RIT Senior Design I, Project Review

P07310: Electronic Shifted Manual Transmission

George Slack Team Guide

Jason Botterill Team Leader, Mechanical Engineer

Vaibhav Kothari Industrial Engineer

Richard Cheng Electrical Engineer

Yi-Fan Zhang Mechanical/Testing Engineer

Sponsor: Polaris Industries

P07310: Polaris ESMT 1

RIT Senior Design I, Project Review

P07310: Project Description

Semi-automatic shifting system for the Polaris Outlaw 525 high-performance ATV.

Target market: High-performance sport ATV riders.

P07310: Polaris ESMT 2

RIT Senior Design I, Project Review

P07310: Key Specifications and Features

Specifications:Weight: < 7 lbs.

Shift Time: < .1 sec.

Cost: < $250/unit @ 5000 units built

Features:

Push-Button Shift Control

Reverse Lockout

Gear indicator

P07310: Polaris ESMT 3

RIT Senior Design I, Project Review

P07310: Control Interface Design

Upshift

Downshift

P07310: Polaris ESMT 4

RIT Senior Design I, Project Review

P07310: System Flowchart

Rider pushes shift button

System cuts ignition

System shifts transmission

System restores ignition

Rider resumes normal operation

P07310: Polaris ESMT 5

RIT Senior Design I, Project Review

P07310: Project Risk Assessment

Risk: Slow electrical design progress PLC not sufficiently specified Sensor parameters not sufficiently defined Motor control scheme not defined

Proposed Mitigation: Increased supporting professor consultation Accelerated deliverables timetable

P07310: Polaris ESMT 6

RIT Senior Design I, Project Review

P07310: Project Risk Assessment

Risk: Lack of suitable test bench design No working design has yet been produced Current designs are inherently flawed

Proposed mitigation: Consult with advising professors Propose simplified design Design/build in parallel with other systems work Backup plan: Use ATV on jack stands for systems testing

P07310: Polaris ESMT 7

RIT Senior Design I, Project Review

P07310: Project Risk Assessment

Risk: Complex mechanical system Mechanical shifting system is inherently complex

Proposed mitigation: Develop secondary plan in parallel with primary solution

P07310: Polaris ESMT 8

RIT Senior Design I, Project Review

P07310: Project Risk Assessment

Risk: Shortened design schedule ATV arrived after concept review (week 5) True concept review occurred in week 8 (3 weeks late) Detailed design phase running behind schedule

Proposed Mitigation: Accelerate deliverables timetable Increase supporting professor input to decrease

development time Reduce scope to necessary functions and features only

P07310: Polaris ESMT 9

RIT Senior Design I, Project Review

P07310: Product Development Process Phase

Phase 0: Planning

Phase 1: Transmission Concept Development

Phase 2: System Level Design

Phase 3: Detailed Design

Phase 4: Testing and RefinementMSD I MSD II

0 1 2 3 4

Current Phase of Development

Alpha Prototype

P07310: Polaris ESMT 10

RIT Senior Design I, Project Review

P07310: Current State of Design

Control interface system meets customer needs Mechanical system meets customer needs (confirmation tests pending) Electrical system is incomplete Test bench design is incomplete On target for $250 cost per unit

Current projected cost per unit: Mitigations:

Development timetables for electrical system and test bench accelerated

Cost per unit projections need to be adjusted for 5000 unit run

P07310: Polaris ESMT 11

RIT Senior Design I, Project Review

P07310: MSD II Schedule Highlights

Wk 2: Design finalized and all components on order Wk. 4: Test bench completed and instrumented Wk. 4: Prototype systems completed Wk. 6: Test bench program completed, begin ATV testing Wk. 8: Function and performance review Wk. 9: Documentation completed (Formal paper, poster, etc.) Wk. 10: Final design review

P07310: Polaris ESMT 12