Automobile HUB

startautoread.com

Automobile

Single plate clutch:

by 1 Comment

Single plate clutch:

Single clutch plate is the most common type of clutch used in motor vehicles for producing a quick disengagement. A single plate clutch consists of a clutch disc, pressure plate, and a cover plate bolted to the engine flywheel. To remove the complete assembly from the flywheel, the cover plate bolts may be removed. When looking at a simplified sketch of a single plate clutch, we can see that the friction plate is held between the flywheel and the pressure plate. There are springs attached circumferentially, which provide axial force to keep the clutch in the engaged position. single plate clutch

The friction plate is mounted on a hub that is splined from the inside, allowing it to slide freely on the gearbox shaft. A clutch pedal is provided to pull the pressure plate against the spring force whenever it is necessary to disengage the clutch. When the clutch pedal is pressed, the pressure plate is moved to the right against the force of the spring. With the movement of the pressure plate, the friction plate is released, and the clutch is disengaged. In actual practice, the construction of the clutch varies, and the pressure plate, springs, release levers, and cover form a sub-assembly known as the cover assembly, which can be directly mounted to the engine block. This design not only contributes to its efficiency but also allows for quick maintenance and replacement when needed.

Advantages of single plate clutch:

(i) Simple in construction, which makes it easier to manufacture and maintain. (ii) Good heat dissipation from the single plate, ensuring that the clutch does not overheat during extended use. (iii) Due to the single plate design, gear changing is easier and smoother, resulting in a more pleasant driving experience. (iv) This type of clutch has better torsional vibration absorbing capacity, which reduces noise and enhances comfort during operation.

Advantages of multiplate clutch:

(a) It has a high torque transmission capacity, making it ideal for high-performance vehicles. (b) The overall size of the clutch is smaller, allowing for more compact engine designs. (c) Smooth drive transmission, which minimizes jerking during acceleration and deceleration. (d) Due to this type of clutch, there is less wear and tear, extending the lifespan of the clutch and related components.

Disadvantages:

(a) The design of this clutch is complicated, making it less accessible for DIY repairs. (b) Maintenance is difficult, often requiring professional service to ensure proper function. (c) The cost of this clutch is higher, which can be a barrier for some consumers.

Applications:

(1) Since it has a high torque transmission capacity, it is commonly used in racing cars, where performance is crucial. (2) They are also used in two-wheelers like Bajaj scooters and motorbikes, demonstrating versatility in various types of vehicles. (3) Additionally, single plate clutches are often found in commercial vehicles, where reliability and ease of use are essential for daily operations. (4) With advancements in technology, single plate clutches are now being integrated into electric vehicles, showcasing their relevance in modern automotive engineering.

Future developments in clutch technology may see the introduction of even more advanced single plate designs, incorporating materials that further reduce weight and enhance durability. Innovations such as smart clutches that can adjust their engagement based on driving conditions may also become more prevalent. As we move towards a greener future, the role of clutches in electric and hybrid vehicles will be critical, necessitating ongoing research and development in this area.

Understanding the mechanics and advantages of single plate clutches is essential for automotive professionals and enthusiasts alike. They not only impact vehicle performance but also play a crucial role in the overall driving experience. By ensuring smooth transitions between gears and minimizing engine strain, these clutches enhance both efficiency and longevity of the vehicle’s drivetrain system. Moreover, as automotive technology evolves, the relevance of single plate clutches continues to grow, making them a vital topic of discussion in the industry.

2 Types of clutches

by Leave a Comment

2 types of clutches are:

There are 2 types of clutches: (i) Positive Engagement or direct clutches (ii) General Engagement Clutches.

2 types of clutches are

The types of friction clutch are:

The different types of friction clutches are:
  1. Cone Clutch.
  2. Multi plate clutch.
  3. Centrifugal clutch.
  4. Single plate clutch.
  5. Semi centrifugal clutch.
  6. Diaphragm clutch.

Cone Clutch:

This clutch consists of contact surfaces in the form of cones. There are two con es internal and external cones. A frictional lining of a wire and asbestos composition are used for fitting an internal cone. To hold the cones together in position, a large and strong coil spring is used.

