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VEHICLE Power & Transmission

CLUTCHES

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Clutch
• A clutch is a mechanical device that engages and disengages
the power transmission, especially from driving shaf to
driven shaf.
• In the simplest application, clutches connect and disconnect
two rotating shafs (drive shafs or line shafs). In these
devices, one shaf is typically attached to an engine or other
power unit (the driving member) while the other shaf (the
driven member) provides output power for work.

8/20/18 © Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur. 2


3 Key Questions Here:
1. What Is The Purpose Of A Clutch?
A. To allow the driver to operate the engine in its most efficient speed
range - nominally 2000 - 3500 RPM, providing an operating speed
range of 1500 RPM (Except when moving off from standstill. During
this transition mode the engine must briefly operate outside of its
designed speed range.)

B. Allows driver to select a suitable gear ratio to increase engine torque


(torque multiplication) to match an increased load requirement.
(Change down to a lower gear - a higher numerical gear ratio.)

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Key Questions
2. What Are The Common Types Of Clutches?

A. MECHANICAL

B. ELECTRO-MAGNETIC

C. HYDRO-DYNAMIC

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Key Questions
Which Materials are Clutches made of?
A. A coefficient of friction that remains stable with
temperature change
B. Excellent thermal conductivity
C. Good wear resistance
D. Resistance to thermal fatigue
E. Good high temperature strength
F. A uniform coefficient of friction over the surface

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Types of Mechanical Clutches
• Positive Engagement
• Frictional Engagement

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Mechanical Clutches- Positive Engagement
• Designed as a binary device either
engaged or disengaged. There are
different designs & applications for
positive engagement clutches. They
can either transmit torque flow in
one-way or two-way.

• A common 2-way Positive


Engagement Clutch is the as dog
clutch ( alternative name is jaw or
tooth clutch). This type operates by Dog Clutch
sliding a toothed hub along a shaf
to engage with matching teeth on a
gear wheel or another shaf , as
shown.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Mechanical Clutches- Positive Engagement //
Contd

 Or it can be an over-running clutch,


which has several forms.
applications like:
 One-way clutch or free-wheeling
clutch. Here , torque is transmitted
only if the rollers are dragged to
wedge between the inner and
outer raceways. Drive is interrupted
when input torque direction is
reversed so that rollers will shif
towards the stop edge in inner race.
A simple application is the free-
wheel built in the bicycle wheel Simple roller-wedge freewheel clutch
sprocket assembly. Cyclist as a result
can "freewheel" down hills.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Mechanical Clutches- Positive Engagement // Contd
 Another form of free-wheeling
clutch is the sprag clutch, as
shown. The sprag element
either wedges ( rotates counter-
clockwise) to couple the inner
and outer raceways, or slips
against both races during
decouple ( rotates clock-wise)
when the torque input direction Simple Sprag freewheel clutch
reverses or if the driven part
rotates faster than driving part.
Sprag elements sit in an array
and supporting springs maintain
their peripheral positioning.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Mechanical Clutches
Frictional Engagement

Also binary devices, either engaged or disengaged.


Power flow is transmitted by friction between driving
and driven components. This clutch family subdivides
into:
 Disc/plate clutch.
 Centrifugal clutch.
 Cone clutch.
 Viscous silicone clutch.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Frictional Engagement
Disc/ Plate Clutch
This type comprises of dual or multi interfacing between a fibrous friction
material facing and a hard metal facing. Can be DRY interfacing or WET
interfacing.

Dry Plate Clutch


( left: single disc/pressure plate, Wet Multi Plate Clutch
right: double disc/ pressure plate)

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.
Flat-plate friction clutches
Friction
springs
plate
W W (axial thrust)
Driving T
shaft
T Driven
shaft
Friction
Pressure lining
plates
Single-plate Friction Clutch (Disengaged position)

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Flat-plate friction clutches
Friction plate springs
W W (axial thrust)
Driving T
shaft
T Driven
shaft
Pressure Friction
plates lining

Single-plate Friction Clutch (Engaged position)

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Flat-plate friction clutches

