Paddle SPaddle Shifterhifter

8/10/2019 Paddle SPaddle Shifterhifter

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Andrew Ajirogi

Ben Aldern

John Odlum

Johnny Chang


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Table of ContentsIntroduction .................................................................................................................................................. 3

Members ................................................................................................................................................... 3

Formula SAE (FSAE) ................................................................................................................................... 3

Background ............................................................................................................................................... 4

Project Design ............................................................................................................................................... 5

Materials ................................................................................................................................................... 5

Flexure Design, actuator lever and mount ............................................................................................... 5

Actuator lever and mount ......................................................................................................................... 7

Electrical .................................................................................................................................................... 8

Testing ........................................................................................................................................................... 9

Results ....................................................................................................................................................... 9


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Introduction

MembersAndrew Ajirogi

is a senior

mechanical

engineer. As

the FSAE

technical

director, he is

knowledgeable

of all the

systems in the

car and system integration.

Ben Aldern is a

senior mechanical

engineer. He is the

FSAE team

principal and

electrical lead.

John Odlum is a

senior mechanical

engineer. He is now

an unofficial member

of FSAE with hisdesign of the mount

and clamp for the

actuator.

Johnny Chang is a

senior mechanical

engineer and FSAE

chassis and

composites lead.

Formula SAE (FSAE)

Formula SAE is an international competition organized by the Society of Automotive Engineers where

college students design, manufacture and test a formula style car. The car built by UC Berkeleys

Formula SAE uses a 2001-2003 Suzuki GSX-R600 engine that has a sequential gearbox. The gears can

only shift in a sequential order (up or down without passing through neutral.) Shifts are actuated by the

rotation of a lever at the gearbox.


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Figure 1: Red arrow (push) is a downshift. The blue arrow indicated a pull, up shift. The gearbox is different for first gear

where the driver will have will downshift (push) to get to first gear and from first gear only pull half to return to neutral

Background

The old shifting system on the car was actuated by a lever mounted to the left of the driver. See Figure

1. This lever was attached to a push-pull cable which ran the length of the car to the transmission. When

a shift was needed, the driver would remove his or her left hand from the wheel, grab the lever, and

push or pull it. Pushing caused an extension of the cable at the shifting spline, causing a downshift.

Pulling retracted the cable, making the car up shift. The system was fully mechanical, but required the

drivers left hand to be off the wheel.

This was problematic in a few specific ways. The time taken between when the shift was needed to

when it was actuated was somewhat slow due to the drivers need to move his or her hand. The lever

also proved to be difficult to actuate at certain critical times. On a Formula SAE competition course with

many turns, frequent shifting is required to maximize performance. If a shift was needed during a turn

the driver would have to make the turn with one hand on the steering wheel or simply wait until out of

the turn and lose time while the engine was in a bad RPM range. As well, toward the end of a race the

drivers arms would be tired from steering, causing increased difficulty in actuating the shift and longer

delays between when the shift was needed and when it was actuated. Both situations would lead to a

decrease in overall performance.

The goal of this project was to install a paddle shifting system to address these issues and eliminate the

detriment of the p sh p ll s stem to o erall performance in a race With paddle shifting the dri er


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Project DesignThe new system is designed with the above considerations in mind. Behind the steering wheel, paddles

attached to steel flexures were installed within the reach of the drivers fingertips. On each side of the

flexure, a momentary rocker-type switch was installed such that when the flexure was pressed towards

the wheel by the driver, the switch would be activated. The flexures acted as a restoring force, returning

to the original position after the driver deformed them to actuate the shift. Once the switch is activated,

it sends a signal to the vehicles engine control unit (ECU). TheECU then determines which type of shift

was called for based on which switch was activated. The ECU then sends current through a relay to an

electric solenoid that actuates the shift. The current creates a magnetic field within the solenoid, causing

the metal arm in the center to extend (downshift) or retract (up shift) depending on the direction of the

current. See Figure 2.

