Lab Manual | constructional details, working principles and operation of the Automobile clutches

Aim To study and prepare report on the constructional details, working principles and operation of the following Automobile clutches:

a) Coil Spring Clutch

b) Diaphragm Spring Clutch

c) Multi plate Clutch

THEORY

Diagram, Constructional Details, Working Principle and Operation of the above

A simplified sketch of a single plate clutch is given in fig 1 Friction plate is held between the flywheel and the pressure plate. There are springs (the number may vary, depending upon design) arranged circumferentially, which provide axial force to keep the clutch in engaged position. The friction plate is mounted on a hub which is splined from inside and is thus free to slide over the gear box shaft. Friction facing is attached to the friction plate both sides to provide two annular friction surfaces for the transmission of power. A pedal is provided to pull the pressure plate against the spring force whenever it is required to be disengaged. Ordinarily it remains in engaged position as is shown in fig.1

 

When the clutch pedal is pressed, the pressure plate is moved to the right against the force of the springs. This is achieving by means of a suitable linkage and a thrust bearing. With this movement of the pressure plate, the friction plate is released and the clutch is disengaged.

In actual practice the construction of the clutch differs. The pressure plate, the springs, the release levers and the cover form a sub assembly, called the cover assembly which can be mounted directly to the engine block, of course, placing the clutch plate in between the flywheel and the pressure plate with the clutch shaft inserted in this arrangement.

Advantages

1 with the single plate clutch, gear changing is easier than with the cone clutch, because the pedal movement is less in this case

2 it does not suffer from disadvantages of cone clutch i.e. bindings of cones etc. and hence it is more reliable

Disadvantages

As compared to cone clutch, the springs have to be more stiff and this means greater force require to be applied by the driver while disengaging.

In the assembled position releases lever rest against the centre opening of the cover pressing there is an eyebolt nut which causes the strut to pull the pressure plate against the springs, thus holding together the assembly. When the cover is bolted onto the flywheel, the pressure plate is further pushed back against the springs, causing them to be compressed further, which relaxes the release levers. Anti rattle springs serve to prevent the undesirable noise due to release levers when the clutch is in the engaged position.

Diaphragm Spring Type Single Plate Clutch

The construction of this type of clutch is similar to that of the single plate type of clutch described above except that here diaphragm springs (also called Belleville springs) are used instead if the ordinary coil springs. In the free condition, the diaphragm spring is of conical form but when assembled, it is constrained to an approximately flat condition because of which it exerts a load upon the pressure plate.

A diaphragm spring type clutch is shown in fig. where shows the clutch in the engaged position and in the disengaged position.

It is seen from the above figures that the diaphragm spring is supported on a fulcrum retaining ring so that any section through the spring can be regarded as a simple lever. The pressure plate E is movable axially, but it is fixed radically with respect to the cover. This is done by providing a series of equally spaced lugs cast upon the back surface of the pressure plate. The drive from the engine flywheel is transmitted through the cover, pressure plate and the friction plate to the gear box input shaft.

The clutch is disengaged by pressing the clutch pedal which actuates the release fingers by means of a release ring. This pivots the spring about its fulcrum, relieving the spring load on the outside diameter, thereby disconnecting the drive.

In this clutch, three straps of spring steel are placed equilaterally so that their outer ends are riveted to the cover, while their centers are riveted to the pressure plate. Drive is transmitted from the cover to the pressure plate via the straps along lines of action through the strap rivet centers. Spring flexure of the straps permits the axial movement of the pressure plate relative to the cover.

Advantages of the diaphragm spring type clutch

This type of clutch has now virtually superseded the earlier coil spring design in many countries in clutch sizes ranging upto 270 mm, in diameter, although in case of heavy vehicles, the coil spring type clutches are still being used because of the difficulty to provide sufficient clamping force by a single diaphragm spring. The diaphragm spring however, offers certain distinct advantages.

i) it is more compact means of storing energy. Thus compact design results in smaller clutch housing.

ii) As the diaphragm spring is comparatively less affected by the centrifugal forces, it can withstand higher rotational speeds. On the other hand, coil springs have tendency to distort in the transverse direction at higher speeds.

iii) In case of coil springs, load deflection curve is linear. Therefore, with the wear of the clutch facing the springs has less deflection due to which they would apply less force against the clutch plate. On the other hand, in case of diaphragm spring, the load deflection curve is not linear therefore, in this case, as the clutch facing wears, force on the plate gradually increases, which means that even in the worn out condition, the spring force is not less than its value in case of new clutch. Further, it is also seen that the load deflection curve depends upon the ratios h/t where h is the free dish height and t is the thickness of the spring. Therefore, in this case with suitable design, the load deflection curve can be improved to give lower release loads.

iv) The diaphragm acts as both clamping spring and release levers. Therefore, many extra parts like struts, eye bolts, levers etc. are eliminated in the diaphragm spring, because of which the loss of efficiency due to friction wear of these parts also does not occur, which results in the elimination of squeaks and rattles.

Multiplate clutch

These clutches are used in heavy commercial vehicles, racing cars and motor cycles for transmitting high torque. In comparison to single plate type, these switches are smoother and easier to operate due to their assembly of friction surfaces contact. They may be used where space is very limited, i.e. in automatic transmission and motor cycles. In the latter cases a multiplate clutch of small operator transmits approximately the same torque as a single plate clutch of twice that diameter. These are also used in cases where very large torques are to be transmitted i.e. in heavy commercial vehicles, cars, special purpose military and agricultural vehicles. These clutches may be dry or wet. When the clutch of this type is operated in a bath of oil, it is called a wet clutch. But these oil immersed or wet clutches are generally used in conjunction with or as a part of the automatic transmission. It consists of a number of thin plates connected alternately to input and output shaft resulting in a very large area of working surface in a comparatively small space. The increased number of plates provides the increased torque transmitting ability of the clutch.

REFERENCE BOOKS

1 Automotive Mechanics – Crouse / Anglin

2 Automobile Engineering by Dr Kirpal Singh

Viva Questions

1. What is the functioning of a clutch?

Discuss various factors affecting the torque transmissions in a clutch

2. Explain the working of multi plate dry clutch

3. What are the essential properties required for a clutch facing materials

4. Explain in detail various causes of clutch troubles. How can these be remedied?

5. Compare the hydraulic and mechanical methods of operating clutches

6. Where and why we use multi plate clutches

7. Discuss the constructional features of a clutch plate

8. Describe semi and fully centrifugal clutches

9. With the help of a suitable diagram, describe the constructional features of a diaphragm type spring clutch

10. Derive mathematical expressions for the torque transmitted in a multiplate clutch with n no of plates

11. Compare dry and wet type of friction clutches.

12. Why are the clutch friction plates perforated?

13. What is the need of a clutch in an automobile

14. Why do we have springs in clutch friction plates

15. What are the functions of a damper springs in a clutch driving disc