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95
NODH I O E A SM I Ouenl O ANG ADF J G I O J E RU I NKOP J EWL S PNZ AD F T O I E OHO I OO ANG AD F J G I O J E RU I NKOPO ANG AD F J G I O J E R
O I E U G I A F E D O N G I U Amu H I O G DN O I E R N GMD S A U K Z Q I N K J S L O G DWO I A D U I G I r z H I O G DN O I E R N GMD S A U K nmH I O G DN O I E R N G
UDMP B D BHMG R I B D P B D L R b E F B A F V NK F NK R EWS P L O C Y Q DMF E F B S A T B G P D r D D L R a E F B A F V NK F NK R EWS P D L Rn E F B A F V NK F N
X A Y H A S g S V N P t Z RWQ S C G Z N J I MN S t R V N P I Z RWQ S C G Z Q DM F E F B S A T B G P D B D D L R B E z B A F V r K F N K R EWS P z L R B E o B A F V N K F N
A A C l u t c h i m a s t e r T c y l i n d e r E R N G M j B N D S A U K Z Q I N K J S L W O I E P Roland
N N b Welter
A U A H I O G D N p I E R N GMD S A U K Z Q H I O G D Nw I E R N GMD
A m O A m O e U A N D L N G e U A I O G D N O I p R N G M D S A U K Z Q I N K J S L W O Q T V I E P Tim
N zHerrmann
R A U A H I r G DNO I q RNGMD S A UK Z QH I O G DNO I y RNGMD
E K J E K J I C K O I a G R D C K M N E S W L N C a W Z Y K F E Q L O P N G S A Y B G D S W L Z U K Sebastian
O G I K Honselmann
C K PMN E SWL N C uW Z Y K F E Q L O P PMN E SWL N C t W Z Y K
Jeremy
M O T M O T M Q O G N v Z D S Q O N V U S G R V L G R a K G E C L Z E M S A C I T P M O S G R U C Z G Z M Keller
O Q O DN V U S G R V L G RmK G E C L Z EMDN V U S G R V L G R x K G
T N U T N U G I N R L e J G D I N E O M N Y A Z T E Z N a X J R C N I F Z K M N D A B O N Y A M E C R J G N I N E E O M N Y A Z T E W N l X J R C N I F E E O MN Y A Z T E W N y X
D C O D C O S V C E S r PMN V C L i N EWC L V V X HN V u a J K U V X E S Y MN R E EWC L OME P S C V C Y L i N EWC L V V F HN V o a J K U V Y L i N EWC L V V F HN V
J Y n J m I J Q Y A H C N CWQ Y B R n L N F X T J U L D Q F H B v t G U PWQ V Z E S L N F A MU A N J Y Q Y O B R n L N F X T J O L D Q F H Bwn G O B R n L N F X T J O L D Q
K P E K P E L O PMS y BUNO P A Y C B E F V BNK T ENA OD F E C K t a C T S V QD E F BN I MB L P O P Q A Y C B E F V BNR T ENA OD F E C Q A Y C B E F V BNR T EN
Z B P Z B P E P e D A l U B o x e S H N E D K U NWD O N C A L V I K n D V F G r g H NW E DWC Y Q B E B G B A Y X S WA D C B P L M I J N T B G H U A Y X S WA D C B P L M I J
T N E T N E HBN ZW i D C V BN I O P L KUH G F Z S A C V B O F E T Z HN A X C F t j K J ZMH Z DHNBNU I O P L K UH G F D S A C V B O F E T U I O P L K UH G F D S A C
C R O C R O E T RWPn I U Z T RHG F D L G END O R T C A S N I NR O A X E V E D K D L a g Q SW I E R T R QHG F D L G END E R T C A S N I NR QHG F D L G END E R T C
B E F B E F S H E C E dHO KH E U P S KUP P L U L G S G E B E R Z Y L I ND E R Z NUB F I Mb CH S E H E BU P S KU P P L UNG S G E B E R Z Y BU P S KU P P L UNG S G
S O B S O B P I O S G e Z N J I O C V F V B O F E T Z HN A X C F t j K J Z MH Z D HN BWC E C B S t P O I O D C V F EWC V T E B NM Z G O H A S E D C V F EWC V T E B NM Z
