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.

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.

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

- 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

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 pressurecondition for proper operation .

(2)

Check the alignment of gear engagelever in the system

(3)

Dont 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

2. Double acting cylinder
3. Valve connectors

1600,00
1200.00

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