Schaeffler Kolloquium 2014 05 en
Schaeffler Kolloquium 2014 05 en
Schaeffler Kolloquium 2014 05 en
79
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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
80
Introduction
A key task that has concerned the automotive industry in recent years has been to reduce consumption. One effective measure
for achieving this goal is to exploit even lower engine speeds for driving. Torque is increased to achieve this without losing power. Doing so allows the engine to run only
very slightly above idle speed and therefore
in an extremely consumption-efficient
range. One challenge is to achieve adequate powertrain isolation even for these
low engine speeds and thus provide drivers
with their usual level of comfort.
Figure 1 [1] shows that the dual mass
flywheel (DMF) is a factor in achieving this
goal, particularly in connection with the
centrifugal pendulum-type absorber. While
twin-cylinder engines have yet been unable to reach the projected fuel savings for
day-to-day use, the increasing numbers of
three-cylinder engines have achieved lower consumption figures. However, lower
consumption places stricter demands on
vibration isolation. The secondary-side
centrifugal pendulum-type absorber (CPA)
was introduced as a concept in conjunction with the DMF as early as 2002 [2], and
successfully went into series production a
few years later. The simple physical principle, modular design and extremely good
isolation have led to increasing acceptance
and proliferation not only in the DMF, but
also in other damping concepts such as
torque converters and clutch discs. There
have also been huge improvements in how
the centrifugal pendulum-type absorber
works thanks to far-reaching understanding of the centrifugal pendulum-type absorber; more detailed information is provided about this below.
As the DMF must also be optimised for
other operating points, such as startup, or
optimised for so called impacts very high
torque peaks when bottoming out the arc
springs compromises must be made.
These compromises also have an indirect
influence on isolation in drive mode. We will
be using examples of impacts that affect
DMFs when stalling the vehicle and demonstrating methods of preventing stress of this
kind and making DMFs more robust. These
result in greater freedom for optimising torsion isolation and so improving driving comfort.
l/100 km
-14 %
Speed amplitude
-21 %
-10 %
4
6.3
5.4
Target
2
0
1,000
1,300
1,800
Speed in rpm
Conventional system
Figure 1
DMF
4.9
81
Second generation
First generation
End stop damper
Flange
Secondary mass
Roller
Pendulum
Figure 2
Development of DMF
centrifugal pendulum-type
absorbers
To date, one million centrifugal pendulumtype absorbers have been produced for sixcylinder, four-cylinder and three-cylinder
engines, and the concept has been continually developed. Prototypes show that the
technology could also be employed in twincylinder engines.
The secondary-side arrangement of the
centrifugal pendulum-type absorber makes
the arc spring damper, which provides preisolation, especially important. Taking engine torque development into consideration
largely automated simulation programs run
through hundreds of variations evaluating
start and drive to find the optimum combination of arc spring and CPA for a vehicle
application. Of course, this requires vehicle
parameters of adequate quality which are
not always available during the early stages
of development in which design takes place.
This is where LuKs wealth of experience really comes into its own, as it allows us to
complete missing data in a meaningful
manner. However, should corrections be required subsequently during to vehicle test-
82
crease can be handled without loss of comfort. For three-cylinder engines acceptable
values of 500 rad/s from about 1,000 rpm
are already achieved (in this example, a diesel engine with 270 Nm). However, these
values can still be significantly reduced: If
the entire clutch system i.e. DMF with
centrifugal pendulum-type absorber and
clutch is designed according to an entirely new layout, (third generation), it is possible to achieve angular acceleration amplitudes of below 200 rad/s from 800 rpm
upwards and without requiring any further
space. The rigidity of drive shafts, in particular, must be incorporated into this concept.
If rigidity changes, it results in a completely
new design. It makes close coordination
with the vehicle manufacturers development process essential.
The considerations mentioned above
relate to a centrifugal pendulum-type absorber integrated below the arc spring
1,000
800
600
400
200
0
800
1,000
1,200
1,400
1,600
1,800
2,000
Speed in rpm
Four-cylinder
Figure 3
450 Nm generation 1
450 Nm generation 2
360 Nm generation 1
Three-cylinder
270 Nm generation 1
270 Nm generation 3
Gravity
This eliminates the need for the beanshaped holes in the flange required for the
circular end stop dampers and creates additional space for greater vibration angles
or heavier pendulums. The added intermediate mass lies relatively far towards the
outer edge in radial terms, thereby improving isolation in the low speed range through
increased inertia. A number of other optimisations, such as optimising the arc
spring damper with the centrifugal pendulum-type absorber as a system, smoother
pitch surfaces and optimised paths, have
together resulted in a significant performance boost, especially at low engine
speeds (Figure 3).
