Research on IPPD method of automotive clutch

doi:10.3785/j.issn.1006-754X.2022.00.052

Chin J Eng Design

2022, Vol. 29

Issue (5): 537-546 DOI: 10.3785/j.issn.1006-754X.2022.00.052

Design Theory and Method

Research on IPPD method of automotive clutch

Zheng-feng YAN(

),Lin-zi HOU,Zhen HAN,Xian-xu BAI(

)

School of Automotive and Transportation Engineering, Hefei University of Technology, Hefei 230009, China

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Abstract

Automobile clutch is an important starting element of automobile transmission system. The traditional design method does not integrate the performance requirements, product characteristics, process flow and process capabilities organically in the whole product development process, and does not consider the reasonable tolerance range of clutch product parameters and the size changes within the life cycle, so it is difficult to meet the requirements of clutch torque transmission capacity and pedal control characteristics in large-scale production. By establishing the IPPD (integrated product and process design) method of automobile clutch based on function-product characteristics-process-process capability, the influence of clutch product characteristics and process parameter tolerances on torque transmission capability and pedal control capability was analyzed, and the method of establishing accurate transmission system dynamics model was proposed. The mapping relationship between torque transmission capability, pedal control characteristics and product characteristics and process parameter tolerance was given; under the condition of meeting the design requirements of manufacturability and assemblability, a cycle mapping relationship of product characteristics and process flow and parameter changes was established, and a robust tolerance design method based on process capability was adopted to optimize the process scheme and process parameters. The proposed clutch IPPD method can better enable the product to meet the performance requirements, thus providing support for improving the design accuracy and reliability of the clutch, and establishing a foundation for the intelligent design of the clutch.

Key words： clutch multi-level integrated product and process design torque transfer handling comfort

Received: 28 July 2021 Published: 02 November 2022

CLC:

U 463.211

Corresponding Authors: Xian-xu BAI E-mail: zf.yan@hfut.edu.cn;bai@hfut.edu.cn

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Cite this article:

Zheng-feng YAN,Lin-zi HOU,Zhen HAN,Xian-xu BAI. Research on IPPD method of automotive clutch. Chin J Eng Design, 2022, 29(5): 537-546.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2022.00.052 OR https://www.zjujournals.com/gcsjxb/Y2022/V29/I5/537

汽车离合器IPPD方法研究

汽车离合器是汽车传动系统的重要起步元件。其传统的设计方法没有在整个产品开发过程中将性能要求、产品特性、工艺过程及过程能力有机地融合，没有考虑离合器产品参数合理的公差范围以及生命周期内尺寸的变化，因此很难满足大规模生产的离合器转矩传递能力和踏板操纵特性的要求。通过建立基于功能—产品特性—工艺及过程能力的汽车离合器IPPD （integrated product and process design，集成产品工艺设计）方法，分析离合器产品特性及工艺参数公差对转矩传递能力和踏板操纵特性的影响，提出了建立精确的传动系统动力学模型的方法，给出了转矩传递能力和踏板操纵特性与产品特性及工艺参数公差的映射关系；在满足可制造性和可装配性的设计要求下，建立了产品特性与工艺过程及参数变化的循环映射关系，采用基于过程能力的稳健公差设计方法进行工艺方案和工艺参数优化。采用所提出的离合器IPPD方法可以更好地使产品满足性能要求，从而为提高离合器设计精度和可靠性提供支撑，为开展离合器的智能设计建立基础。

关键词： 离合器, 多层次, 集成产品工艺设计, 转矩传递, 操纵舒适性

Fig.1 IPPD method of automobile clutch

Fig.2 IPPD flow chart of automobile clutch

Fig.3 Process of technical scheme determination, evaluation and selection

Fig.4 Typical automobile clutch and its operating mechanism

Fig.5 Working characteristic curve of typical automobile clutch cover assembly

Fig.6 Bonding diagram of power transmission systems of automobile and clutch

Fig.7 Diaphragm spring

Fig.8 Load and separation characteristic curve of diaphragm spring based on main dimensional tolerance change

Fig.9 Variation curve of friction coefficient of friction plate with the number of dutch cycle and temperature

Fig.10 Wave spring

Fig.11 Axial compression characteristics of wave spring

Fig.12 Product process matrix of automobile clutch

Fig.13 Mapping relationship between product characteristics and process parameters

Fig.14 Robust design simulation roadmap

Fig.15 Friction plate tester

Fig.16 Relation curve between friction coefficient of friction plate and temperature

Fig.17 Wave spring axial compression testing equipment

Fig.18 Relation curve between axial compression displacement and axial load of wave spring

Fig.19 Automobile clutch comprehensive performance testing equipment

Fig.20 Automobile clutch pedal control characteristic testing equipment

Fig.21 Automobile clutch torque curve

Fig.22 Automobile clutch pedal control characteristic curve


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