(a) (b) (c)

Figure 2: (a) Solidworks CAD of the actuator in the extended position (downshift) (b) In the neutral position (wait for signal)

(c) is the retracted position (upshift)

Materials

-FlatShifter electric solenoid

-Steel flexures

-MoTeC M400 engine control unit (ECU)

-Steel actuator mount

-Aluminum actuator clamp

-Electrical relays and wiring

-Aluminum shifter spline

Flexure Design


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- The flexure must also be robust, due to the cyclical loads that are imposed on it. Therefore the

stress in the flexure must not exceed the endurance limit stress of 4130 normalized steel (at 870

degrees Celsius)

The mesh for the stress region was set to fine (triangles of length 0.158 inches). The mesh size was

determined through inspection of mesh sensitivity, or the amount the stress in a region changes due to

mesh size with the same force and constraints. The mesh sensitivity converged at the element size

previously mentioned. See Figure 3

Figure 3: A finer mesh is seen by the smaller triangles on the left.

There is a stress concentration at the corner after the switch mount; this is assumed to be non

representative due to the sharp edge in the CAD. The manufactured part has a fillet and mitigates this

stress riser. The rest of the stress plot shows stress 50ksi and below, which is right around the

endurance limit for 4130 steel. See Figure 4.


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Figure 5: Deflection in the region near the switch lever is transitioning from green to yellow (indicted by red arrow) which is

the 2.9-3mm region, meeting the design specification.

A two pound force is applied at the back face of the flexure where the paddle will be bonded. The front

face of the flexure is fixed to simulate a bolted connection to the rear face of the steering wheel. The

front of the flexure is fixed as an approximation to the bolted connection between the steering wheel

and the flexure. This approximation is valid because the clamping force from the bolts connecting the

steering wheel to the flexure is much larger than the force applied to the flexure. See Figure 5.

Actuator lever and mount

Before choosing an actuator we assessed the requirements of the transmission. To engage the next gear

the selector shaft needs to be rotated approximately 15 degrees for up shifts and downshifts and

requires a minimum of 78 lb-inches to move through this motion. This torque was measured with a

strain gauge attached to the cockpit lever of the old push-pull system. All of the force that went into the

lever was applied through this strain gauge and with precise measurements of the levers involved we

were able to calculate the torque at the selector shaft.

With this knowledge we set out to choose an actuator and assessed pneumatic, hydraulic, electric gear,

and electric solenoid systems. We chose the electric solenoid system because of the low parts count,

simplicity, availability, and cost.

Electric solenoids produce much of their force at the end of the stroke and thus its necessary to use the

entire stroke The lever at the selector shaft with the old system was 1 25 long and with a rotation of


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Electrical

The electrical system utilized the Motec M400 that the team already had. The solenoid was purchased

separately from a company who makes a similar product for disabled motorcyclists. The circuit was

relatively simple and easy to integrate into the system. Figure 6 shows how a upshift is completed.

Figure 6: The wiring diagram shows how a driver gets an upshift. Pulling the upshift paddle sends a signal to the ECU and the

ECU sends a signal to a relay that powers the actuator.


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TestingIn order to prove the new system, we ran the car with data acquisition with several relevant sensors

including gear position, switch input status, output status, and engine RPM. These datasets allowed us

to tune the system parameters to achieve the fastest and most reliable shift times.

Figure 7: This picture shows a snapshot of the paddle shifter system working. For videos, please visit

http://www.youtube.com/user/calfsae

Results

Below are two graphs showing data gathered while running with the old push-pull lever and with the

new paddle shifters. The shift shown from the old system was executed in 204 milliseconds and the

paddle shifters executed the shift in 170 milliseconds, 16.5% faster. More importantly, the driver was

able to keep his hands on the steering wheel during both up- and downshifts, allowing him to maintain

better control of the car.


