Hand Operated Clucth For Four-Whleer: A Project Report
Problem summary
Conventional separate clutch and gear operating system used in automobile have several limitations and disadvantages such as response delay, wear of clutch plate, wear of gears, and requirement for auxiliary components like clutch pedal and its linking mechanism, separate gear lever and its shifting mechanism. And auxiliary component increases over all weight of clutch and gear system and hence automobile. It is difficult to operate pressing clutch pedal by left leg with force and keeping it press and then shifting of gear lever by left hand to attain required gear torque and speed to automobile; leads to pain in leg hand while at the same time right hand busy with steering wheel; all this leads headque also more driving skill is required while using conventional separate clutch and gear system in automobile.
Introduction
This invention relates to operate the clutch by the hand and reduce headqua of operating conventional clutch and gear system. Our invention relates to operate the clutch used in automotive vehicle. As clutch connect and disconnect main engine shaft and gear box input shaft, accurate, timed, easy, suitable, safely control operation of clutch is very important for automobile system perhaps so many drawbacks present with conventional pedal operated automobile clutch system. So it is necessary to operate anyone of pedal either clutch, brake, accelerator with handle but again the so many problems with acceleration and brake if they are operated by handle mount system.
Aim of the project and objectives
The object of the invention is to provide inventive, innovative, novel method and novel device for operating clutch and shifting gear with hand operated clutch technology. And another objective of this invention is to replace conventional clutch control method. i. e. clutch pedal to simple,easy,safe,ergonomically correct,light weight, driver frindely,economical,less space mounted,easly controlled hand operated clutch technological system to operate clutch and gear shifting mechanism. It is still another object of this invention is to provide driving skill of operator and provide more technology and product to automobile world.
Problem specification
For some drivers gear shifting can cause some confusion at driving specially in traffic situation. A crowded road on hill or sudden detour makes lot of tension on the driver. One of the most difficult situations is to select the right gear and engage it at right time. It is difficult to disengage the clutch at hill without stalling the engine.
Plan of work
This invention relates to mechanisms for controlling the selection and engagement of various gear relations of automotive vehicle transmission gearing. We are going to make a new master cylinder design to mount on gear changing lever to make more simple clutch operation. Mounting the master cylinder on gear lever is most difficult thing but it is very easy to use then conventional system. We are going to connect flexible high pressure hose to the sleeve cylinder from master cylinder. And that sleeve cylinder operate the lever of the clutch which operate the diaphragm. And clutch is operated by the hand. This makes the gear shifting method more effective and economical.
Required Tools
Arc welding machine
Arc welding is a process that is used to join metal to metal by using electricity to create enough heat to melt metal, and the melted metal when cool result in a binding of the metals. It is a type of welding that uses welding power supply to create an electric arc between an electrode and the base material to melt the metal at the welding point. They can use either alternate direct currant, and consumable and non consumable electrodes. The welding region is protected by some type of shielding gas, vapor or slag. Arc welding processes may be mannuly,semi automatic or fully automatic. Today it remains an important process for the fabrication of steel structures and vehicles.
Screw driver
A screw driver is tool, manually or power, for Turing screws. a typical simple screw driver has a handle and a shaft, and a tip that the user insert in to the screw head to turn it. The shaft is usually made of tough steel to resist bending or twisting.
Nut and bolt
A nut is type of fastener with the traded hole. Nuts are almost always used in conjunction with a mating bolt to fasten multiple parts together. The two partner are kept together by a combination of there threads friction, a slight stretching of the bolt, and compression of the parts to be held together.
Open end wrench
A one piece with a u shaped opening that grips to opposite faces of the bolt or nut. This wrench is often double ended, with the different size opening at each end. The ends are generally oriented at an angle of around 15 degrees to the longitudinal axis of the handle. This allows a greater range of movement in and closed spaces by flipping the wrench over.
Analysis
We analyze that while driving in difficult situation like traffic and driving on grades surfaces it is difficult to operate clutch and gear making it less comfortable driving in city and states. And some drivers may worn-out the clutch and stall the engine this may cause damaging the parts of power train like wear of clutch plate, wear of gears.
Design methodology
First of all, we think about mechanism or system of how to use clutch easily without use of leg. We saw we can put the clutch lever on gear shifting knob making it more driver friendly to operate. So we think about system which can operate clutch, there many system to operate clutch,
- Hydraulic system
- Mechanical system
- Electrical system
Hydraulic system
In hydraulic system requires many components as master cylinder, sleeve cylinder, flexible high pressure hose pipe, reservoir, hydraulic fluid. It is an easy and smooth operating system. it is more reliable then electrical system.
