1. AUTOMATIC SHIFT CONTROLS FOR ATV SPONSOR: POLARIS INDUSTRIES
P08310 – POLARIS OUTLAW 525 DESIGN TEAM
AUTOMATIC SHIFT CONTROLS FOR ATV
SPONSOR: POLARIS INDUSTRIES
Team Members
Eric Gambon (Team Lead)
Nathan Almeter (Mechanical Engineer)
Tim Faulhaber (Mechanical Engineer)
Ajay Vangapaty (Electrical Engineer)
Mishal Patel (Electrical Engineer)
James Leon (Electrical Engineer)

2. P08310 – POLARIS OUTLAW 525 DESIGN TEAM
PROJECT DESCRIPTION
Electro-Mechanical System To Automatically Shift a Manual Transmission On a Polaris Outlaw 525 All Terrain Vehicle (ATV)
High Level Customer Needs/ Engineering Specifications
Lightweight <7 lbs. Additional Weight
Fast Shifting <0.1 sec. per shift
Maintains User Safety Built in safety features

3. Mechanical Design Concept
P08310 – POLARIS OUTLAW 525 DESIGN TEAM
Mechanical Design Concept
BATTERY
COMPRESSOR
SOLENOID VALVES
AIR RESERVOIR
MICROCONTROLLER
PNEUMATIC CYLINDER

4. Mechanical Technical Risk Assessment Current High Level Risks
P08310 – POLARIS OUTLAW 525 DESIGN TEAM
Mechanical Technical Risk Assessment
Current High Level Risks
Weight specification of less than 7 lbs of additional weight.
Pneumatic system failure based on contaminants and foreign materials.
Air line failure due to debris from riding in rough terrain.
Proposed Mitigations
Design the attachment piece and covers with a lightweight material (Aluminum).
Design covers to protect the critical components (cylinder & valves).
Use reinforced tubing and design it to be not in direct view of debris being thrown from the tires.

5. Electrical Design Concept
P08310 – POLARIS OUTLAW 525 DESIGN TEAM
Electrical Design Concept
BATTERY
PUSH-
BUTTONS
MICROCONTROLLER
SOLENOID VALVE
RPM

6. Electrical Technical Risk Assessment Current High Level Risks
P08310 – POLARIS OUTLAW 525 DESIGN TEAM
Electrical Technical Risk Assessment
Current High Level Risks
Feedback from shifting of gear
Components withstanding heat, and external parasites
Proposed Mitigations
Place a limit switch to detect pneumatic cylinder position
Design covers to protect the critical components (PCB)

7. State of Design Summary
P08310 – POLARIS OUTLAW 525 DESIGN TEAM
State of Design Summary
Design meets all customer needs
Engineering specifications are met except for:
Weight limitation of 7 lbs. (Currently at 5.5lbs. + weight of fittings, brackets, and cover)
Budget criteria is based on 500 pieces (initial cost of goods based on 1 piece order).
Specified Build Cost (ea.) = $250 / 500 orders
Current Development Cost (ea.) = $436 / 1 order
Mitigations:
Weight will be controlled by designing covers to size & by using lightweight material.
Quotes are out to the appropriate suppliers based on a 500 piece order.
Alternative parts may need to be specified (Once quotes are returned)

8. Current State of Design
P08310 – POLARIS OUTLAW 525 DESIGN TEAM
Current State of Design
Phase 0: Planning
Phase 1: Concept Development
Phase 2: System Level Design
Phase 3: Detailed Design
Phase 4: Testing & Refinement
MSD I
MSD II
Alpha
Prototype 1 2 3 4
Current Design Phase

9. MSD II Project Major Milestones
P08310 – POLARIS OUTLAW 525 DESIGN TEAM
MSD II Project Major Milestones
5/25/07 – Design Completed & Parts Ordered
9/17/07 – Functional Alpha Prototype Complete
10/1/07 – Design Verification Complete: Initiate Design Revisions
10/5/07 – Design Review: Design Verification Testing Results
10/22/07 – Documentation Finalized: Formal Paper, Poster
-Tentative-