An example is the clutch found in most


automobiles.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.
BASIC ASSEMBLY COMPONENTS
Dry Disc Clutch
1. FLYWHEEL FACE
2. CLUTCH DISC
3. PRESSURE PLATE ASSEMBLY ( Clutch Cover)
4. CLUTCH RELEASE MECHANISM
5. ( Release Bearing, Fork & Attachment, Cable/Hydraulic Release, Pedal)

The clutch components including the release mechanism


Source: Toyota, May’s
© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.
© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.
Clutch plate or friction plate

Friction lining
Torsional
springs

Splined boss
(hub)

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Pressure plate and housing
Clutch
housing

Diaphragm
spring

Pressure
plate

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.
Multi plate clutches
In a multi plate clutch, the torque is
transmitted by friction between several pairs
of co-axial annular driving faces maintained
in contact by an axial thrust.
Both sides of each plate are lined with friction
material, so that a single-plate clutch has two
pairs of driving faces in contact.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Multi plate clutches

n = no. of pairs of driving faces.


Then, for a plate clutch, the maximum
torque transmitted is

T  nWr m

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Multi plate clutch
Pressure plates

1 2 3 4 5 6

driver driven

No. of driving
pairs n = 6 Friction plates

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Dry Disc Clutch//contd..

Clutch Release Mechanisms:


•Can be cable/ rod mechanism.
•Can be hydro-mechanical, employing
master and slave cylinders using brake
fluid.
•Can be pneumatically operated, like in
Cable clutch release
commercial vehicles transmissions. Source: Ed May’s

Hydro-mechanical clutch release


© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.
Source: Ed May’s
Frictional Engagement
Wet Multiplate Clutch
This clutch type is an assembly of
alternating steel plates set and
steel-lined plates set. One set is
splined to the driving component,
while the other set is splined to
the driven component. The
assembly may be engaged by a
piston actuated by hydraulic
pressure which opposes the
disengagement force of return
spring(s)

Applications: Motorcycles clutch,


automatic transmissions clutches,
etc.
A wet multiplate clutch assembly.
Source: Howstuff Works

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Frictional Engagement
Centrifugal Clutch
This type of clutches operates by the centrifugal
effect. The engine or motor rotates a plate fitted
with clutch shoes that are pulled inward by
return springs.

The clutch remains disengaged as long as the


engine/ motor speed is below the threshold
speed when the centrifugal outward force acting
on the rotating shoes overcomes the spring
tension force. Then the frictional lining on the
shoes catches on the driven drum and torque is
transmitted across the clutch.

Common applications: low to medium torque


transmission in general like go-carts, moped
drives, chainsaws, line trimmers. May exist in
other applications like some automatic
transmissions lock-up converters.
Exploded view of a centrifugal clutch
Source: www.dansmc.com

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Centrifugal clutch F=mrω2

Driven
ω shaft

Driving ω
shaft
Friction
lining

Total friction torque , T = nµR(F-P)

8/20/18 © Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur. 28


Frictional Engagement
Cone Clutch

This clutch type is made of a conical


profiled disc and a mating drum. A
suitable mechanism slides the disc a
splined shaf to engage against the conical
drum. Usually, frictional material is
layered on the conical disc periphery, or
the disc or its periphery is made of sof
metal like bronze or brass which grabs
well to cast ion drum.

Applications : low to medium torque


transmissions like small marine outboard
engines. Adopted in the manual gearbox
synchronisers to bring speeds of the
mainshaf and the selected gear wheel
very close during engagement.
Illustration of a simple cone clutch
Source: www.tb-training.co.uk

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Cone clutch
α = semi-apex angle of
the cone
α
Only one pair of driving
surfaces is possible, n =1

w
Driving Driven
shaft shaft
Friction
lining
The maximum torque transmitted = T = μWrm cosecα

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.
VISCOUS COUPLING CLUTCH
This clutch type makes advantage of the
change of properties of silicone fluid with
temperature. Unlike all fluids, silicon
becomes more viscous with temperature
rise due to shear between the coupling
multiplates when their respective speeds
differ very much. Therefore, the “thickened”
silicone will bond between the plates to
bring them at same speed.