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Figure 8: Push-pull system downshift in 204 milliseconds

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REV

CHKMATERIAL:

SHEET 1 OF 1SCALE DRAWING

2012 Steering Subassem

SCALE: 1:2

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UNLESS OTHERWISE SPECIFIEDTOLERANCES:ANGULAR: 2DEGONE PLACE DECIMAL 0.030"TWO PLACE DECIMAL 0.01"THREE PLACE DECIMAL

DRAW

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REVISIONS

ATA

ZONE

Paddle Shifter Assembly

11/25/2011

11/25/2011

11/25/2011ATA

ATA

ATA11/25/2011

REV. DESCRIPTION DATE APPROVED

AA INITIAL RELEASE

ITEMNO.

PART NUMBER DESCRIPTION QTY.

1 paddle-flexturePADDLE-FLEXTURE-SWITCH

ASSEM 1

2 QuickRelease_v01_TT QUICK RELEASE 1

3Racetech240mmWheel_v02_TT

RACETECH STEERINGWHEEL

1

4 Racetech QuickRelease Spline

QUICK RELESE SPLINE 1

5 2012-DR-03-000FRONT CLUTCH MOUNT

ASSEM1

6 27 AN3 BOLT 1

7 2012-DR-04-000 CLUTCH LEVER ASSY 1

8 AN3_Nut AN3 NUT 7

9 number10_bolt #10 SHCS 0.75" 6

DETAIL ASCALE 1 : 1

9

3 X3 X

3

1

2

4

5

6

7

83 X

3 X

9 8

A

SolidWorks Student LicenseAcademic Use Only


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ATA

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ATA

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REVISIONS

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11/22/2011INITIAL RELEASEAA

APPROVEDDATEDESCRIPTIONREV.

ITEM NO. PART NUMBER DESCRIPTION QTY.1 flexure FLEXTURES 12 number2_bolt 2-56x0.75" bolt 43 paddles Paddles 2

4 Switch SS-5GL13T Limit Switch P/N: SS-5GL13T 2

5 90545A003 2-56 Hex Nut 4

DRAWING

TEAM CAL SIMRACEWAY

paddle-flexture

3DREV

PADDLE-FLEXTURE-SWITCH ASSEM

DO NOT SCALE SHEET 1 OF 2SCALE: 1:1

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SIZEATA

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2D

AA

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D

0.005"

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DRAW

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3

4

1

5



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0.

9

0.

9

SHEET 2 OF 2

TEAM CAL SIMRACEWAY

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DRAWING

paddle-flexture

SCALE: 1:1

PART NUMBER

B

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8 7 6 5 4 3 2 1

C

B

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B

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SIZE DRAW

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0.20.2

BOND PADDLESWITH HYSOL 9309 (X2)



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flexure

MATERIAL:

SIZEREV

DRAWINGCHK

TEAM CAL SIMRACEWAY

DO NOT SCALE

3D

SCALE: 1:1

PART NUMBER

B

TITLE:

NAME DATE

AISI 4130 Steel, normalized at 870C

FLEXTURES

B

ATA

SHEET 1 OF 1

A

2D

A

B

D D

C C


0.005"

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DRAW

AA+ATA 11/21/2011

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ATA 11/21/2011

REVISIONS

ZONE REV. DESCRIPTION DATE APPROVED

AA INITIAL RELEASE 11/21/2011 ATANOTES:

WATERJET PART, .030" sheet1.DEBUR ALL EDGES2.DRILL OUT HOLES (IF NECESSARY)3.

ALL DIMENSIONS ARE SYMMETRICAL TO THE LEFT4.SIDE OF PART

UP

89R0.070

DOWN

89R0.070

UP

90R0.070

UP

89R0.070

UP 90 R 0.070

DOWN

89R0.070

UP 90 R 0.070

UP

90R0.070

1.208

8.149

0.089

0.257

1.973

0.342

3X

0.067

4X1.986


REVISIONS

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2.4

Aluminum

JLC

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11/27/2011JLC

NOTES:

1. AND BELT SAND TO SIZE)

JLC

DEBUR ALL EDGES

WATERJET PART (CAN BE CUT

2.

