1、Simulation & design tools 仿真及設(shè)計工具,Clutch calculation 離合器計算,3,Clutch calculation離合器計算,Clamp load calculation COEF test technique Range laws Clutch torque Thermal adaptation Start-up energy Decision table & curves Life time calculation Wear test techniques Calculation code,工作壓力計算 COEF試驗(yàn)技術(shù) 范圍確定的原則 離合器扭

2、矩 熱能的匹配 啟動的能量 判定表及曲線 壽命的計算 磨損試驗(yàn)的技術(shù) 計算規(guī)則,Clamp load calculation工作壓力計算,5,Clamp load calculation工作壓力計算Clutch torque capacity離合器傳扭能力,Calculation of the clutch maximum torque capacity 離合器最大傳扭能力計算,離合器傳遞扭矩 壓緊載荷 摩擦系數(shù) 作用半徑 摩擦面數(shù)目,6,Rating and analysis of friction coefficient Wear rating and analysis Analysis

3、of thermal clutch issue,Clamp load calculation工作壓力計算COEFF test technique COEFF 實(shí)驗(yàn)方法,定義和分析摩擦系數(shù) 定義和分析磨損 分析離合器熱能結(jié)果,7,Test cycle 試驗(yàn)次數(shù),Clamp load calculation工作壓力計算COEFF test technique COEF 試驗(yàn)技術(shù),8,Clamp load calculation工作壓力計算 COEFF test technique COEF試驗(yàn)計算,3 energy levels Basic Energy Level (BEL) Energy is

4、 sufficient to induce enough wear in a short period of time Medium Energy Level (MEL) Average energy between BEL and HEL High Energy Level (HEL) Hard duty cycle but remaining non-destructive 2 temperature levels 80 and 200C .,3種能量水平 基本的能量水平(BEL) 在短期內(nèi)吸收由于磨損產(chǎn)生足夠的能量 中等能量水平(MEL) 處于基本和高的之間 高的能量水平(HEL) 在惡

5、劣的條件下循環(huán)但是沒有破壞 2個溫度水平 80和200C.,9,Clamp load calculation工作壓力計算COEFF test technique COEFF試驗(yàn)技術(shù),10,Clamp load calculation工作壓力計算Torque measurement 扭矩測量,OD: Outer diameter of facing 摩擦片外徑 ID:Inner diameter of facing 摩擦片內(nèi)徑,扭矩:Nm,摩擦系數(shù)計算,壓緊力,摩擦片面數(shù),摩擦片外徑,摩擦片內(nèi)徑,平均扭矩,11,Clamp load calculation工作壓力計算Measurement of

6、 the friction coefficient 測量摩擦系數(shù) ,For a step : Friction coefficient “mini courant” definition 對每一階段:記錄發(fā)現(xiàn)最小的摩擦系數(shù) For the test : Friction coefficient “mini courant” definition 對試驗(yàn):記錄發(fā)現(xiàn)最小的摩擦系數(shù) Minimal value of the mini courant of all the steps 所有的階段中最小值的,12,Friction coefficient value for clamp load cal

7、culation 用摩擦系數(shù)對工作壓力進(jìn)行評價,Clamp load calculation工作壓力計算Measurement of the friction coefficient 測量摩擦系數(shù) ,摩擦系數(shù),計算用摩擦系數(shù)(平均值-10%,平均值,13,Calculation of the clutch maximum torque capacity 離合器最大傳扭能力計算,Clamp load calculation工作壓力計算Clutch maximum torque capacity離合器的最大傳扭能力,離合器傳遞扭矩 壓緊載荷 摩擦系數(shù) 作用半徑 摩擦面數(shù)目 離合器比率 預(yù)載荷：軸承

8、預(yù)載荷,沒有軸承預(yù)載荷:,有軸承預(yù)載荷:,14,Clamp load calculation工作壓力計算Clutch maximum torque capacity離合器最大傳扭能力,壓緊載荷,15,Clamp load calculation工作壓力計算Energy levels方法能量水平,The question is how to determine energy levels in order to have consistent test results vs. clutch sizes The answer is a range logic built on : facing s

9、urface vs. size law pressure plate mass vs. size law pressure plate mass vs. engine power law energy law,針對離合器尺寸問題在于如何確定能量的水平使得與試驗(yàn)結(jié)果一致 回答建立在邏輯推理的上 摩擦片表面與尺寸原則 壓盤質(zhì)量與尺寸原則 壓盤質(zhì)量與發(fā)動機(jī)功率的原則 能量原則,16,Clamp load calculation工作壓力計算Facing surface vs. size law摩擦片表面與尺寸的規(guī)律,17,Clamp load calculation工作壓力計算Pressure pla

