Research Article

Available ONLINE www.vsrdjournals.
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VSRD-MAP, Vol. 2 (4), 2012, 125-139

____________________________
1,3
Lecturer,
2
Professor,
1,2,3
Department of Mechanical Engineering, Yeshwantrao Chavan College of Engineering, Nagpur,
Maharashtra, INDIA. *Correspondence : pdk121180@yahoo.com
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RR E
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CC H
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Automatic Gear Shifting Mechanism and
Electric Drive in a Bicycle
1
P.D. Kamble*,
2
S.P. Untawale and
3
S.B. Sahare
ABSTRACT
Today's bicycles are primarily simple bicycles with no gear mechanism. Those with gears come with a hoard of
problem. Not to mention the problems associated with chain. One solution to this problem lies in the electric
two wheelers aka the "Yo Bikes". While they provide the comfort similar to the gasoline fed vehicles and other
auxiliary facilities like charging of mobile phones etc, they are far from being economical if their onetime cost is
considered. Hence there is a need to apply a suitable gear mechanism.
Our concept "Automatic gear shifting mechanism and electric drive" is an attempt to support the gears of
bicycle to help us change them at regular velocity interval. This project also aims at bringing a normal geared
bicycle nearer to a moped. In other words, it will provide general public with an economical version of electric
two wheelers.
Keywords : Bicycles, Automatic Gear Shifting Mechanism, Electric Drive.
1. INTRODUCTION
1.1. Gear Bicycle
This bicycle is employed with gear mechanism used to reduce human effort. This bicycle is employed with gear
mechanism used to reduce human effort, during bicycling we need a high speed when moving on a plane road,
while long steep hills and/or heavy loads may indicate a need for lower gearing, this can result in a very low
speed. Balancing a bicycle becomes more difficult at lower speeds. For example, a bottom gear around 16 gear
inches gives an effective speed of perhaps 3 miles/hour (5 km/hour) or less, at which point it might be quicker to
walk. All these purposes can be fulfilled by gear bicycle.
P.D. Kamble et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 2 (4), 2012
126

Fig. 1 : Gear Bicycle
1.2. Gear Mechanism
Geared bicycle are equipped with gear system ranging from 5 to 18 gear ,in order to achieve different speed
ratios. The gearing supplied by the manufacturer on a new bicycle is selected to be useful to the majority of
people. Some cyclists choose to fine-tune the gearing to better suit their strength, level of fitness, and expected
usage. When buying from specialist cycle shops, it may be less expensive to get the gears altered before delivery
rather than at some later date.
1.3. Gearing Range
The gearing range indicates the difference between bottom gear and top gear, and provides some measure of the
range of conditions (high speed versus steep hills) with which the gears can cope; the strength, experience, and
fitness level of the cyclist are also significant. A range of 300% or 3:1 means that for the same pedaling speed a
cyclist could travel 3 times as fast in top gear as in bottom gear (assuming sufficient strength, etc.). Conversely,
for the same pedaling effort, a cyclist could climb a much steeper hill in bottom gear than in top gear.
1.4. Types of Gear Change Mechanisms
There are two main types of gear change mechanisms, known as derailleurs and hub gears. These two systems
have both advantages and disadvantages relative to each other, and which type is preferable depends very much
on the particular circumstances. There are a few other relatively uncommon types of gear change mechanism
which are briefly mentioned near the end of this section. Derailleur mechanisms can only be used with chain
drive transmissions, so bicycles with belt drive or shaft drive transmissions must either be single speed or use
hub gears.
127

Fig. 1.2 :Gear Change Mechanisms-Derailleurs Fig. 1.3 : Gear Change Mechanisms-hub Gears
1.5. Electric Vehicle
It is incorporated with BLDC motor to make the drive effortless.

Fig. 1.4 : Electric Vehicle
2. OBJECTIVES
To design a bicycle to reduce the effort of the rider.
To provide an interface between an electric driven bike and a normal geared bike.
To provide people with an economic electric cycle.
128
3. TECHNICAL OVERVIEW COMPONENTS
3.1. BLDC Motor

