. MACHINE SHOP TECHNOLOGY -S.S.MANIAN

4. JIG AND FIXTURE DESIGN - R.K.JAIN

5.FLUID POWER BY -E.SUNDRAMOORTHY

PHOTO VIEW

PHOTO VIEW