– Efficient Comfort Low drag wet clutches while maintaining performance
Efficient Comfort – Low drag wet clutches while maintaining performance Matt Frary Missing foundation Transmission Torque converter Friction material 1 Schaeffler Symposium 2014 Matt Frary Foundation blocks Friction coefficient [µ] 0.16 0.12 Min 0.08 0.04 0 1 10 Time in hours 2 Schaeffler Symposium 2014 Matt Frary 100 1000 Foundation blocks Friction coefficient [µ] d 0 dv d 0 dv Slip speed in rpm 3 Schaeffler Symposium 2014 Matt Frary Motivation Improve quality control for Schaeffler customers Opening the friction material Black box means: • Understanding parameters that affect performance • Controlling those parameters 4 Schaeffler Symposium 2014 Matt Frary Development Dedicated development since 2004 Collaboration with additive suppliers and university 5 Schaeffler Symposium 2014 Matt Frary Current foundation Can predict and modify functional parameters Friction coefficient [µ] d 0 dv d 0 dv Slip speed in rpm ATF modifier Chemical effects Surface contact area Molecule shape and density 6 Schaeffler Symposium 2014 Matt Frary Permeability Surface condition Material flexibility Torque converter experience Series production since 2009 1.3 Mio torque converter clutches in production in 2014 Friction coefficient [µ] 0.14 0.13 Schaeffler 0.12 0.11 Competition 0.10 0.09 0.08 0 7 Schaeffler Symposium 2014 0.5 Matt Frary 1 Speed in m/s 1.5 2 Foundation for transmission clutch Transmission Transmission Clutch? Torque converter Friction material 8 Schaeffler Symposium 2014 Matt Frary Transmission friction material Schaeffler Competitor 0.20 Friction coefficient (µ) Friction coefficient (µ) 0.20 0.16 0.12 0.08 0.04 0.00 0.50 1.00 1.50 2.00 0.16 0.12 0.08 0.04 0.00 0.50 Speed in m/s 40°C 9 Schaeffler Symposium 2014 90°C Matt Frary 1.00 1.50 Speed in m/s 120°C 40°C 90°C 120°C 2.00 Shifting clutch foundation First planetary automatic transmission Clutch plates Return spring 10 Schaeffler Symposium 2014 Matt Frary Piston Carrier Carrier •Functioning inner and outer splines Example production experience •Reduced space •Reduced cost Riveted assembly Bearing raceways 11 Schaeffler Symposium 2014 Matt Frary Pierced flow holes Piston and return spring Sheet metal piston •Enhanced value assembly •Reduced space Integrated diaphragm spring •Produced since 2009 Riveted retaining plate Simple seals Clutch plates Piston Return spring 12 Schaeffler Symposium 2014 Matt Frary Carrier Optimizing function Without separators External separators Schaeffler separators •Separates all plates •Only line contact •No additional parts 13 Schaeffler Symposium 2014 Matt Frary Results 1.6 Without plate separators Drag torque in Nm 1.4 1.2 1 0.8 0.6 0.4 With plate separators 0.2 0 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Relative velocity in rpm 14 Schaeffler Symposium 2014 Matt Frary The paradox of clutches Torque in Nm 6 0.1mm/facing 4 0.2mm/facing 0.3mm/facing 2 0 0 500 1000 Speed in rpm 15 Schaeffler Symposium 2014 Matt Frary 1500 2000 The paradox of clutches 14 Possible torque error 12 Torque in Nm 10 400 8 6 200 4 Pre-fill pulse 2 0 0 0 0.5 1 Time in seconds 16 Schaeffler Symposium 2014 Matt Frary 1.5 2 Pressure in bar 600 The Challenge for Today's Clutch Torque in Nm 500 400 300 200 100 0 0 10 20 30 Volume in cc 17 Schaeffler Symposium 2014 Matt Frary 40 A New Principle Torque in Nm 500 400 300 200 100 0 0 10 20 30 Volume in cc 18 Schaeffler Symposium 2014 Matt Frary 40 Design Concept Rotary actuator Main piston 19 Schaeffler Symposium 2014 Matt Frary Ramp ring Operation 20 Schaeffler Symposium 2014 Matt Frary A New Manufacturing Potential •Reduced mass and inertia •Eliminated acid •Eliminated adhesive Softer friction material in the same overall thickness 21 Schaeffler Symposium 2014 Matt Frary Added function 6000 SAE#2 Disc 5000 Force in N 4000 3000 Composite friction disc 2000 1000 0 0 0.05 0.1 0.15 Deflection in mm 22 Schaeffler Symposium 2014 Matt Frary 0.2 0.25 Summary Two stage piston Stamping technology Riveted assembly Plate separator Slim thrust bearing Composite facing Reduced drag Reduced mass Reduced environmental impact Improved controllability 23 Schaeffler Symposium 2014 Matt Frary “ You can't build a great building on a weak foundation. You must have a solid foundation if you're going to have a strong superstructure. ” Gordon B. Hinckley 1910 – 2008 X. Schaeffler Symposium 2014
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