Fig. 3.1 : BLDC Motor
Brushless DC motors (BLDC motors, BL motors) also known as electronically commutated motors
(ECMs, EC motors) are electric motors powered by direct-current (DC) electricity and having electronic
commutation systems, rather than mechanical commutators and brushes. The current-to-torque and frequency-
to-speed relationships of BLDC motors are linear.
BLDC motors may be described as stepper motors, with fixed permanent magnets and possibly more poles on
the rotor than the stator, or reluctance motors. The latter may be without permanent magnets, just poles that are
induced on the rotor then pulled into alignment by timed stator windings. However, the term stepper motor
tends to be used for motors that are designed specifically to be operated in a mode where they are frequently
stopped with the rotor in a defined angular position; this page describes more general BLDC motor principles,
though there is overlap.
Brushless Versus Brushed Motor
Brushed DC motors have been in commercial use since 1886.BLDC motors, however, have only been
commercially possible since 1962.
Limitations of brushed DC motors overcome by BLDC motors include lower efficiency and susceptibility of the
commutator assembly to mechanical wear and consequent need for servicing, at the cost of potentially less
rugged and more complex and expensive control electronics. BLDC motors develop maximum torque when
stationaryand have linearly decreasing torque with increasing speed.
A BLDC motor has permanent magnets which rotate and a fixed armature, eliminating the problems of
connecting current to the moving armature.
We are using 250 watts with a torque of 500 kg BLDC motor.
129
3.2. Microcontroller 8051
The AT89S52 is a low-power, high-performance CMOS 8-bit microcontroller with 8K bytes of in-system
programmable Flash memory. The device is manufactured using Atmels high-density nonvolatile memory
technology and is compatible with the industry- standard 80C51 instruction set and pinout. The on-chip Flash
allows the program memory to be reprogrammed in-system or by a conventional nonvolatile memory
programmer.
By combining a versatile 8-bit CPU with in-system programmable Flash on a monolithic chip, the Atmel
AT89S52 is a powerful microcontroller which provides a highly-flexible and cost-effective solution to many
embedded control applications.
3.3. 12 v Battery
We are using a 12 V lead acid battery. A lead-acid battery is an electrical storage device that uses a reversible
chemical reaction to store energy. It uses a combination of lead plates or grids and an electrolyte consisting of a
diluted sulphuric acid to convert electrical energy into potential chemical energy and back again. The electrolyte
of lead-acid batteries is hazardous to your health and may produce burns and other permanent damage if you
come into contact with it. Thus, when dealing with electrolyte protect yourself appropriately!
3.4. 6v Battery
We are using 6V lead acid battery for giving supply to the Microcontroller and the actuator.
3.5. Belt Drive
We are using v-belt and pulley arrangement for transmitting power from BLDC motor to the rear wheel of the
bicycle.
3.6. Dynamo

Fig. 3.2 : Dynamo
A bicycle dynamo is attached to the side of rear wheel whose shaft is rotated with the rotation of rear wheel,
developing a voltage of 6V and more which charges the 6V battery used for the operation of micro-controller.
130
3.7. Tachometer
Tachometer is a device used for the measurement of speed. We are using an analog tachometer having a speed
range of 0-40 km/hr.
3.8. Tachometer IC
This IC converts analog signal to digital signal. This IC is placed in between analog tachometer and micro-
controller. It converts the analog signal coming from analog tachometer to digital signal which then delivers to
the micro-controller.
3.9. Voltage controller IC LM 7805
It is used to control the voltage, whatever may be the voltage i.e. 6V, 12V, and 24V the regulator will give the
constant voltage of 5V.
IR Sensor & Photo Diode : A Passive Infrared sensor(PIR sensor) is an electronic device that measures
infrared (IR) light radiating from objects in its field of view. PIR sensors are often used in the construction of
PIR-based motion detectors (see below). Apparent motion is detected when an infrared source with one
temperature, such as a human, passes in front of an infrared source with another temperature, such as a wall.
This is not to say that the sensor detects the heat from the object passing in front of it but that the object breaks
the field which the sensor has determined as the "normal" state. Any object, even one the exact same
temperature as the surrounding objects will cause the PIR to activate if it moves in the field of the sensors.
3.10. 6v Gear Motor
It is a stepper type motor and acts as a actuator for actuating shifting mechanism. It rotates as per the degree of
rotation.
3.11. Motor driven IC
It is used to give a constant voltage supply to the motor or actuator whenever required.
4. AUTOMATIC GEAR SHIFTING MECHANISM
4.1. Circuit Diagram of Automatic Gear Shifting Mechanism

131
Fig. 4.1 : Circuit Diagram Of Automatic Gear Shifting Mechanism
4.1.1. Working
As the speed of bicycle varies, the needle of the tachometer also varies. An IR sensor is embedded at every
speed limit point in tachometer. As needle passes over the IR sensor, an analog pulse is generated. This pulse is
converted to digital signal with the help of tachometer IC and is sent to the microcontroller.
The microcontroller senses the signal and develops an output logic which is delivered to the motor driver IC. On
receiving the logical signal the motor driven IC actuates the motor or actuator. Then the actuator actuates the
gear shifting mechanism depending upon the speed of the bicycle.
Extra connection for charging of other accessories is provided in microcontroller.
4.2. Electric Drive