10、te mass vs. size law壓盤質(zhì)量與尺寸的規(guī)律,18,Clamp load calculation工作壓力計算Surface temperature 表面溫度,Surface temperature formula 表面溫度公式,19,C,f,E,S,e,=,(,),1,Conical strain vs. energy and thickness 錐型變形與能量和厚度,Clamp load calculation工作壓力計算Conical strains錐型變形,20,0,0.1,0.2,0.3,0.4,0.5,0.6,0.7,0,50,100,150,200,250,300,

11、350,400,Energy in kJ,Conicity in mm,Thickness 15 mm,Thickness 26 mm,Thickness 28mm,138 kJ,HEL size 250,237 kJ,HEL size 350,315 kJ,HEL size 430,Finite element method results有限元計算的結(jié)果 Energy dissipated in 3 seconds 能量分為3檔,Clamp load calculation工作壓力計算Energy law能量規(guī)律,21,Clamp load calculation工作壓力計算Energy

12、law能量規(guī)律,22,Clamp load calculation工作壓力計算Thermal flux law熱能變化規(guī)律,23,Example of clamp load calculation 工作壓力計算的例子,Thermal adaptation熱能匹配,25,Thermal adaptation熱能匹配Start-up energy calculation vs. the slope起步能量的計算與坡度,26,Thermal adaptation熱能匹配Start-up energy vs. slope起步能量與坡度,27,Thermal adaptation 熱能匹配Start-u

13、p energy calculation at wheel slipping 在車輪滑動下起步能量計算,28,Thermal adaptation熱能匹配Decision table 判斷表,29,Thermal adaptation熱能匹配Start-up energy curves vs. usage起步能量曲線與應(yīng)用,30,Thermal adaptation熱能匹配Decision curves判斷曲線,Life time calculation壽命計算,32,Life time calculation壽命計算Basic hypothesis 最初假設(shè),33,Wear test pro

14、cedure磨損實(shí)驗(yàn)程序,34,Life time calculation壽命計算F202 wear rate ( 430 size )F202磨損比率(430mm),35,52.5,105,158,210,50C,80C,110C,150C,0.61,0.15,0.07,0.035,0.5,0.12,0.08,0.04,0.55,0.14,0.1,0.05,0.1,0.05,0,0.1,0.2,0.3,0.4,0.5,0.6,0.7,0.8,0.9,F202 wear in mm for 10000 oprations,52.5,105,158,210,50C,80C,110C,150C,2

15、8.8,9.4,6.6,6.6,23.6,7.6,7.6,7.6,26.0,8.8,9.4,9.4,9.4,9.4,0.0,5.0,10.0,15.0,20.0,25.0,30.0,35.0,40.0,F202 wear in mm3 / MJ,Life time calculation壽命計算F202,36,52.5,105,158,210,50C,80C,110C,150C,0.75,0.55,0.29,0.15,0.55,0.3,0.2,0.1,0.52,0.2,0.13,0.06,0.08,0.045,0,0.1,0.2,0.3,0.4,0.5,0.6,0.7,0.8,0.9,F491

16、 wear in mm for 10000 oprations,52.5,105,158,210,50C,80C,110C,150C,35.4,34.6,27.4,28.3,26.0,18.9,18.9,18.9,24.6,12.6,12.3,11.3,0.0,0.0,7.6,8.5,0.0,5.0,10.0,15.0,20.0,25.0,30.0,35.0,40.0,F491 wear in in mm3 / MJ,Life time calculation壽命計算F491,37,Life time calculation壽命計算F510,52.5,105,158,210,50C,80C,1

17、10C,150C,0.49,0.19,0.12,0.055,0.33,0.14,0.095,0.045,0.29,0.11,0.045,0.025,0.035,0.02,0,0.1,0.2,0.3,0.4,0.5,0.6,0.7,0.8,0.9,F510 Wear,in mm for 10000 oprations,52.5,105,158,210,50C,80C,110C,150C,0.49,0.19,0.12,0.055,0.33,0.14,0.095,0.045,0.29,0.11,0.045,0.025,0.035,0.02,0,0.1,0.2,0.3,0.4,0.5,0.6,0.7,

18、0.8,0.9,F510 wear in mm forr 10000 oprations,52.5,105,158,210,50C,80C,110C,150C,23.1,12.0,11.3,10.4,15.6,8.8,9.0,8.5,13.7,6.9,4.3,4.7,3.3,3.8,0.0,5.0,10.0,15.0,20.0,25.0,30.0,35.0,40.0,F510 wear in mm3 / MJ,38,Life time calculation壽命計算Basic hypothesis最初假設(shè),Start-up in a 6 % slope for long haulage, 8 % for off road. Gross Combination Weight 10 kJ for each gear changing Variables :% of start-ups (usually 15%) start-up gear axle ratio and tire size