The torque is usually transmitted from the engine to the flywheel and internal cone to the splined gearbox shaft when the clutch is engaged, A foot operated pedal or lever system is applied to pull out the internal cone and overcome the spring pressure resulting in separation of contact surfaces or disconnection of the drive. A two-way cone clutch is generally employed in an overdrive gear. the friction material is provided on both the inside and outside facing of the cone. The moving cone acts as the male member to hold the cone stationary while the female member of the clutch drives the cone of the input speed.

Advantages of cone clutch:

(1) The normal force acting on the friction surfaces is larger than the axial force as compared to single plate clutch.
(2) It is smaller in size than single plate clutch.
(3) Less force is required to press the clutch pedal.

Disadvantages of cone clutch:

(1) There is possibility of stickiness of male cone to female cone of flywheel, so it becomes difficult to disengage the clutch.
(2) Small amount of wear of contact surfaces causes “slip” between the two cones.

Applications:


(1) In early days it was used in larger vehicles such as buses and trucks.
(2) It is used on no gear small two wheelers.
(3) It is used to operate the hoist, cranes etc. which are operated by Engine Generator set.

 

Single plate clutch:

Construction:

Single plate clutch is the most common type of clutch used in motor vehicles for producing a quick dis engagement. Basically, it consists of a clutch a disc, pressure plate and a cover plate bolted to the engine flywheels. In order to remove complete assembly from the flywheels cover plate bolts may be removed. A simplified sketch of a single plate clutch is shown in the figure. Friction plate is held between the flywheel and the pressure plate. There are springs attached circumferentially which provide axial force to keep the clutch in the engaged position. The friction plate is mounted on a hub which is splined from inside and free to slide on the gear box shaft. A clutch pedal is provided to pull the pressure plate against the spring force whenever it is required to be disengaged. When the clutch pedal is pressed, the pressure plate is moved to the right against the force of spring. With the 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.

Advantages:

(i) Simple in construction.
(ii) Good heat dissipation from single plate.
(iii) Due to single pate the gear changing is easier.
(iv) This type of clutch has better torsional vibration absorbing capacity.

Advantages of multiplate clutch:

(a) It has high torque transmission capacitor.
(b) The overall size of the clutch is smaller.
(c) Smooth drive transmission.
(d) Due to this type of clutch there is less wear and tears.

Disadvantages:

(a) The design of this clutch is complicated.
(b) Maintenance is difficult.
(c) The cost n this clutch is more.

Applications:

(1) Since it has high torque transmission capacity, it is used in racing car.
(2) They are used in two wheelers like Bajaj scooter, motor bikes etc.

Diagram: 

                                                               clutch plate

 

 

 

What is clutch?

by 1 Comment

Clutches:

A clutch is a mechanical device that engages and disengages the power transmission means shaft, especially from the driving shaft to the driven shaft. When we have to change the gear in the transmission system then for that time we have to use the clutch. Clutch plate is defined as the mechanism to transmit rotary motion from driving shaft to drive Shaft as and when required without stopping the driving shaft. A layout of transmission of system which includes location of clutch.

or

A clutch is a mechanism which enables the rotary motion of one shaft to be transmitted at will to second shaft, whose axis is coincident with that of the first.

clutch

The purpose of clutch:

(a) To transmit power smoothly.
(b) Once the clutch is engaged, the clutch must transmit power without slipping.
(c) During initial pick up of vehicle from stationary to moving the engine is running but the vehicle is stationary.
(d) To overcome the self-inertia of vehicle.
(e) For gradual engagement of rotary motion from the engine to the gear box shaft.
(f) These are also used to disengage the drive from engine to gear box for changing of different gears.
(g) At the time of stopping of vehicle the clutch is utilized to disengage engine from drive wheels and enable smooth stopping of the vehicle.
(h) Clutch also takes the care of speed and torque fluctuation for engine crankshaft to gear box input shaft since clutch is made up from friction material.

Working of clutch:

The clutch is located between the engine and gear box. When the clutch is engaged, the power flows from the engine to the rear wheels through the transmission system and the vehicle moves. When the clutch is disengaged, the power is not transmitted to the rear wheels and the vehicle stops while the engine is still running. Clutches are useful in devices with two rotating shafts one will act as a driver and the other is a driven shaft. One of the shafts is typically driven by a motor or pulley and the other shaft is driving another device.

