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Research on Clutchless Quick Gear Shifter for Formula Student Vehicle

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 10 | Oct 2020 www.irjet.net p-ISSN: 2395-0072

Research on Clutchless Quick Gear Shifter for Formula Student Vehicle

Ameya Dabhade1, Saurabh Walekar2, Hrishikesh Marne3, Harsh Salvi 4, Manish Naik 5,
Rohan Bhise6
1-6Mechanical Engineering Department, Trinity College of Engineering and Research, Pune, Maharashtra, India
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Abstract - The purpose of this paper is to develop a shift times, a decrease in weight, and better performance
clutchless gear shifter for formula SAE car. With this proposed overall. The system will be designed with increased
system, clutch is completely eliminated during shifting of performance, light weight, and reliability as the driving
gears. While shifting gears without clutch, safety of the parameters. When finalized, it will allow the driver to
transmission system also taken into consideration. This system actuate a shift almost instantaneously without losing any
also eliminates control of the car.

Weight of unnecessary shifter rod and assures a fair and Before selecting electric button shifter as a gear shifting
smooth shift without any lag. This paper discusses the concept media several different options were considered. The said
and design of this system. objectives could be fulfilled by using hydraulic as well as
pneumatic apart from electric button shifters Hydraulic and
Key Words: Quick gear shifter, Clutchless gear shifter, pneumatic systems has its limitations over electronic
Button shifter, cliptronix, fsae system. Since the project is related to racing vehicle
hydraulic and pneumatic systems adds more weight to the
1. INTRODUCTION vehicle. Also fluids used in hydraulic systems has tendency
to catch fire which would make the driver more vulnerable
Formula SAE is an international competition organized by to injury.
the Society of Automotive Engineers where college students
design, manufacture and compete with a formula style car. 2. LITERATURE SURVEY
The car built by Trailblazers Motorsports team uses 2015
KTM Duke Engine that has a 6-speed sequential gearbox. The There are several similar projects in the market may it be
gears can only shift sequentially in order, and shifts are hydraulic, pneumatic or electric. Each has its advantages and
actuated by the rotation of a lever at the gearbox. The limitations but all of them are very effective in their
current shifting system is completely mechanical and is operations. The shift process is divided into three stages. The
actuated by a lever mounted to the driver’s left side. When a duty ratio of the solenoid valve controls the motion state of
shift is needed the driver is required to remove his hand the piston of the hydraulic cylinder, In the in the rapid oil
from the wheel, grab the lever, and push or pull it. This filling stage ,the clutch piston gets a larger motion speed,
system is problematic in a few specific ways. The time taken and the slow motion in the slow contact phase of smooth
between when the shift is needed to when it is actuated is shift. There is a greater pressure between the main and the
somewhat slow due to the driver’s need to remove his hand driven disks of the last phase, which can transmit greater
from the wheel. The lever also proved to be difficult to torque. Using this control mode to shift gears can not only
actuate at certain critical times as there is always some play increase the shifting speed but also ensure the smoothness
in the linkages. On a Formula SAE competition course with of shifting. [2]
many turns, frequent shifting is required to maximize
performance. If a shift is needed during a turn the driver This paper is about Design and fabrication of a
would have to make the turn with one hand on the steering semiautomatic gear. Shifting mechanism for a racing car like
wheel or simply wait until after the turn and lose time while Go Kart a. This gear shifting mechanism had been design to
the engine was in a bad RPM range. Both situations lead to a overcome issues like –gear shifting. problem while gear
decrease in overall performance. shifting, to eliminate fully manual gear shifting ,so that driver
can give more attention to steering, to reduce the effort and
The goal of this project is to design and implement an timing of gear shifting which is more important racing
electronic button shift system to address these issues and basically where few milliseconds. Make you a winner or a
eliminate the detriment of the push-pull system to overall loser. The idea of pneumatic shifter rose when there was
performance in a race. With button shifting, the driver would some going on discussion on different mechanism for
be able to actuate a shift without removing his or her hand shifting gear .Performing some analysis on basic design and
from the steering wheel, increasing control at every point in on available data design was bought onto existence [3]
the race. As well, the amount of energy required by the
driver to actuate the shift is minimized to reduce the fatigue This paper explains the maximum and minimum reductions
of the driver during a race. This would ideally lead to faster per stage of planetary gear pairs and also the advantages of

© 2020, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 1652
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 10 | Oct 2020 www.irjet.net p-ISSN: 2395-0072

using planetary gear pair system over the other systems. 4.2 Actuator:
Also allows us to study on determination of reduction ratio
of this planetary gearbox. On the basis of certain parameters A solenoid operated actuator is selected to perform shifting.
like torque density weight and volume the comparison It receives power directly battery and actuates the
between planetary gears and helical gears is done. The respective gear. Selection of solenoid actuator is done on
detailed study of planetary gear trains helps us to determine how much force it can generate. Force required to shift gears
reduction ratio for each stage. [4] can be calculated by using spring mass or load cell.

To automate the manual transmission in two wheelers 4.3 Voltage Regulator:

hydraulic and pneumatic drives are used. But these
equipment results higher weight of vehicle. Also the Some of the components used in the system works at voltage
response of this system gives sluggish response and leakages less than power supply voltage. In order to prevent any
issue. To avoid this AMT is used. Electromechanical device damage to these components voltage regulator is used. The
based on DC motors is used to automate the gear system in purpose of a voltage regulator is to keep the voltage in a
two wheelers. Instead of using log for gear shifting gear circuit relatively close to a desired value. Voltage regulators
shifted automatically based on speed. This mechanism is are one of the most common electronic components, since a
reliable and quick as compare to hydraulic and pneumatic power supply frequently produces raw current that would
drive. The cost of this system is very low. Also it gives otherwise damage one of the components in the circuit. A
comfort to the rider. [5] voltage regulator generates a fixed output voltage of a preset
magnitude that remains constant regardless of changes to its
3. PRINCIPLE OF WORKING input voltage or load conditions.