Fig. 4.2 : Electric Drive
4.2.1. Working
The BLDC motor along with the V belt pulley drive arrangement is mounted on the diagonal link of the bicycle.
The BLDC motor is powered by a 12 volt Lead acid battery. As the switch is on, the motor starts and delivers
the power to the rear wheel of the bicycle with the help of V belt pulley drive. Gear reduction is performed
using different diameter pulleys in order to increase the torque which is going to be given to the rear wheels.
Also an voltage controller is provided on the handle to vary the speed of the BLDC motor.
4.3. Selected Electric Drive Mechanism

Fig. 4.3 : Working of Electric Drive
132
4.4. Handlebar

Fig. 4.4 : Handlebar
Final Bicycle Design

Fig. 4.5 : Final Bicycle Design
5. DESIGN CALCULATION
DC motor Torque: 500Kg-Cm=49.05N-m
Two stage speed reduction
I. Teeth on DC motor shaft=10
Teeth on gear=70
Hence after speed reduction of 7:1, the RPM of motor is reduced to 171.42 from an initial 1200 RPM.
II. Teeth on sprocket attached to gear=24
Teeth on freewheel attached to hub=16
Hence a further speed reduction up to 114.28 RPM is achieved.
It should be noticed that the 114.28RPM available at the rear wheel is the maximum speed available.
133
It is subjected to further reduction depending upon the weight of rider, prevailing road and other practical
conditions.
Center distance is that 450mm. from motor shaft to freewheel attached to rear wheel.
5.1. Design of Roller Chain Drive
Power,
P=
2nN1
60

P=
2n120049.05
60

P = 6.163 KW
Design power, Pd = PRK
(For 10 hrs-day with moderate shock, Kl = 1.2 )
= 6.1631.2
= 7.396 KW
Power capacity of roller chains,
Power in HP =10.05 HP
From data book, refer chart
Pitch of chain, p = 11.95mm.
Chain No. = 30
Length of chain in pitches,
Lp =
11+12
2
+
2C
P
+
P(11-12)^2
40C

=
16+24
2
+
2450
8
+
8(16-24)^2
40450

=135.52mm.
Pitch circle dia. Of smaller sprocket,
d1 = p.cosec (
180
16
)
= 11.95(
180
16
)
= 61.27mm.
134
Pitch circle dia. Of larger sprocket,
d2 = p.cosec (
180
24
)
= 11.95(
180
24
)
= 91.55mm.
Tooth load, Ft =
Pd
v

Pitch line velocity, V =
nN
60

=
n61.271200
100060

= 3.84m/s
Number of links =
dcsgn powc
powc cupuct o] oIIc chun

powcr copocity o rollcr coin
= p^2 [
v
104

v
1.41
526
(26 25 cos
180
11
)] Kc
= p^2 [
3.84
104

3.84
1.41
526
(26 25 cos
180
16
)] 1
= 0.0815 KW
So,
The Number of links =
7.396
0.0815

= 90.748
91 links
5.2. Dimensions of Roller Chain
Roller dia., dr =
5
8
p
=
5
8
11.95
= 7.46 8mm.
Chain width, w =
5
8
p
=
5
8
11.95
135
= 7.46 8mm.
Pin dia., dp =
5
16
p
=
5
16
11.95
= 3.73 4mm.
Thickness of link plate =
1
8
p
=
1
8
11.95
= 1.49 2mm.
Maximum height of pin link plate,
Hp = 0.82 p
= 0.82 11.95
= 9.799 10mm.
Maximum height of roller link plate,
Hp = 0.95 p
= 0.95 11.95
= 11.35 12mm.
5.3. Design of Shaft
As the input or motor torque = 49.05 N-m.
The shaft will be design.
By considering the load of motor = 6 kg. at 1 end of shaft = 58.86 N
And another end of shaft, the load of power transmission wheel = 1 kg. = 9.81 N
So, the bending moment, M1 = 58.860.01
= 0.5886 N-m
M2 = 9.810.002
= 0.01962 N-m
Taking maximum bending moment as M1 = 0.5886 N-m.
136
Torque equivalent, Te = I
2
+ H
2

= 49.05
2
+0.5886
2

= 49.053 N-m.
Shear stress of shaft by considering mrtl of shaft is Carbon steel (SAE 1050)= 679 MPa
And factor of safety = 2.5
So, the os = 679/2.5 = 268 MPa
1c
n
32
d^4
=
cs
d
2