Functions of a Clutch:

     

      1. To permit engagement or disengagement of a gear when the vehicle is stationary, and the engine is running.

      1. To transmit the engine power to the road wheels smoothly without shock to the transmission system while setting the wheel in motion.

      1. To permit the engaging of gears when the vehicle is in motion without damaging the gear wheels.

    Characteristics of good clutch:

       

        1. It should engage gradually to avoid sudden Jerks.

        1. It should be easily operated.

        1. It should be dynamically balanced.

        1. It should be free from slip when engaged.

        1. It should be as small as possible so that it will occupy minimum space.

        1. The wearing surfaces should have long life.

        1. It should be easily accessible and have simple means of adjustment.

        1. It should be able to dissipate large amount of heat which is generated during the clutch operation due to friction.

      Principle of operation of a clutch:

      The clutch principle is based on friction. When two friction surfaces are brought in contact with each other and pressed, they are united due to friction between them. If one is revolved, the other will also revolve.

      The friction between the 2 surfaces depends upon:

      (i) Area of surface. (ii) Pressure applied upon them. (iii) Coefficient of friction of the surface materials.

      One surface is considered as driving member and the other as driven member. The driving member is kept rotating. When the driven member is brought in contact with the driving member, it also starts rotating. When the driven member is separated from the driving member, it stops revolving. In this way a clutch operates.

       

      What is torsion bar?

      by Leave a Comment

      Torsion bar:

      The torsion bar is a single solid alloy steel rod. Vertical movement of vehicle (i.e. bouncing) induces torsional shear stress in the bar, hence the name “Torsion Bar”. Torsion bars are used in independent suspension system. It is connected to the vehicle frame and end of bar is connected to wheel rim. For heavy commercial vehicles, hollow torsion tubes are used instead of solid bars (so as to reduce the self-weight).

      A torsion bar suspension system usually consists of the following components:

      • Torsion Bar: The main spring element.

      • Control Arm: Attached to the end of the torsion bar and connected to the wheel.

      • Adjuster: A mechanism that allows the tension of the torsion bar to be adjusted, changing the ride height or suspension stiffness.

      • Frame Mounting: The fixed point where the torsion bar is attached to the vehicle frame.

      When you think of a vehicle’s suspension system, you likely imagine coil springs or shock absorbers. However, there’s another important component that plays a vital role in suspending and stabilizing many vehicles: the torsion bar. While not as commonly discussed, the torsion bar is an essential part of suspension systems in certain vehicles, especially trucks, off-road vehicles, and military vehicles.

      Torsion bar diagram:

      Torsion bar

      How Does a Torsion Bar Work?

      The basic principle behind a torsion bar is torsion, which refers to the twisting of an object under applied torque. When a load is placed on the suspension, it applies torque to the torsion bar, causing it to twist. As the bar twists, it stores the energy in the form of rotational force. Once the load is removed, the torsion bar attempts to return to its original position, releasing the stored energy and returning the suspension to its neutral state.

      The amount of twist the torsion bar can handle depends on several factors, including:

      • Material strength: Typically made from high-strength steel to handle the stresses.

      • Bar diameter: A thicker bar will provide more resistance to twisting.

      • Length: Longer bars are more flexible, while shorter bars are stiffer.

      • Mounting position: The torsion bar is mounted at the vehicle’s frame, and the suspension arm typically connects to the opposite end.

      Types of Torsion Bars:

      1. Straight Torsion Bars: These are the most common and simplest type, where the torsion bar is a single straight bar that twists along its length.

      2. Torsion Axles: Some vehicles, especially off-road vehicles, use torsion axles, which incorporate multiple torsion bars into a single system to handle more load and improve the vehicle’s stability.

      3. Independent Suspension Systems: In some vehicles, torsion bars are part of an independent suspension setup, where each wheel is independently suspended and controlled, providing improved traction and handling.

      Advantages of torsion bar:

        1. Adjustability: One of the key benefits of torsion bars is that they can be adjusted to change the ride height or stiffness of the suspension system. By adjusting the tension (twist) of the bar, you can fine-tune the suspension to suit specific needs, such as heavy load-bearing or off-road performance.

