ELECTROMAGNETIC GEAR SHIFTING
MECHANISM FOR TWO WHEELERS
1​
Indra Asokan
IIIrd year B.E.Automobile Engineering
Rajalakshmi Engineering College
Chennai 602105
indrachintu@outlook.com
3.​
Prahlatha Varadhan.T.P.M.
IIIrd year B.E. Automobile Engineering
Rajalakshmi Engineering College
Chennai 602105
tpmvaradhan@gmail.com
Abstract - ​This paper discloses an
automatic gear change control apparatus
for an automobile and a method of
controlling such apparatus. A rotational
output of an internal combustion engine is
connected to drive wheels of the automobile
and a load device. When a gear shifting-up
of an automatic transmission is to be
effective, the load applied by the load device
is increased, or the load device is connected
to an output rotation shaft of the engine via
a selectively-connecting device, thereby
reducing the rotation speed of the output
rotation shaft of the engine to a required
level. Electromagnetic gear shifting
mechanism for two wheeler is simple and
innovative concept. The two buttons are
used to activate the electromagnetic coil so
that the gear will be changed.
I. INTRODUCTION:
​In the vehicle drive is transmitted from the engine
to the flywheel through clutch to gear box and to the
driving wheels. Then the vehicle is moved for this
transmission of power, gear box is important
component. The gear box comprises a set of gears
2.​
Jeevith.
IInd​ ​year B.E. Automobile Engineering
Rajalakshmi Engineering College
Chennai 602105
jeevith.parthiban@gmail.com
4.​
Arunkumar.R.
Assistant Professor
Automobile Engineering
Rajalakshmi Engineering College
Chennai 602105
for transmission. It is used for a vehicle to be able to
travel at a range of speeds with maximum
efficiency. Higher gears require less energy or fuel
for the vehicle to operate, but can only be utilized at
higher speeds or the vehicle would stall or be
inefficient. Lower gears require more power per unit
distance, but allow for greater control and are
effective at low speeds. It is difficult to understand
when riding the basic pedal bike. Note that when we
are travelling at a moderate speed, it is much easier
to pedal in a higher gear than it is in a lower one.
The main benefit of the gear system is that it saves
large quantities of energy and fuel. For manually
operated vehicles, a significant amount of money
can be saved. In addition, less pollution is released
into the environment. The gear system also allows
easy of use. Drivers can select the appropriate gear
for the driving speed and find their vehicles
convenient to operate. Gear systems are now
installed in virtually every car and motor vehicle, as
well as on most adult pedal bikes.
II. GEAR SHIFTING MECHANISMS
​Most all current motorcycles shift with a lever
operated by left foot. With the transmission in
neutral, gears are selected by pressing down for first
and then letting the lever return to the center
position. Then, hooking our toe under the lever,
pulling up for second gear. Third and all subsequent
gears are selected by pulling up on the lever after
allowing it to return to the center position. Sounds
complicated but it is quite easy to do. Things were
not always so easy. In the 1970s and earlier, the
British made bikes that shifted with the right foot.
Some were down for first and up for everything
else. Some were up for first and down for the rest.
Then the Japanese jumped in with neutral all the
way up and everything else down, or neutral down
all the rest up​. ​To make things really interesting
they also came up with a rotary shift, which went
1,2,3,4, neutral, 1,2,3,4, neutral… etc. Supposedly IV.
this was to make city riding easier. All you had to
do was shift down one more time to get into neutral,
as you come up to a stop light. One bike, the
Bridgestone 175, even gave you a choice between
four gear rotary shift or five gear one-up, the rest battery performance. The energy and power
down shifting. A lever on the crankcase let you
choose. Not only that, but before 1965 there was an performance of an electric vehicle. Performance of
extra neutral between fourth and fifth gears too.
Some of the bikes from the 1920s and earlier even
had hand shifting with a lever on the tank. We
III. SELECTION OF COMPONENTS:
​ The Components used are
● Battery
● Solenoid
● Switch
● Tension cable
● Connecting Wires
● Gear pedal
BATTERY​:
A battery represents only 10% of the initial cost
of today’s electric vehicle, yet the ultimate
operating costs of vehicles are heavily dependent on
available from a battery directly affect the load
an electric vehicle is strongly dependent on the
energy extractable from a battery is a function of the
rate at which energy is removed, i.e., the power.
Considering the cost, availability and the charging
capacity, the lead acid battery is chosen.