Applications: Viscous coupling for full-time


all wheel drives, viscous limited slip
differentials, engine cooling fan clutch

Illustration: Cut-away view of viscous LSD top, and detailed drawing bottom
© Nimo Source: www.arstechnica.de/
Khundrakpam, Mechanical Engineering Department, NIT Manipur.
ELECTRO-MAGNETIC CLUTCH

 Mainly a Binary Clutching Device, either


engaged or released.
 Application in operating compressors for car air
conditioning or to compress air for commercial
chassis systems ( Brake/ Suspension ..etc)
 Advantage: Simple construction, operates
through electric/electronic control.
 Disadvantage: Limitation on peak torque to be
transmitted, electric power continuous
consumption while engaged.
 On the other hand, another type of electro-
magnetic clutch is developed for traction
applications, and is named the “ Magnetic
Powder” clutch. This type can produce a
coupling rate that is variably controllable by
excitation level infinitely from 0% ( released) to
100 % ( fully engaged).
Simple construction of an electro-magnetic clutch
Source: Ogura Industrial Corp.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


ELECTRO-MAGNETIC CLUTCH

On the other hand, another type of electro-magnetic clutch is


developed for traction applications, and is named the “ Magnetic
Powder” clutch. This type can produce a coupling rate that is
variably controllable by excitation level infinitely from 0%
( released) to 100 % ( fully engaged).

Sectional View of Magnetic Powder Clutch


Source: LIEDTKE Antriebstechnik GmbH &
Co.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Hydrodynamic Clutches
This family subdivides into 2 common
designs:
1. Fluid Coupling: As shown is made of 2
torus wheels fitted with vanes and the
whole housing is filled with a hydraulic
fluid ( e.g. automatic trans. Fluid).
Fluid couplings are usually used in shock-
less start-up drives, as they prevent
heavy starting load to hit motor/engine. Top fig: Sectional view of a fluid coupling,
There will be a lot of slippage between Bottom: view of Drive/Driven members
Source: www.autotran.us
driven and driving members upon start-
up and transient running, but they will
eventually approach full coupling on
steady-state running.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Hydrodynamic Clutches
2. The Torque Converter. This is the other
type of hydrodynamic clutch family. As shown
on right, it is similar to the fluid coupling,
except that instead of 2 major members for
the coupling case, here we got 3 members;
the impeller ( or pump), the turbine, and the
stator with its oneway clutch and stationary
support.

Torque converter features multiplication of


input torque in stall-condition ( i.e. when
excessive resistance load applied on output
turbine shaft that will slow it behind the
impeller). The disadvantage is the slippage
that takes place at top revolution speed, A sectional view of a 3 elements torque converter
Source: www.dolphintransmissions.com
because of the fluid as the energy
transmission media.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Torque transmitted from Clutch
As we have seen from the previous slides that the clutch
system an important system in the vehicle – without the
clutch system - vehicle will not be able to transmit the power
output via the transmission then to the final drives to the
wheels.
If we look at the clutch plate – it is design to withstand
maximum engine torque, torsional vibration, sudden change
in engine rotation etc.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


Force , Torque & Coefficient of Friction

During operation there is some pressure operating over the face of the clutch plate
-given F = pA.
p= hydraulic pressure and A = the surface area
It is also noted that the frictional force on the face of the clutch is simply the normal
force (F) times the coefficient of friction force materials (μ).

The clutches friction forces are used to transmit torque.

Therefore: Frictional torque (Ft) = friction force X effective radius.

Where “Pa “ is the applied pressure where “D” is the large diameter of the clutch plate

and where as “d” is the smaller diameter.

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


To determine the Frictional Force: Ff =

We can also use this formula to determine the


frictional force on the surface of the clutch:

Torque transmitted

)n

Refer example on hand out

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.


An Overview Presentation

Relevant Chapters in H. Heizler


“ Advanced Vehicle Technology
Chapters 2 & 4
In Bosch H/Book 5th Ed pg 590

© Nimo Khundrakpam, Mechanical Engineering Department, NIT Manipur.

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