F E I F E I W R E Q R r U Z T R E K J H A S N I N R O A X E V E D K D L a g Q S W I E R T F D G V T Q U j x R E L K J H G F D S A MM B V C X Y M L M O L K J H G F D S A MM B V C
CWD A Y WT R D X E S Y WA T P H C E E B E R Z Y L I ND E R Z NU B F I Mb C H S E HBNBMR T X A g Y WP H C E Q A Y WS X E E C R F V E G B Z P H C E Q A Y WS X E E C R
P J MR I J H L MO K N I J U H B Z G V G O H A S E D n K L P S X W E WC E C B S t P O I T R T V N H O U b I J B Z G V T F C R D X E S NWA S R E C V B Z G V T F C R D X E S NW
C G T I D G L E T U O A D G J L Y C B M X Y M L M O K t I J B H U Z G F D G V T Q U j x R H E H T F L U J a D G Y C B MW R Z I P S F H K T V N Z L M O Y C B MW R Z I P S F H K T
J T Z A E T O I Z RWQ E T UOMB C Y F V E G B Z H e U J M I K O Q A Y LMR T X A g Y I O I B P O RU T E TMB C Y N V X A D G J L KH E S Y S C BMB C Y N V X A D G J L KH
V WM K R W U U M P I L Z E M S k C I T A S R E C V F g K N U T E Q T F C X V N H O U b I R x R S K U P O W R W Z T W H N E D K U NW P O N C A L V I K Z T W H N E D K U NW P O N
A K DW J K P S D F G H J K L P O I U Z NM I QWO I r E U H B Z GWR Z V T F L U J a D Y g Y K L P F L K J K O I U Z T R EWQ Y X C V B NM I QWu O I U Z T R EWQ Y X C V B
L S J Q D S Y K J H G F D S A Y V N P I E S Y S C B F aMH T I L Q N V X D B P O R U T E I b I X A Y H A S g S V N P I Z RWQ S C G Z N J I MN S t R V N P I Z RWQ S C G Z N J
E K J N C K O I J G R D C K I O PMN E U J L Y C BM t p I E P NN R E D C S K U P OWR D a D U K O G I K C K PMN E SWL N C X W Z Y K F E D i O P PMN E SWL N C X W Z Y K
MO T V Q O G N T Z D S Q OMG DN V UNM I Q l i n e s B C S D G T R E H K L P F L K J E T E C Z G Z Mq g O DN V U S G R V L G R V K G E C E Z EMDN V U S G R V L G R V K G
T N U Z I N R L U J G D I N G R E X OM I MN S t R E d L P Q A C E Z RWD X A Y H A S g RWR t s l o k z I N E X OMN Y A Z T E WN F X J L R N I F E X OMN Y A Z T E WN F X
D C O L V C E S O PMN V C S E Y L J N F E D i O P N A S A Y B G D SWL Z U K O G I K C J K J OME P S C V C Y L J N EWC L V V F HN V R D J K U V Y L J N EWC L V V F HN V
J Y I X Q Y A H I NCWQ Y J A uB R E E C E Z EMS S C I T PMO S G RU C Z G ZMq g g S gMU A N J Y Q Y O B R E L N F X T J O L s Q F HB Q F G O B R E L N F X T J O L a Q
N J K L N J R A K D O B N J O R O z D F J L RN I F Z EMND A B O i z q a t s l o k z I C K C N S R D O J N J O I D F N G K L D F MG O I Z PM F D R O I D F N G K L D F MG O I
A A O I U A ND O NG I U A R NH I O G R D J K U V X n S Y MN R E z WC L OME P S C V g q g E P NN R A U A H I O G DN O I E R N GM t S A U K Z Q H s O G DN O I E R N GMk
UDMA B D BHMG R e B D P B D L R B F HCBM X Y s F B S Z E g L N F AMU A N J Y Q I z I A T B G P D B D D L R B E F B A F V NK F Nq R EWS P D L R B E F B A F V NK F N
A A O I U AND ONG I U A RNH I n s t a l l a t i onO e l eme n t s N S RD O J N V C V E PNNR A U A H I O G DNO I E RNGMD S A l K Z QH I O G DNO I E RNGMD
MO T V Q O GN T Z D S Q OMG DN V U S AUD L R B rD A B O i z q a t s l PNNR A UQ Y Q C Z G ZMO Q O DN V U S G R V L G R V K G E C L Z EMDN V U S G R V L G R V K G
