DESIGN AND FABRICATION OF

BUTTON OPERATED GEAR

SHIFTER IN TWO WHEELER USING
SOLENOID ACTUATOR
BY
KETAN RANANAVARE
ABHISHEK RANE
NAGESH RATHOD
MANALI REDKAR
Under the guidance of
Prof. ASHWINI KUMAR SINGH

G.V.Acharya Institute of Engineering and Technology,

Department of Mechanical Engineering
Shelu
• This study describes in detail in an understandable way to how
to convert the traditional manually gear shifting mechanism by
using solenoid actuator.

• This project aims at modifying the gear shifter mechanism in

current automotive technology.

• The main idea of the project is to use a solenoid actuator that

can produce certain amount of linear force which is suitable
for perfect gear shifting.
OTHER TYPES OF GEAR SHIFTER

MANUAL GEAR SHIFTER

• The gear shifting in the bike is
processed by the driver using the
foot.

Limitations:

1. This type of gear shifting

requires more effort by the rider.
2. It becomes difficult for
handicapped people to use this
type of gear shifter mechanism
 PNEUMATIC GEAR SHIFTER

• Pneumatic gear shifter uses an

electro-pneumatic actuator
which produces the required
force for shifting gears.
Limitations:
1. Hoses

2. Canisters

3. Consumables
 ELECTROMAGNETIC GEAR SHIFTER

• It uses a solenoid actuator to create the required force for gear

shifting.

• Electromagnetic gear shifter is the most suitable gear shifter for

bikes. It consists of a solenoid actuator, relay connection and two
push buttons.

• It consumes power from the main battery of the bike, hence there is
no need of any further maintenance in this system.

• Its wiring is also not much complicated part, since it is compatible

to the electrical connections of any bike.
 COMPONENTS
• Solenoid actuator
• Solenoid actuator is a device
which converts electrical
energy into mechanical work.

• It is of a pull-push type
actuator for upshifts and
downshifts respectively.

• It should be customized
according to the force and
stoke required for the gear
shifting.
 RELAYS
• Direct contact between the
switch and the actuator may
damage the switch and also harm
the user in some cases.

• A relay is an electrically operated

switch. Relays are used where it
is necessary to control a circuit
by a separate low power signal.

• This automotive relays can

withstand higher current with
proper ease and are quick to
actuate.
 BATTERY
• Lead-acid Battery.

• 12V DC (>7 AH)

• More current giving capacity

for solenoid actuator.

SECIFICATION:
• Weight: 2.65 KG(s)
• Battery Type: VRLA Battery
• Compact in size
 PUSH BUTTONS
• It is small in size.

• It is a push button of quick

return type.

• It is placed well within the

reach of the drivers thumb.
 WORKING

SYSTEM BLOCK DIAGRAM

CIRCUIT DIAGRAM
SELECTION OF SOLENOID ACTUATOR

• According to the force required for the perfect gear shifter.

• According to the stroke required by the engine.

• Should consume less current for 100% efficiency.

• It should be light in weight.

• It should be easily mounted.

 DESIGN CALCULATION
Shifting Torque

• Shifting torque is the torque required

by the engine gear shifting sprocket
for perfect gear shifting.

• . The total torque required can be

determined using the formula:

• T=FxR
Where,
• T= Torque required for the gear
shifting sprocket.
• F= Force applied at the open end of
the lever.
• R= Length of the lever
 SOLENOID FORCE
• It is the load a solenoid can hold, pull or push at the starting point
of its stroke. This force can be varied depending on the design of
the solenoid.
• The formula for the solenoid is given below:
𝑵×𝑰 𝟐 𝝁𝟎 𝑨
𝑭= 𝟐
𝟐𝒈

• Where,
• 𝜇0 = 4𝜋 × 10−7
• F= Solenoid force in Newtons.
• N= Number of turns.
• I= Current in Amps.
• A= Area of the solenoid.
• g= length of the gap between the solenoid and the piece of metal.
 APPLICATION

1. It can be used in any bikes using different mounting methods.

2. It can be used for handicapped drivers.

3. It can be used in bikes used for racing in competitions like MotoGP

championships.
THANK YOU.