AWD Disconnect - Escaping the clutches of the dog...FWD 25 Schaeffler Symposium 2014 Brian Lee PTU...
Transcript of AWD Disconnect - Escaping the clutches of the dog...FWD 25 Schaeffler Symposium 2014 Brian Lee PTU...
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AWD Disconnect -
Escaping the clutches of the dog
Brian Lee
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To think outside the box you must be
outside of the box.
” “
Alfreda Doyle Poet
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Pickup Car
Schaeffler Symposium 2014 Brian Lee 2
AWD disconnect consensus?
RWD RWD
FWD FWD
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Schaeffler Symposium 2014 Brian Lee 3
The good 'ole dog clutch
Why the consensus on a
dog clutch?
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Schaeffler Symposium 2014 Brian Lee 4
The good 'ole dog clutch
Failure mode Cause Effect
CRACK!
It's only a dog clutch.
What could go wrong…?
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Schaeffler Symposium 2014 Brian Lee 5
Wedge clutch disconnect
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Schaeffler Symposium 2014 Brian Lee 6
Wedge clutch disconnect
Actuator
Magnet
Armature
Spring
Clutch
Carrier
Wedge Plate
Hub
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Brian Lee
Wedge clutch function
Brian Lee
Taper
Connect Disconnect
2mm
Schaeffler Symposium 2014 7
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Schaeffler Symposium 2014 Brian Lee 8
Wedge clutch function
Brian Lee
FT
Plate
Hub
Carrier
α
To
μ1
μ2
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Schaeffler Symposium 2014 Brian Lee 9
Actuation principle
Input shaft
Output shaft
Carrier
Hub
Switchable
spring
F = -Y
F = X
Electromagnet Plate
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Schaeffler Symposium 2014 Brian Lee 10
What's a switchable spring?
Forc
e
+
Diaphragm spring characteristic
Deflection
0 _
Clutch engaged
Clutch disengaged
Deflection
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Schaeffler Symposium 2014 Brian Lee 11
Requirements of the magnet
Forc
e
+
Deflection
_
Disengaged
Engaged
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Schaeffler Symposium 2014 Brian Lee 12
Magnet design
a
Air gap "a"
Forc
e
0
Required
force
Required
stroke
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Schaeffler Symposium 2014 Brian Lee 13
Magnet design
Travel
Forc
e
0
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Schaeffler Symposium 2014 Brian Lee 14
Clutch lockup testing
Motor
Input inertia
1x106 Kg mm2
Output inertia
5x104 Kg mm2
Torque meter
Test Sample
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Wedge clutch lockup
Schaeffler Symposium 2014 Brian Lee 15
- Input speed
- Output speed
- Torque
Torque spike
Time in sec
Sp
ee
d in
RP
M
To
rqu
e in
Nm
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Dog clutch lockup
Schaeffler Symposium 2014 Brian Lee 16
- Input speed
- Output speed
- Torque
Time in sec
Sp
ee
d in
RP
M
To
rqu
e in
Nm
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Dog clutch lockup
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- Input speed
- Output speed
- Torque
Time in sec
Sp
ee
d in
RP
M
To
rqu
e in
Nm
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Wedge clutch To
rqu
e s
pik
e in
Nm
Delta speed in RPM
Wedge
ATF
Wedge
75W-90
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Schaeffler Symposium 2014 Brian Lee 19
Dog clutch To
rqu
e s
pik
e in
Nm
Delta speed in RPM
Dog
ATF & 75W-90
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Schaeffler Symposium 2014 Brian Lee 20
Wedge vs. dog clutch To
rqu
e s
pik
e in
Nm
Delta speed in RPM
Dog
Wedge
ATF
Wedge
75W-90
25-30% Improvement
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Schaeffler Symposium 2014 Brian Lee 21
Wedge – high speed lockup S
pe
ed
in
RP
M
Time in sec
- Input speed
- Output speed
- Torque
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Schaeffler Symposium 2014 Brian Lee 22
Dog – high speed lockup S
pe
ed
in
RP
M
Time in sec
- Input speed
- Output speed
- Torque
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Schaeffler Symposium 2014 Brian Lee 23
High speed lockup
Time in sec
Sp
ee
d in
RP
M
- Input speed
- Output speed
- Torque
Dog tooth
clash
Dog tooth
backlash
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Schaeffler Symposium 2014 Brian Lee 24
PTU disconnect
FWD
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Schaeffler Symposium 2014 Brian Lee 25
PTU disconnect
65 mm
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The world hates change, yet it is
the only thing that has brought
progress.
” ‟
Charles Kettering
1876-1958