        2. Compact and Simple Design: Torsion bars are simpler and more compact compared to other suspension components like coil springs. They save space and reduce the complexity of the suspension system, which is why they are commonly used in military vehicles and off-road trucks.

        3. Durability and Strength: Torsion bars are built to withstand heavy loads and the wear and tear of rough terrain. They are made from high-quality steel, ensuring durability and a long lifespan even under challenging conditions.

        4. No Need for Additional Parts: Unlike coil or leaf springs that require additional suspension components (such as shock absorbers or mounting brackets), torsion bars operate with minimal parts, making them an efficient choice for vehicles where space and weight are critical.

        5. Smooth Ride: Torsion bars can offer a smoother ride compared to traditional leaf springs, particularly in vehicles that require flexibility in handling rough terrain. Their ability to resist deformation over time also ensures the suspension maintains its integrity.

      Disadvantages of torsion bar:

      1.  

        1. Limited Load Capacity: While torsion bars are strong and durable, they are not typically as capable of handling extremely heavy loads compared to leaf springs. This makes them less suitable for vehicles that require high load-bearing capabilities.

        2. Maintenance: Over time, torsion bars can experience wear due to constant twisting, which may lead to a decrease in performance. They can also lose their ability to return to their original position, especially in older vehicles.

        3. Suspension Stiffness: While adjustable, torsion bars can sometimes provide a stiffer ride compared to coil springs. This can be a disadvantage in terms of ride comfort, particularly in passenger vehicles designed for long-distance travel.

        4.  

      Applications of torsion bar:

      1.  

      • Off-Road Vehicles: Torsion bars are commonly used in off-road vehicles, especially trucks, SUVs, and military vehicles. They help these vehicles handle rough terrain by providing shock absorption and stability without the complexity of traditional suspension systems.

      • Military Vehicles: Military trucks and armored vehicles frequently use torsion bar suspension systems due to their durability and ease of adjustability in various combat conditions.

      • Heavy-Duty Trucks: Some heavy-duty vehicles use torsion bars for suspension, especially in the rear suspension of trucks designed to carry heavy loads.

      • Automobile Manufacturing: While less common today, torsion bars were once used in the suspension systems of cars and light trucks, especially in models designed for rugged use.

      Conclusion:

      The torsion bar may not be as commonly discussed as coil or leaf springs, but it remains an essential part of many vehicle suspension systems, especially in heavy-duty and off-road applications. Its simplicity, durability, and adjustability make it an attractive option for manufacturers who need an efficient, space-saving, and robust solution for shock absorption and load handling.

      What is helical spring?

      by 1 Comment

      Helical spring:

      Helical springs are most commonly used in ” Suspension System”. They occupy smaller space and can have fixed or variable spring rates. Their energy storage capacity is higher than leaf springs. They are very light in construction and require no maintenance. 

                                                                             Or

      A helical spring is a type of mechanical spring that is wound in the shape of a coil, typically made of steel or other elastic materials. It is designed to absorb and store energy when compressed, stretched, or twisted. The spring’s helical structure allows it to provide resistance and return to its original shape once the force is removed. This makes it a crucial component in various applications, including vehicle suspension systems, machinery, and household items like mattresses.

      Helical spring

      How Does a Helical Spring Work?

      Helical springs operate on the principle of elasticity. When a force is applied to compress or extend the spring, it deforms but returns to its original shape when the force is removed. The spring’s ability to store and release energy makes it essential for absorbing shocks, maintaining tension, or providing support in a wide range of mechanical systems.

       

      Advantages of helical coil spring:

      • Compact Design: Their spiral shape allows them to be more compact and efficient than other types of springs.

      • Versatility: Helical springs can be used in a variety of applications, from heavy-duty industrial machinery to everyday household products.

      • Durability: Made from strong materials, they are designed to last and maintain their functionality even under continuous stress.

      Light in weight and requires smaller space. They take care of bending loads as well as vertical shear loads. Good vibration damping capacity and ability to absorb shocks.

      Helical spring

      Disadvantages of helical coil spring:

        1. Lower load carrying capacity and hence cannot be u ed commercial vehicles like trucks.
        2. Difficult and costly to manufacture.
        3. Poor ability to take care of side thrusts and torque.
        4. Usually “Helper Spring”, i.e. additional spring (giving ‘nested’ construction) is needed.