UDMA B D BHMG R I B D P B D L R B k R EWS P L s C Y Q gMF E F B S A T B G P D BN J N A TB G P D B D D L R B E F B A F V NK F NK R EWS P D L R B E F B A F V NK F N
F E I S R E Q R I U Z T R E W Q L K J H S A g K Z Q I Q K o S L W i k a p I E P N N R A U U A U V T Q U o t R E L K J H G F D S A MM B V C X Y M L M O L K J H G F D S A MM B V C
C F V NK F Nk R EWS P L O C Y Q gME C L Z EMS B C I T PMO S G RUC Z G ZMO Q BDBMR T X A z YWPHC E Q A YWS X E E C R F V E G B Z PHC E Q A YWS X E E C R
P J A S R E H L MO K N I J U H B Z G V K R EW S P L O C Y Q DM F E F B S A T B G P D B U A U V N H O U b I J B Z G V T F C R D X E S NWA S R E C V B Z G V T F C R D X E S NW
C G T J D G L E T U O A D G J L Y C B M X Y M L M O K N I J B H U Z G F D G V T Q U o t R Q O Q T F L U J r D G Y C B MW R Z I P S F H K T V N Z L M O Y C B MW R Z I P S F H K T
J T Z U E T O I Z RWQ E T UOMB C Y F V E G B Z HNU J M I K O Q A Y LMR T X A z Y BDBB P O RU T E TMB C Y N V X A D G J L KH E S Y S C BMB C Y N V X A D G J L KH
V WM O R W U U M P I Z R W O U Z T W H A S R E C V F H K N U T E Q T F C X V N H O U b I R t R S K U P O W R W Z T W H N E D K U NW P O N C A L V I K Z T W H N E D K U NW P O N
A K D L J K P S D F G H J K L P O I U Z V N Z L MO I J E U H B Z GWR Z V T F L U J r D Y z Y K L P F L K J K O I U Z T R EWQ Y X C V B NM I QWu O I U Z T R EWQ Y X C V B
L S J A D S Y K J H G F D S A Y V N P I Z A S R E C V F H K NU T E Q T F C X V NH O U b I b I X A Y H A S e S V N P I Z RWQ S C G Z N J I MN S t R V N P I Z RWQ S C G Z N J
E K J I C K O I J G R D C K I O PMN E S V N Z L MO I J E U H B Z GWR Z V T F L U J r D r D U K O G I K C K PMN E SWL N C X W Z Y K F E D i O P PMN E SWL N C X W Z Y K
L S J A D S Y K J H G F D S A Y V N P I Z RWF V E G B Z HNU J M I K O Q A Y L MR T X A z Y X A Y H A S u S V N P I Z RWQ S C G Z N J I MN S t R V N P I Z RWQ S C G Z N J
E K J I C K O I J G R D C K I O PMN E SWL A S R E C V F H K NU T E Q T F C X V NH O U b I U K O G I K C K PMN E SWL N C X W Z Y K F E D i O P PMN E SWL N C X W Z Y K
MO TMQ O GN T Z D S Q OMG DN V U S GR V N Z LMO I J E UHB Z GWR Z V T F L U J rD C Z G ZMo x O DN V U S G R V L G R V K G E C E Z EMDN V U S G R V L G R V K G
T N U G I N R L U J G D I N G R E X O M N Y A Z T E W N F X J L R N I F Z K M N D A B O B N x z p e w n q m I N E X O M N Y A Z T E W N F X J L R N I F E X O MN Y A Z T E W N F X
D C O S V C E S O PMN V C S E Y L J N EWC L V V F HN V R D J K U V X E S Y MN R E i WC L OME P S C V C Y L J N EWC L V V F HN V R D J K U V Y L J N EWC L V V F HN V
MO TMQ O GN T Z D S Q OMG DN V U S GR V L G R V K G E C E Z EMS A C I T PMO S G RUC Z G ZMa x O DN V U S G R V L G R V K G E C E Z EMDN V U S G R V L G R V K G
A A O R U A ND ONG I U A RNH I O G DNO I E RNGMD S A U K Z Q I NK J S LWO zwu I E P NNR A U A H I O G DNO I E RNGMD S A U K Z Q H I O G DNO I E RNGMD
96
Introduction
More than 100 years after the invention of
the automobile, it seems as if the technology of clutch release systems, is a mature
one, without the necessity of changes.