11/27/2011


AA INITIAL RELEASE 11/27/11 JLC

NAME DATE

CHK

REV

TEAM CAL SIMRACEWAY

3D

SHEET 1 OF 1DO NOT SCALE DRAWING

paddles

SCALE: 1:1

PART NUMBER

A

SIZE

TITLE:

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C

B

A

B

2D

Paddles

6061-T6 (SS)MATERIAL:

C

D

0.005"


D

A


DRAW

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0

0.071

2xR1.0

2xR0.3



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1.

500

REVISIONS

ATA

11/21/2011

11/21/2011ATA

ATA

11/21/2011ATA


AA INITIAL RELEASE 11/21/2011

CLUTCH ASSEMBLY

ITEMNO.


1 2012-DR-03-001 CLUTCH MOUNT CYLINDER 1

2 2012-DR-03-002FRONT CLUTCH MOUNT,

STEERING SIDE1

3 2012-DR-03-004 CLUTCH PIVOT 1

42012-DR-03-003_paddleshift

FRONT CLUTCH MOUNT 1

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SIZE

DRAWING

DR-03-000

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3D

2D

B

A

D

C

D

C

1

B


0.005"

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DRAW

AA+

3

1

4

2AND DR-03-002 FLUSHTOP OF DR-03-001

BOTTOM OF DR-03-001AND DR-03-002 FLUSH

0.

560

0.

940

2.

000

A0.125

A


NOTESREVISIONS

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0.035

1. DEBUR ALL EDGES

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NAME DATE

CHK

CLUTCH MOUNT TUBE

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2012-DR-03-001

SHEET 1 OF 1SCALE: 1:1

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SIZE

TITLE:

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3D

MILD STEELMATERIAL:

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DRILL OUT ALL HOLES2.

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DEBUR ALL EDGES

ATA



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SHEET 1 OF 1

FRONT CLUTCH MOUNT, STEERING SIDE

SCALE: 1:1

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SIZE

TITLE:

8 7 6 5 4 3 2 1

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MILD STEEL

3D


2D


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O SC O O

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0.25

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0.20

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3X

1.250

ATA

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DEBUR ALL EDGES2.

NOTES:

WATERJET PART1.DRILL OUT ALL HOLES

3.

11/25/2011




TEAM CAL SIMRACEWAY

REV3D

2012-DR-03-003_paddleshift


PART NUMBER

A

SIZE

TITLE:

8 7 6 5 4 3 2 1

C

B

A

B

C

DD

ANAME DATE

CHK


2DMATERIAL:

MILD STEEL

0.005"

FRONT CLUTCH MOUNT


DRAW

AA+

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2.

5


NOTES:REVISIONS

ZONE REV DESCRIPTION DATE APPROVED

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0.250

0.

500

0.

250

0.649

0.188TH

RU

0.250

ATA

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DRILL ONE HOLE AND FLIP PART TO DRILL1.THE OTHER HOLE, DO NOT DRILL IN ONESETUPWATERJET PART2.DEBUR ALL EDGES3.

11/21/2011



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2012-DR-03-004

SHEET 1 OF 1

CLUTCH PIVOT

SCALE: 1:1

PART NUMBER

A

SIZE

TITLE:

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B

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B

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CHKMATERIAL:

NAME DATEA

0.005"

MILD STEEL

3D


2D


DRAW

AA+SolidWorks Student LicenseAcademic Use Only


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2.6

INITIAL RELEASE ATA

11/25/2011

11/25/2011ATA

ATA

11/25/2011

AA

ATA

11/25/2011

REVISIONS


ITEM NO. PART NUMBER DESCRIPTION QTY.