The project is based on the concept of flat shifting of gear in 4.4 Relay:
which there is no need to use clutch for gear shifting. Normal
clutch less shifting is mostly done at higher speeds and Relays are the switches which aim at closing and opening the
sometimes it also causes severe problems to the circuits electronically as well as electromechanically. It
transmission system. Hence in order to save the time during controls the opening and closing of the circuit contacts of an
shifting and to protect the transmission system this project electronic circuit. When the relay contact is open (NO), the
is done. Following figure shows the flowchart of the system. relay isn’t energizing with the open contact. However, if it is
closed (NC), the relay isn’t energize given the closed contact.
However, when energy (electricity or charge) is supplied, the
states are prone to change.

4.5 Gear position sensor:

A gear position sensor is a car part that monitors your shift
rail's position inside your vehicle's gearbox. It was
developed to observe, supervise, and inspect the position of
the shift rail through a combination of two or three sensors
like it in each transmission.

4.6 Display:
The function of the display for the shift system is to inform
Fig -1: Circuit diagram of clutchless gear shifter the driver or what gear they are currently in. To serve the
purpose 14 segments or 16 segments LED display can be
4. REQUIRED COMPONENTS used.

4.1 Battery: 4.7 MCU:

Since the project requires electric power source to run the Immediately prior to shift actuation, both spark and fuel
system, a 12V battery as selected as a power source. As for need to be restricted so that a ‘flat shift’ can be performed.
the normal working of vehicle it has 12V battery. This Flat shift is a term which describes the event where the
project uses the same battery to run the vehicle as well as engines speed is retarded, eliminating the need for the driver
electronic gear shifting. to lift off of the accelerator while shifting. This function will
allow for a faster and more accurate shift when compared to
conventional means where the driver must lift off of the
accelerator.

© 2020, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 1653
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 10 | Oct 2020 www.irjet.net p-ISSN: 2395-0072

The microcontroller, which will serve as the intelligent [3] Tanmay J Wadgaonkar, Madhur R Pawar, Swapnil V
control must be able to use both input and output signals to Vaidya," Design and Manufacturing of Pneumatic Gear
Shifter for Go-Kart",International Journal of Engineering
control both electrical input as well as output requirements. Research & Technology, Vol. 5, Issue 8, 2016.
Microcontroller system must communicate with the ECU [4] Rahul Sharma, Avichal Agarwal, Udit Sharma," Design of
semi-automatic electronic gear shifting mechanism
regarding the RPM of the vehicle to avoid the shift by ",International Journal of Research in Engineering and
mistake of a driver as shifting buttons will be placed close to Applied Sciences, Vol. 5 , Issue 8, 2015.
the driver’s finger. [5] A. A. Jagatap, S. D. Lokhande,"Automated manual
transmission for Two wheelers", International
5. WORKING Engineering Research Journal,special Issue 2, Page
No.40–45, 2015.
For the first time to make a gear shift from neutral to first [6] Pawan R. Gurav , Rajesh M.Mhatre, Deepak B. Pal , Sahil
gear driver has to use clutch. This is the only time driver R.Satvilkar, Geeta J. karmarkar, “Button operated gear
would use clutch to make shifts. From first gear to second shifter in two wheeler using stepper motor”
International Journal of Scientific & Engineering
driver simply has to press the upshift button on the steering Research, Volume 8, Issue 3, March-2017.
wheel. As driver presses the upshift or downshift button, a
[7] Lee Redstone, Lewis Weston, Jason Deglint. (2012).
signal sent to the MCU which in turn will open the normally FSAE Electronic Shifter. Retrieved 13 July, 2015
closed relays. [8] Andrew Ajirogi, Ben Aldern, John Odlum, Johnny Chang.
(2011). Team Raptor Paddle Shifters. Retrieved 13 July,
These relays are placed in the circuits of spark plug and fuel 2015
injector. When made open cuts the power of spark plug and [9] SAE INDIA RULEBOOK
fuel injector. This causes the engine to slow down for a
[10] K. J. Purohit, H. J. Prajapati, D. D. Patel, M. B. Patel, K. J.
moment, in which the gear shifting happens. As there is no Parekh," A Review Paper on Development of Automatic
power or spark supply driver may not lift his foot off the Gear Shifting Mechanism", International Journal for
accelerator. Scientific Research & Development,Vol. 3, Issue 12,2016

At the same time MCU sends the signal to the solenoid

actuator to perform the required shifting as per requested by
the driver.

To safeguard the transmission system, a safety feature is also

provided. When driver requests upshift or downshift
microcontroller gets feedback of an engine RPM and
compares it with previously saved chart and takes the
decision about the shifting. If the driver requests the
downshift and the RPM is higher than recommended then it
does not allow downshift unless the RPM falls to the
necessary limit and vice versa for upshift.

6. CONCLUSION

The main objective of this project was to reduce the shifting

timing is achieved. System takes less than a second to shift
the gears. Since it does not uses any mechanical links which
adds the unnecessary weight is eliminated. Because of the
quick shifting the vehicle performance is noticeably
increased at turns as well as at straight patches.

This system also safeguards the transmission system from

shift by driver’s mistake.

REFERENCES

[1] Richard Pittman, Sean Feschak, usab Hmeiden, Kevin

Castillo, “Formula SAE Paddle Shift System”
[2] Qingwen Ren et al 2018 IOP Conf. Ser.: Mater. Sci. Eng.
394 042074

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