However, even in this seemingly evolved
family of products, the innovation dynamic
remains high. Current developments aim
to further increase robustness, replace
existing materials with polymer materials,
and integrate sensors in the master cylinder.
Master cylinders with integrated sensors have only been used in a few cases
in the past. The proliferation of systems
such as start/stop or the electronic parking brake is now leading some car manufacturers to consider such sensors in the
master cylinder as obligatory. The sensors make it possible to measure the travel on the clutch pedal and thus determine
the drivers intent.
Materials too are evolving. While for
decades cast iron or aluminum alloys
were dominant, in new applications,
master cylinders, pipes and slave cylinders are almost always made of plastic.
Initial problems with the use of polymer
materials, such as master cylinder
squeaking, high adhesive friction and
volume expansion, have since been resolved. The technologies necessary for
the use of plastics have been constantly
refined and are now solid and economical. Even in double clutch systems,
which have higher, continuous loads,
plastic cylinders are gradually becoming
established. Current developments are
focused on using plastic in the pedal
box.
Ultimately, the robustness requirements for the components used in clutch
operation have risen significantly. Even
just a few years ago, one million cycles
97
was the going operating load specification for release systems. Now, it is not
unusual to require two to three million
cycles accompanied by increased requirements regarding the ambient conditions of temperature, water and contaminant exposure.
P = Primary seal
S = Secondary seal
Figure 1
Figure 2
Secondary
New clutch master cylinder with a one-piece housing and seals mounted to
the pistons
98
Friction load
measurement
Time
Path of travel
Figure 5
Tribological test stand for basic trials on seal friction and noise excitation
Friction load
300
200
100
0
50
40
Speed
Seal standard EPDM
Seal LSR
Figure 4
10
20
30
Pressure p in bar
40
Load F in N
99
120 C
20 C
Time
Figure 3
400
Pedal travel
Opposing surface
Path of travel
Elastomer specimen
Fluid
Volume expansion in mm
Normal load
Clutch load
Friction load
30
20
10
0
Figure 6
6
8
10
Travel s in mm
12
14
100
Hall series
linear
3D Hall
linear
Blanks
Solution
Hall Array
Figure 9
Inductive
linear and position
101
Hall
position
Lead
frame
Solution
Induktiv
(magnet-free)
Smart Hall IC
Hall switch
102
5 V supply
Optional
(Redundancy)
Linear signal
Position
Pipes have the task of transferring the hydraulic pressure safely and with as little
friction and volume loss as possible. In
addition, pipes are supposed to prevent
engine vibrations propagating as far as
the pedal box. Installation elements such
as dampers and anti-vibration units are
used for this.