Mechanical system
In mechanical system less components are require which includes clutch wire, return spring etc. it is the most economical system. It requires more effort to operate the clutch. Easy to maintain mechanism.
Electrical system
In electrical system requires many components as coil, rectifier, transducer, sensor. This system is the most complex system. It requires coding to operate particular function. Costlier system then other systems.
Implementation strategy
Hand operated clutch for four wheeler
We find all components which we require for our invention like master cylinder, sleeve cylinder, flexible high pressure hose, piston, hydraulic fluid.
Construction
When you depress the clutch lever, it pushes a rod attached to the master cylinder. This mechanical pressure is applied by the lever is transformed to hydraulic pressure. The master cylinder is connected to the reservoir containing hydraulic fluid which will be forced by the fluid hose in the clutch slave cylinder. Typically a clutch assembly is provided between a power source at an engine, of a vehicle and a transmission system of the vehicle to provide a smooth shift between gears. The clutch assembly generally includes clutch plates, a clutch release pin, a clutch shaft, and clutch springs. The clutch assembly can be actuated by a clutch actuation assembly, for example, a cable clutch actuation assembly or a hydraulic clutch actuation assembly. When a driver of the vehicle manually imparts a force on the clutch lever, the piston forces the fluid to flow to sleeve cylinder and sleeve cylinder operate the fulcrum of the clutch. This engages and disengages the clutch in a smooth motion.
Working
The driver applies force on gear knob to downward side. this force resulting in to pressing the piston towards downwards side and piston forces the fluid towards sleeve cylinder through flexible high pressure hose. The sleeve cylinder pushed out the piston towards the fulcrum lever and fulcrum lever moves in forward direction in one end and at the other end moves backward direction by this motion the diaphragm of the clutch disengages clutch plate. When the driver release force from the gear knob the piston moves upward with the help of spring. By this motion the fluid comes back into reservoir and clutch gets engage.
Implementation:
Normally the clutch and gear operated separately by foot and hand we found a problem while changing gears it gets difficult to apply and maintain pressure on clutch pedal and then shift gear with left hand. So we decide to make a system that can allows to operate clutch and gear and the same time. So we come with conclusion that we mount clutch lever on gear selector. So we made design of master cylinder which can operate by the hand. And we install that master cylinder at gear knob by pressing the lever for the clutch the clutch gets engage and disengage.
Design:
Piston
The piston we are design is for multi purpose it use as a lever for operating clutch, and also act as a piston to pressure the fluid. So it make it reliable and economical.
Master cylinder
This cylinder is design to install piston, reservoir and connection for the flexible high pressure hose. Cylinder is made from the cast iron. The piston is sealed by the o ring in cylinder.
Master cylinder assembly
This master cylinder assembly contain parts like piston or clutch operating lever, return spring, master cylinder, reservoir, flexible high pressure hose pipe, reservoir cap.
Calculation:
Calculations for master cylinder DATA
Force required to operate lever is 6kg. Stroke(S) =15. 6mm Force required=6kg = 6*9. 81=58. 86 N To prevent buckling, let us calculate the minimum piston rod diameter K = (3. 142EI)/ (FL2) Where, E = modulus of elasticity, kg/cm2 = 2. 1*106 kg/cm2 for steel I = (3. 14*d4)/64 cm4 (for solid circular piston. ) d = rod diameter (cm) L = buckling length (cm) F = Factor of safety =3. 5 assume So, K = 6 kg L= 2*15. 6 L =3. 12 cm K = (3. 142 EI)/ (FL2) 6 = {(3. 142*2. 1*106)/3. 5*3. 122}*{3. 14 d^4/64} D4 = 2. 0092*10-4 We have assume rod diameter on safe side= 2 mm Assume 5 bar maximum pressure Effective area (Af) = F/P = 6*9. 81/5*105 = 1. 1772*10-4 m2 = 117. 72 mm2 Af = 3. 14 D2/4 D = 12. 25mm Piston diameter. Let’s assume spring force( FS) = 9. 81 N FA = 58. 86 N FS = 9. 81 N 16 Effective force (FE) = FA-FS = 49. 05 N Workdone = F*S = 49. 05*(15. 2*10-3) = 0. 7456 Nm Lets required velocity V =3 cm/sec Flow (Q) = A*V = {3. 14*D2/4}*V = {3. 14*12. 25*10-3/4}*{3*10-2} = 3. 534*10-6 m3 /sec Q = 3. 534*10-3 lit/sec 17
Conclusion
After mounting this system in Maruti Suzuki alto we find that the it get very easy to use less headque. Reduce the clutch delay then the conventional system. The components are less so vehicle become lightweight and lower the cost of clutch system. So we find that this system is very helpful in automobile and may gets more advantages in commercial heavy load vehicle.