​Fig 1.0 Drum Shifter

Motorcycle transmissions are made up of gears in
constant mesh. Because of this, there are no
synchromesh to speed up the gears. The gears are V.
already spinning. To change between gears need COIL​:
some kind of gear shifter mechanism to go along
with that gear shift lever.
​Fig 1.1 Lead Acid Battery
MAGNETIC FIELD PRODUCED BY A
When an electrical current is passed through the
coil windings, it behaves like an electromagnet and
the plunger, which is located inside the coil is
attracted towards the centre of the coil by the
magnetic flux setup within the coil’s body, which in
 turn compresses a small spring attached to the one
end of the plunger. The force and speed of the
plunger movement is determined by the strength of
the magnetic flux generated within the coil.
pedal to tighten the tension cable. Upper end of the
solenoid is connected to the gear pedal and the
lower end is connected to the switch.
Battery supplies power to solenoid. The solenoid
is connected is connected to the battery through the
switch. Battery positive terminal is connected to the
switch and the negative terminal of the battery is
grounded. Two switches are used to actuate the
solenoid i.e. green colour switch is used for gear up
and red colour switch is used for gear down.

​Fig 1.2 Electromagnetic Coil

VI. SPECIFICATION OF SOLENOID​:

1. Voltage : 12v dc
​Fig 1.3 Block Diagram
2. Duty cycle : 5 to 100 %
3. Stroke cycle : 50mm max VIII. WORKING​:
4. Holding force : 41N to 95N ​The gear shifting mechanism is done by actuating
5. Power : 14 watts the switch, which is present in the handle bar. There
are two switches available on handle bar. One
VII. TENSIONS CABLES​: switch (red colour) is for increase the gear ratio and
​Cables
are a construction of wire strands, laid (i.e. another one (green colour) is for decreasing the gear
twisted) helically around a core, to form a tension ratio. Green switch is connected to the solenoid (s1)
member of symmetrical cross section. Cables have a and the red switch is connected to the solenoid (s2).
high strength-to-weight ratio as the wire strands are If the green switch is pressed, the current flows
drawn to high strengths and laid to share tensile from battery to the solenoid (s1). The
loads efficiently. There are two fundamental cable electromagnetic coil inside the solenoid (s1) gets
constructions: wire rope (“flexible construction”) energized. So the magnetic force is developed and it
and structural strand (“stiff construction”). The attracts the cylindrical shaped rod which is
construction and subsequent mechanical properties connected to the gear pedal using tension cable. The
are determined by the wire pattern and wire size tension cable is tightened in a nut which is welded
used for the core and outer strands. at the end of gear pedal.
Now the front end of the gear pedal is pulled
VIII. ​CONSTRUCTION​: down by the action of solenoid (s1), so the gear is
​The important component of this project is changed from the neutral position to the first gear. If
solenoid. There are two solenoids used i.e., one for the same green switch is pressed again second gear
ascending gear and another solenoid for descending is activated by the solenoid (s1). Similarly third and
gear. Solenoid is connected to the gear pedal fourth gear is shifted through switch.
through a tension cable, a nut is welded at the gear Red switch is used for reducing the gear. If the
red switch is pressed once current flows from
 battery to the solenoid (s2). So the increasing gear
ratio can be achieved.
Max torque 9.8 Nm at 5000 rpm
IX. ENGINE SPECIFICATIONS​:
Acceleration (0-60 Km/hr) 9 seconds

Cruise speed for optimal fuel 45 Km/hr

efficiency

Fuel consumption under test Around 67 Km/litre

conditions

Oil consumption (average) 1200 Km/litre

XI. TRANSMISSION​:

Fig 1.4 Engine Clutch Wet multi-plate type

Type Two stroke Transmission 4 speed constant mesh

Cooling system Air cooled Gear shift pattern All down, heel-toe shift

Bore 50.0mm Primary Reduction 3.125 (50/60)