Pipes are currently made of steel/rubber or polyamide (PA 12 and PA 612) materials. Currently, pipes made of plastic
are becoming increasingly common because of their low costs [1]. LuK now uses
PA 610 for almost all pipes. This plastic is
more than 60 % based on plant raw materials. The global availability of prematerials
is better than for PA 12 and PA 612. The
Travel
Travel
Actuation load
Since, in contrast to the linear travel signals, the position signals are not available
from active diagnostic functions, safety
goals according to ISO 26262 are often
not completely met at vehicle levels with
position points derived from the linear
travel signal. For applications with high
safety requirements, LuK therefore recommends using a travel sensor with two
independent travel signals, which are processed by the respective controllers and
which can be compared as needed for increased safety. A stabilized 5 V power
supply is provided in this case by a controller and the sensor signals are preferably provided as pulse-width modulation
(PWM) or as digital signals (for example
SENT). One advantage of this solution is
that the information needed for different
Sliding load
Disengage
Engage
Figure 11
103
Master cylinder signal processing in the vehicle; left: commonly used today; right: future
concept
Spring load
Figure 10
Power supply
Vehicle CAN
Travel
104
Straight
5x1
Figure 12
Calculation application
Flow profile
10
0.1
0.01
0
200
400
600
800
1,000
Frequency f in Hz
Slave cylinder
Master cylinder
Figure 13
10
1
0.1
0.01
200
400
600
800
1,000
preformed
Master cylinder
Slave cylinder
5.9 x 1.3
1
0.1
0.01
0.001
0
200
400
600
800 1,000
Frequency f in Hz
Frequency f in Hz
Steel / rubber
Polyamide
Figure 14
10
105
Without damper
Without damper
Damper in position 2
PipeSim helped in carefully studying the vibration transmission up to the master cylinder and identifying the best corrective measures. This generally involves a vibration
damper with appropriate tuning, an anti-vibration unit or a combination of the two at
an optimal point along the pipe. The simulation also allows for early determination of
the pipe routing, which is available even before test vehicles.
The following example shows the procedure and the advantages of the simulation: The pipe is first divided into multiple
segments based on its mechanical design. An excitation is then specified as a
frequency curve via the slave cylinder.
Based on the transmission behavior of the
line, this generates a corresponding pressure vibration in the master cylinder. The
diagram of the results is shown in Figure 14
on the left; the black line shows the curve
for a steel/rubber pipe and the red line
shows a typical PA pipe: The steel/rubber variant exhibits a resonance of the
incoming vibrations at approx. 150 Hz.
Problems with pedal vibration can be expected there. The pressure curve over the
frequency for the plastic pipe is largely
106
MC
SC
10-1
10-2
10-3
0
400
800
101
100
10-1
10-2
10-3
400
800
Frequency f in Hz
Frequency f in Hz
Without damper
With damper
Figure 15
100
Disengage
101
MC
101
SC
100
10-1
Engage
10-2
10-3
400
800
MC
SC
Frequency f in Hz
Without anti-vibration unit
+ damper
With anti-vibration unit
+damper
Direction of flow
Air bubbles
107
Slave cylinder
plastic prevails
Idle time
Damper
Anti-vibration unit
Figure 16
Figure 17
Travel adjusted clutch (TAC) and cover-mounted release system (CMR) with smaller cover
bearing on the end of the guide sleeve [2]
108
Figure 18
109
LuK technology
Rotary potentiometer
Upper
switch
Magnet
Lower
double
switch
Figure 19
Travel sensor
Simplified design of the pedal box by integrating the sensor system in the master cylinder
pense and increases the stiffness by eliminating the joints. Even the pedal would be
manufactured from plastic for this type of
solution. In the example shown, there are
two possible joint points between the pedal
and pedal box. As a
result, two different
ratios can be used
in the same structure. The spring is
configured as a cylindrical coil spring
and mounted in the
middle, covered by
the housing. The
sensor is mounted
on the side of the
master cylinder or
integrated in the
structure.
An ergonomically perfect design of the loadtravel characteristic
curve on the pedal
is indispensable
[4]. Various autoPedal box for clutch operation made of plastic with integrated
motive manufacturers are pursuing
master cylinder and sensor
Figure 20
110
111
Summary
Literature
[1] Welter, R.; Wolf, B.; Ineichen, L.: Leitungssysteme fr die Kupplungsbettigung.
VDI Reports no. 2139, 2011, pp. 231-240
[2] Welter, R.; Wittmann, C.; Hausner, M.; Kern, A.;
Ortmann, S.: Deckelfester Zentralausrcker fr
Kupplungen. VDI Reports No. 2206, 2013, pp. 67-79
[3] Welter, R.; Lang, V.; Wolf, B.: Clutch Operation;
9th Schaeffler Symposium, 2010, pp. 61-74
[4] Zink, M.; Hausner, M.; Welter, R.; Shead, R.:
Clutch and Release System; 8th LuK Symposium, 2006, pp. 27-45
Over-center spring
Tension piston
Stopping
Pressure
connection
Figure 21