P07310: Electronic Shifted Manual Transmission

1. 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

2. 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

3. 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

4. P07310: Control Interface Design Upshift Downshift P07310: Polaris ESMT 4 RIT Senior Design I, Project Review

5. Rider resumes normal operation System restores ignition System cuts ignition System shifts transmission P07310: System Flowchart Rider pushes shift button P07310: Polaris ESMT 5 RIT Senior Design I, Project Review

6. 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

7. 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

8. 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

9. 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

10. 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 Refinement MSD I MSD II Alpha Prototype 0 1 2 3 4 Current Phase of Development P07310: Polaris ESMT 10 RIT Senior Design I, Project Review

11. 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

12. 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 RIT Senior Design I, Project Review