Automatic Shift Controls for ATV

Sponsored by:

Joel Notaro

Polaris Industries

Advised by :

Professor George Slack

Project Family:

Modular, Scalable, Open Architecture Control Systems

Track:

Systems and Controls

Team Member Organization

Industrial Design Sarah Bicho

Matt Dombovy-Johnson

Ashley ShoumTeam Lead

ME

Design forManufacture

Electrical Subsystem

Mechanical Subsystem

Bibhu Shah

Feng Li

Jon Willistein

Keith Cobb

Project Description

System that will automatically shift polaris outlaw 525 ATV

System must be:

Able to shift in 0.1 seconds

Add no more than 7 lbs.

Operable in all track and weather conditions

Easy to install

Able to shift smoothly (cut engine spark)

Easy to use

Packaged ergonomically and aesthetically pleasing

Market to ATV racers and enthusiasts

Design ConceptMechanical Concept

Clamp and Pivot Mount*

Electric Solenoid**

Bracket/Chain Guard*

Shift Tab*

*Part designed to be machined

**Part to be ordered from a vendor

Design ConceptShift Controls

Design ConceptGear Indicator

Design ConceptShift Control Program

System Architecture

Shift Selection

Controls/SoftwareTransmission

Engine

Power

TPS

RPM

Shift Status

Shift Solenoid

Spark Cutout

ATV Connections

Risk Assessment

High Level Risk Mitigation

Solenoid force and throw specifications do not meet required needs for shift.

Investigate other manufacturers or revert back to pneumatic system.

Current draw for solenoid is not available from system with all running components.

Investigate other solenoid manufacturers, add an aftermarket stator.

Control software not able to efficiently keep gear count.

Research gear solenoid sensor.

Current State of Design

• Design expected to meet all customer needs – Test Plan being developed to measure all specifications

• Project prototype budget on target

– Prototype Budget $1300– Material Costs $590 (form B.O.M.) –All shipping and fabrication pricing TBD

• Schedule – Design drawings need to be finalized – Parts need to be ordered (no major lead times have been

identified) – Machining schedule to be developed

•All other deliverables/mitigations – Conduct meetings with Brinkman about machinability and

timeline – Documentation – Evaluate all Customer Feedback

Current Project Status

Current Status

MSD 1- Proposed Schedule

MSD II Milestones

• End of MSD 1- All parts ordered, drawings finalized, parts ready to be machined

• End of MSD 1- Machining schedule determined

• December 15- All components received and installed

• December 19- All pre-system test plan/Bench tests are complete, verified and documented