1 2012-DR-04-001 SHIFT LEVER 1

2 2012-DR-04-002 CLUTCH LEVER CABLE RESTRAINT 1

REV

MATERIAL:

SIZE

DRAWING

2012-DR-04-000

SHEET 1 OF 1

TEAM CAL SIMRACEWAY


PART NUMBER

B

TITLE:

NAME DATE

CHKSS - 304

CLUTCH LEVER ASSY

A

3D

2D

B

A

D

C

D

C

1

B


0.005"

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1

HOLE ALIGNED TO CENTERLINE

OF 2012-DR-04-001



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BENDING

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NOTES:

PROFILE IS CNC BENT1.TOTAL UNBENT LENGTH : 14.85"2.HOLES ARE DRILLED OUT AFTER

ATA

REVISIONS



REV

MATERIAL:

SIZE

DRAWING

2012-DR-04-001

SHEET 1 OF 1

TEAM CAL SIMRACEWAY


PART NUMBER

B

TITLE:

NAME DATE

CHKSS - 304

SHIFT LEVER

A

3D

2D

B

A

D

C

D

C

1

B


0.005"

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DRAW

AA+

6.188

2.

0

0.37

5

0.190

THRU

0.

188

0.2


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2X16

0.37

5

0.018

11/25/2011ATA

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TOP AND BOTTOM SLOTS ARE FOR1.

ATA

MATING TO DR-04-001 FOR WELDING


REV

TEAM CAL SIMRACEWAY


2012-DR-04-002

SHEET 1 OF 1

CLUTCH LEVER CABLE RESTRAINT

SCALE: 1:1

PART NUMBER

A

SIZE

TITLE:

8 7 6 5 4 3 2 1

C

B

A

B

C

DD

CHKMATERIAL:

NAME DATEA

0.005"

SS - 304

3D


2D


DRAW

AA+

1.

0

CENT

EROFTUBE

0.250

THRU

2.

0

2X 0.375


BOM TableITEMNO.


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1 2012-EN-01-ENGINE-MOCKUP Engine 1

2 mounting piece Clamp to engine mount 1

3 mounting bracket swivel side Actuator clamp part 1 1

4 mounting bracket Actuator clamp part 2 1

5 7806K62 Thrust bearing 2

6 2012-DR-05-008 Rod end 1

7 kliktronic body Actuator 1

8 new spline Spline lever 1

9 90576A115 M6x1 nut 110 97135A215 1/4-28 nut 1

11 92235A242 M6x1 bolt 2

12 91290A264 M5x1 bolt 2

13 .25-28x1.5 for clamp 1

14 10-32x1.5 for clamp 2

BA

BA

11/27/2011JLC

12

1

11

8

6

9

11/27/2011

7

1052

3

13

142

11/27/2011

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TEAM CAL SIMRACEWAY

rear drawing

Mount mechanism

SHEET 1 OF 2SCALE DRAWING

SCALE: 1:1

PART NUMBER

E

SIZE

TITLE:

8 7 6 5 4 3 2 1

C

B

A

B

C

DD

A

DO NOT

NAME DATE

CHK


2D

MATERIAL:

3D

0.005"


DRAW

A-02SolidWorks Student LicenseAcademic Use Only

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JLC

11/27/2011

BA

11/27/2011

BA

11/27/2011

Mount mechanism (fully assembled)

D

DO NOT


0.005" 2D

3D

rear drawing

2012 Full Car Model

SCALE DRAWINGSHEET 2 OF 2SCALE: 1:1

PART NUMBER

E

SIZE

TITLE:

8 7 6 5 4 3 2 1

C

B

A

DATE

CHKMATERIAL:

TEAM CAL SIMRACEWAY

B

D

A

REV

C

NAMETOLERANCES:ANGULAR: 2DEGONE PLACE DECIMAL 0.030"TWO PLACE DECIMAL 0.01"THREE PLACE DECIMAL

DRAW

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RIght View


NOTES:REVISIONS


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Mount Clamp

11/27/2011

Aluminum

Machine Center and through holes before cutting

11/27/2011

J EO

in two

J EO

11/27/2011


ATA

0.5

00

NSF 10/32 Screw TappedNSF 10/32 ScrewClearance

3.246

2.7

69

0.381

1.969

46

1.383

0.4

31

0.600

0.2

50

0.3

75

1.863

REV

TEAM CAL SIMRACEWAY


mount clamp


PART NUMBER

A

SIZE

TITLE:

8 7 6 5 4 3 2 1

C

B

A

B

C

DD

ANAME DATE

CHK


2DMATERIAL:

3D

0.005"

TOLERANCES:ANG ULAR: 2DEGONE PLACE DECIMAL 0.030"

TWO PLAC E DECIMAL 0.01"THREE PLACE DECIMAL

DRAW


REVISIONS


S 2 20

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11/27/2011ATA

J EO

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Mounting Weld Locations

Steel

J ig in car to fit

Notes:AA INITIAL RELEASE 11/27/2011 ATA

REV

TEAM CAL SIMRACEWAY


tubemount


PART NUMBER

A

SIZE

TITLE:

8 7 6 5 4 3 2 1

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B

A

B

C

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ANAME DATE

CHK


2DMATERIAL:

3D

0.005"



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0.999

2.1

93


REVISIONS



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ATA

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11/27/2011

J EO

Mounting Tubes

11/22/2011BA


Steel

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Tubes


PART NUMBER

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SIZE

TITLE:

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C

B

A

B

C

DD

ANAME DATE

CHK


2DMATERIAL:

3D

0.005"



DRAW

AA+

0.500TRUE

TRUE 0.402

3.250

0.500


REVISIONS



NOTES:

j fil

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0.150

2.4

37


ATA

J EO

Waterjet Profile1.Drill Hole2.Debur Edges3.

11/22/2011

Steel

Mountig Piece

11/27/2011

11/27/2011

BA REV

TEAM CAL SIMRACEWAY


mounting piece


PART NUMBER

A

SIZE

TITLE:

8 7 6 5 4 3 2 1

C

B

A

B

C

DD

ANAME DATE

CHK


2DMATERIAL:

3D

0.005"



DRAW

AA+

0.210

2.052

2.1

29


NOTES:

1 DEBUR ALL EDGES AFTER MACHINING

REVISIONS



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0.113

0.275

0.

750

0.500

11/1/2011JO

11/21/2011

11/21/2011ATA

ATA

1. DEBUR ALL EDGES AFTER MACHININGAA INITIAL RELEASE 11/21/2011 ATA

REV

TEAM CAL SIMRACEWAY


2011-DR-09-001-AA

SHEET 1 OF 1

CLUTCH MOUNT BOSS

SCALE: 2:1

PART NUMBER

A

SIZE

TITLE:

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C

B

A

B

C

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CHKMATERIAL:

NAME DATEA

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Mild Steel

3D


2D

TOLERANCES:

ANGULAR: 2DEGONE PLACE DECIMAL 0.030"TWO PLACE DECIMAL 0.01"THREE PLACE DECIMAL

DRAW


ATA

DATE

REVISIONS

ZONE REV. DESCRIPTION APPROVED

AA INITIAL RELEASE 11/28/11

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spline lever

/ /

ITEM NO. PART NUMBER DESCRIPTION QTY.1 2012-DR-06-001 Purchased Part 12 new spline 1

CHK SHEET 1 OF 1

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C

D

DATE

3D

MATERIAL:

NAME

D


2D0.005"

ATOLERANCES:

ANGULAR: 2DEGONE PLACE DECIMAL 0.030"TWO PLACE DECIMAL 0.01"THREE PLACE DECIMAL

DRAW

AA+

Make lever arm and spline parallel

0.

35

0

1 2

3.33


12345678

1

NOTES:

Waterjet profile

REVISIONS




32/32

0.236

3.3

34

1.2570.200

3.7

13

REV

TEAM CAL SIMRACEWAY


new spline


PART NUMBER

A

SIZE

TITLE:

8 7 6 5 4 3 2 1

C

B

A

B

C

DD

ANAME DATE

CHK


2DMATERIAL:

3D

0.005"

TOLERANCES:

ANG ULAR: 2DEGONE PLACE DECIMAL 0.030"


DRAW

AA+J EO 11/27/2011

11/27/2011ATA

New Spline Arm

drill hole1. Waterjet profile2.

11/27/2011J EO

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