      1.  

      1.  

      1.  

      Applications of helical coil spring:

        1. Used in all two-wheelers (like bikes, mopeds, scooter, etc.).
        2. Used in all three wheeled vehicles (like auto rickshaw, small pickup load carriers, etc.)
        3. Used in front suspension of LMV (light motor vehicles) like passenger cars.

       

      1. Design Considerations:

      When designing or selecting a helical spring for a specific application, several factors need to be considered to ensure it meets the required performance criteria:

      • Material Choice: The spring material affects its strength, durability, and fatigue resistance. Common materials include carbon steel, stainless steel, and alloy steels. For more demanding applications, materials like titanium or Inconel may be used.

      • Spring Rate: This refers to the stiffness of the spring, or how much force is needed to compress or extend the spring by a given distance. A higher spring rate means the spring is stiffer and harder to compress or extend.

      • Wire Diameter: The thickness of the wire used in making the spring influences the load-carrying capacity and durability of the spring. Thicker wires provide more strength.

      • Number of Coils: The number of coils determines the spring’s flexibility and load distribution. More coils generally provide greater flexibility, while fewer coils offer greater stiffness.

      • Free Length and Solid Length: The free length is the uncompressed or unstressed length of the spring, while the solid length refers to the length the spring will occupy when fully compressed. These factors must be designed to match the requirements of the specific application.

      2. Helical Spring Manufacturing Process:

      The process of making a helical spring typically involves several steps:

      • Wire Drawing: The raw material (usually wire) is drawn into the desired thickness using a drawing machine.

      • Coiling: The wire is then wound into a coil shape, using a machine that wraps it around a mandrel or die, forming the helical shape.

      • Heat Treatment: After coiling, the spring is heat-treated to improve its strength and elasticity. This process is essential to ensure the spring performs well under stress and retains its shape over time.

      • Grinding and Finishing: The ends of the spring are often ground to ensure flatness, and the spring may be coated or treated to resist corrosion or wear.

      3. Helical Spring Fatigue:

      One of the main challenges for helical springs is fatigue, which occurs when a spring is repeatedly stressed and deformed. Over time, the constant load on the spring can cause microscopic cracks that eventually lead to failure. To combat fatigue, high-quality helical springs are designed with specific materials and manufacturing techniques to enhance their durability. Regular maintenance and replacement of worn-out springs are essential in high-stress applications.

      4. Helical Spring Testing:

      To ensure the performance and reliability of helical springs, several tests are often conducted during the design and manufacturing process:

      • Load Testing: Springs are tested under various loads to determine their load-bearing capacity and how they respond to compression or tension.

      • Fatigue Testing: This test simulates the repeated loading and unloading of the spring to assess its fatigue resistance over time.

      • Dimensional Inspection: The spring is measured to ensure it meets the required dimensions, including wire diameter, number of coils, and overall size.

      5. Helical Spring Innovations:

      As industries evolve and technology advances, innovations are continuously made in the design and application of helical springs. These innovations include:

      • Variable Pitch Springs: Springs with coils that are spaced unevenly, providing a varying spring rate. These are used in specific applications where the load distribution changes dynamically.

      • Plastic Helical Springs: In addition to traditional metal, plastic materials like nylon are also being used to create helical springs. These plastic springs are lighter and resistant to corrosion, making them ideal for certain low-load or delicate applications.

      6. Helical Spring vs Other Types of Springs:

      Comparing helical springs to other types of springs can provide more context for their advantages:

      • Helical Springs vs. Leaf Springs: While leaf springs are best suited for heavy-duty applications, helical springs offer more compactness, greater flexibility, and smoother performance in vehicles.

      • Helical Springs vs. Coil Springs: The term “coil spring” is often used interchangeably with helical spring, but coil springs can also refer to other spring types (e.g., torsion coils). Helical springs specifically refer to a spring wound in a helix shape.

      In conclusion, helical springs are an essential component in many systems due to their versatility and ability to absorb and store energy. Whether in vehicles, machinery, or household products, their simple yet effective design continues to make them indispensable in modern engineering.

      1.  

      1.