Stroke 50.0mm Final Reduction 3.154 (41/13)

Piston displacement 98.2cc

XII. GEAR RATIO​:
Gradability 1 in 2.6

Carburettor UCAL Mikuni VM 18 First gear 2.909 (32/11)

SS
Second gear 1.800 (27/15)
Starting system Primary kick
Third gear 1.277 (23/18)
Lubrication system Suzuki “CCI”
Top gear 0.954 (21/22)
Compression ratio 6.7:1
Drive chain ½” 5/16”
X. PERFORMANCE​:
Links 112 links

Maximum horsepower 5.74 KW (7.8 BHP)

@5500 rpm XIII. ELECTRICAL​:
Max speed Top gear (4th Around 82 km/hr System DC type
gear)
 Microcontroller is the heart of the system which
Ignition type PEI electronic
handles all the sub devices connected across it. We
Ignition timing 24⁰ ± 2⁰ B.T.D.C. have used Atmel 89s52 microcontroller.
@3000 rpm
Deepan. V, Suresh. D and Arjunraj. P - “NEW
Spark plug NGK-BP7HS, MODI CLUTCH ACTUATED SYSTEM FOR TWO
Champion L82YC
WHEELER” - International Journal of
MICO W5BC
Multidisciplinary and Current Research.
Battery 12V 2.5 Ah/10HR

Generator Flywheel A DEVICE OF PUSH BUTTON GEAR AND

CLUTCH ACTUATION BY VACUUM POWER,
Fuse 10A
FOR SINGLE CYLINDER ENGINED TWO AND
THREE WHEELER VEHICLES.
XIV. CONCLUSION​: EXPERIMENTAL STUDY ON INTELLIGENT
​Working in this area has provides a lot of practical GEAR-SHIFTING CONTROL SYSTEM OF
knowledge regarding, planning, purchasing, CONSTRUCTION VEHICLE BASED ON
assembling and machining. The application of
CHAOTIC NEURAL NETWORK
electromagnetic coil produces smooth operation. We
have developed a “AUTOMATIC PNEUMATIC, PLC CONTROLLED,
ELECTROMAGNETIC GEAR SHIFTING AUTOMOTIVE GEAR SHIFTING MECHANISM
SYSTEM” which helps to know how to achieve low
MUNTASER MOMANI, MOHAMMED
cost automation. By utilizing more strategies, this can
be modified and developed according to the ABUZALATA, IGRIED AL-KHAWALDEH AND
application HISHAM AL-MUJAFET DEPARTMENT OF
MECHANICAL ENGINEERING, FACULTY OF
XV. LITERATURE SURVEY​:
ENGINEERING TECHNOLOGY.
Now-a-days, the clutch is controlled by hands and
gear shifting using foot. Though the system is XVI. REFERENCE:
comfortable there are some drawbacks felt. To 1. NK Giri - “Automobile Mechanics”
overcome these drawbacks some modifications are 2. Kirpal Singh - “Automobile Engineering”
suggested (switch operated gear shifting for two 3. PD Kamble, SP Utawale, SB Sahare -
wheelers). The leverage mechanism normally
“Automatic Gear Shifting Mechanism and
employed in vehicles uses more of manpower and
has frictional losses. Control of gears through Electric Drive In Bicycle”.
switch and electric circuits will be more convenient 4. P Alexander, T Sudha, M Umamageshwari -
and comfortable for the driver. Moreover the time “Automatic Gear System In Two Wheeler
lag of operation will be very less when compared to Using Embedded System”.
conventional system. 5. WWW.CARBIBLE.COM
P. Alexander M.E., T. Sudha M.E., 6. WWW.AUTOSHOP101.COM
M.Umamageshwari M.E.- “AUTOMATIC GEAR
TRANSMISSION IN TWO WHEELERS USING
EMBEDDED SYSTEM” - INTERNATIONAL
JOURNAL OF ADVANCED RESEARCH IN
ENGINEERING AND TECHNOLOGY.