The example of a four-cylinder diesel
engine shows that when using the first generation absorber an increasing of the engine
torque from 360 to 450 Nm leads to a clear
deterioration in isolation. In contrast, when
the second generation is used, a torque in-
Figure 4
83
CPA on outer edge with end stop dampers between the pendulums
84
With additional
single pendulum
First generation
single pendulum
a) Flange
b) Main pendulum
c) Secondary pendulum
d) Intermediate mass
e) End stop damper
f ) Pressure spring
g) Roller
a
g
Parallel pendulum
(first generation)
Second-generation
double pendulum
Second-generation
single pendulum
Flange
e
g
g
a
Trapezoidal pendulum
(second generation)
b
a
c
Pendulum II
f
e
Pendulum I
Figure 6
85
Clutch discs without a pendulum, with a single pendulum and with a double pendulum
system
Figure 7
86
125
Engine
87
3,000
Total acceleration amplitude in rad/s
2,000
1,000
0
1,000
1,200
1,400
1,600
1,800
2,000
Speed in rpm
Torsion-damped
clutch disc
Torsion-damped
clutch disc
+ CPA
Eng. Trans. Veh.
Torsion-damped
clutch disc
+ 2x CPA
Eng. Trans. Veh.
DMF
Sec. +
Eng. Trans. Veh.
DMF + CPA
Sec. +
Eng. Trans. Veh.
Transmission
100
Figure 9
75
50
25
0
1,000
1,500
2,000
2,500
1,000
1,500
Speed in rpm
Torsion-damped
clutch disc
Eng. Trans. Veh.
Figure 8
2,000
2,500
Speed in rpm
Torsion-damped
clutch disc + CPA
DMF
Sec. +
Eng. Trans. Veh.
Comparing five damper concepts based on isolation of a three-cylinder engine with rigid
side shafts in 6 th gear
normal torsion-dampened clutch disc, despite the CPA. This is achieved by reducing
the mass of all individual parts affected. Detailed comments about mass reduction of
this kind can be found in another article [4]. In
conjunction with a CPA, the actual torsional
damper in the clutch disc is dampened to a
lesser extent which benefits isolation at
higher engine speeds. Another significant
benefit is that the centrifugal pendulum-type
absorber aids isolation in the creeping range,
i.e. the low torque range. This allows the
creeping stage to be designed for steeper
rates and higher torques. In this way, creeping rattle can be largely prevented.
The introduction of clutch discs with
centrifugal pendulum-type absorbers pro-
88
CPA of
6 kg reduces
vibrations:
Points of operation
Stalling when moving off
High
Medium
Engine side by 30 %
Transmission side 46 %
by
High
Rare
Engine: 2,400 Nm
Transm.: 12 gears
Weight: 40 t
Figure 10
T transmission in Nm
1,000
500
Without CPA
With CPA
Figure 11
Rare
Medium
Infrequent
Engine start
Medium
Infrequent
Emergency braking
Medium
Rare
Low
Rare
Figure 12
89
Meaning
Classifying impacts
Reducing impacts
Frequency of
occurrence
Medium
Jackrabbit start
2,000
Impact level
90
1,000
8,000
3,000
0
67.5
68.0
Engine
Secondary
Transmissions
Time in s
68.5
69.0
Clutch engagement
time: 890 ms
Impact
1.0
0.5
Point of
injection
0.0
6,000
Impact
similar to
68.5 s
3,000
5
10
Crankshaft revolutions
15
Clutch engagement
time: 900 ms
-8,000
0.0
0.2
0.4
0.6
0.8
1.0
75
50
25
0.0
0.2
0.4
0.6
Time in s
0.8
1.0
Figure 15
Figure 13
8,000
100
1.5
91
-1,000
Figure 14
400
Transmission
n = 770 rpm
6,000
1,000
-8,000
800
2,000
Engine
Secondary
Cumulative frequency in %
1,200
2,000
-1,000
Speed in rpm
2,000
4,000
Impact in Nm
92
93
Torque
Torque
Additional storable
energy
Round wire
High level impacts
lead to jamming
Embossed wire
Summary
The evolution of the centrifugal pendulumtype absorber in conjunction with overall
damper tuning improved the isolation
achieved by DMFs to such an extent that it
can also cope with higher engine torques
and cover todays three-cylinder and even
twin-cylinder engines . Furthermore, they
still have further potential, as regard to isolation, for dealing with the expected further
Figure 16
80
40
0
-40
-80
2.0
1.0
0.0
-1.0.
No striking
n = 574 rpm
0.0
0.1
Engine
Figure 17
0.2
Time in s
Transmission
0.3
0.4
0.0
0.1
0.2
Time in s
0.3
0.4
Secondary
Literature
[1] Kroll, J.; Kooy, A.; Seebacher, R.: Land in
sight? 9th Schaeffler Symposium, 2010,
[2] Kooy, A.; Gillmann, A.; Jaeckel, J.; Bosse, M.: DMF
Nothing new? 7th LuK Symposium, 2002
[3] Reik, W.: Torsional vibration isolation in the
powertrain. 4th LuK Symposium, 1990
[4] Schneider, M. et al.: The Clutch Comfort Portfolio: From a suppliers product to an equipment
criterion. 10th Schaeffler Symposium, 2014