49.05332
n
32
d^4
=
26810^3
d
2

Dia. Of shaft, d = 9.3210
-3
m
10 mm.
5.4. Design the Welding of Plates & Dimensions of The Weld
There are two plates are welded on cycle rod.
As the width of plate is 3.8cm.
Thickness of plate is 1.5cm.
Length of plate is 7.6cm.
Length of cycle rod plate is 4.3cm.
When welding of plate is design, consider the weight of motor is 6kg = 58.86N.
Stresses on the weld plate =71.01 10
-3
N/mm
2
.
P = otwclJ 0.707 S b +oswclJ 0.707 S 2x
58.86 = 71.01 10
-3
(0.707 15 38 + 0.707 15 2x)
x =38mm.
Length of weld, lw = 2x+b+12.5
= 238+38+12.5
= 126.5mm.
137
5.5. Bearing Design
From data book;
As per the shaft dia. = 10mm.
Bearing inner dia. is 10mm.
And outer dia. is22mm.
Ball bearing is selected.
5.6. Key Design
From data book;
As per the shaft dia. = 10mm.
Width of key is 3mm.
Height of key is 3mm.
Length of key is 6mm.
Thickness of key is 1.8mm.
6. FABRICATION
Manufacturing consideration in designing machine parts:
Machining Process : The process used for giving final shape to machine components according to planned
dimension is known as machining process. The common operations used for this process are cutting, drilling,
etc.
Surface Finishing Process : The process used to provide a good surface finish for this component are known as
surface finishing process. E.g. abrasive belt grinding.
Joining Process : The processes used for joining machine component are known as joining processes. E.g.
welding.
Part list:
Table 1 : List of Parts Used in Bicycle
SR. No. PARTS QUANTITY
1 GEARED BICYCLE 1
2 MICROCONTROLLER 1
3 BLDC Motor 1
4 Lead Acid Battery 1
5 Dynamo 1
138
6 Chain Drive -
7 Tachometer 1
8 sprockets 2
7. ADVANTAGES
Health Benefits : Electric bicycles can be a useful part of cardiac rehabilitation programs, since health
professionals will often recommend a stationary bike be used in the early stages of these. Exercise-based cardiac
rehabilitation programs can reduce deaths in people with coronary heart disease by around 27% and a patient
may feel safer progressing from stationary bikes to electric bicycles. They require less cardiac exertion for those
who have experienced heart problems.
.

Environmental Effects : Most electric bicycles can be classified as zero-emissions vehicles, as they emit no
combustion byproducts. The environmental effects of electricity generation and power distribution and of
manufacturing and disposing of (limited life) high storage density batteries must be taken into account.
Even gear shifting will be possible.
Less wear and tear, so the life of the bicycle will be more.
Light in weight.
Equipped with two power sources.
8. DISADVANTAGES
Upfront costs may be higher than for a comparable gasoline powered motorcycle or scooter depending of the
battery type used.
Shorter range before recharging.
Longer "fill up" or recharge time.
Lower maximum speed at similar price points.
Electric power outlets are often not conveniently located near streets or driveways.
9. COMPARISION WITH ELECTRIC BIKES AVAILABLE IN THE MARKET
The most important benefit of our bicycle is its cost which is cheaper than bicycles available in the market.
Due to different gear ratios load coming on the motor will be less.
It will weigh less.
It will travel a long distance as compared to others in one charging.

139
10. CONCLUSION
It is sometimes very hard to drive your car to the nearby market place and hunt for a parking space to get a small
thing like a milk bottle or say a bread packet. Instead, you or your son/daughter could go by the electric bicycle
and get such thing and come back within less than the time it would take you to return home by your car. Hence
over viewing all the points we can say that electric bicycle with an automatic gear system is simple, economical
and eco friendly.
11. REFERENCES
[1] Dr. I. D. De Vries The potential of electric bicycles to provide low cost transportation, mobility and
economic empowerment in South Africa. Proceedings of 25th southern African transport conference
[2] A. Muetze and Y. C. Tan,| Electric Bicycles, IEEE Industry Applications Magazine, July/August, pp. 12-
21, 2007.
[3] C. Whelan, Electric Bikes are taking off, New York Times, March 14, 2007.
[4] J. Weinert, C. Ma and C. Cherry, The transition to electric bikes in China: history and key reasons for
rapid growth, Transportation, Vol. 34, pp. 301-318, 2007.
[5] S. Bhanoo, For cyclists needing a boost, this wheel may help, New York Times, December 14, 2009.
[6] Bouwman, Mirjan E An environmental assessment of the bicycle and other transport systems,
University of Groningen, Netherlands, 2000.
[7] OConnell, D.P. & De Vries, I.D., 2010. Digital energy metering for electrical system management,
Proceedings of the 2010 ACM Symposium on Applied Computing, Crans-Montana/Siere, Switzerland 22-
26 March 2010.

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