LuK Tractor Torsion Dampers

Transcription

1 LuK Tractor Torsion Dampers

2 24/7 LuK Tractor Clutches: No. 1 in the field at all times! The genuine LuK portfolio has the right parts for every possible use OE quality and operational comfort included. LuK is the leading manufacturer of clutch technology, supplying all major tractor manufacturers worldwide. LuK damping systems provide a highly effective system to dampen vibrations. Rely on our cost effective products with prolonged operating life. Have the freedom to work your field 24/7. We move the world with quality. Schaeffler Automotive Aftermarket is a specialist in components and services involving the complete drivetrain in passenger cars and commercial vehicles from engines, to transmissions, to chassis. As a globally active company we move millions of people every day in cars, trucks, buses, and tractors. Our products are used in almost every new vehicle throughout the world and for good reason: Schaeffler is the innovation-leader in original equipment manufacturing and aftermarket sales and is a guarantee of the very highest quality. 2 3

3 Installation positions of the torsion dampers Why torsion dampers? Installation positions Torsion dampers have the task of reducing torsional vibration between the engine and transmission. To understand the function of a torsion damper, we must first understand a little about the way in which an engine works. Moderating the effects: flywheels With a swing This This effect effect of of speeding up and up and slowing slowing down down between between each cyl- each cylinder s power power stroke stroke is moderated is moderated by using by using a heavy a heavy flywheel flywheel attached attached to the to crankshaft. the crankshaft. The flywheel The flywheel absorbs absorbs the torque the torque peaks coming peaks from coming the cylinders from the and cylinders maintains and this maintains inertia throughout this inertia the throughout engine cycle. the engine cycle. However, using a heavy flywheel also has disadvantages, However, using a heavy flywheel also has disadvantages, especially especially with regard to the engine s response to load changes, with regard to the engine s response to load changes, and its overall and its overall fuel consumption. fuel consumption. Gearbox rattle Gearbox rattle The result of this acceleration and deceleration is to excite all of the shafts and gears in the transmission (especially those not The actually result transmitting of this acceleration torque), making and deceleration them rattle against is to excite each other all of the at shafts high frequency and gears - generating the transmission uncomfortable (especially noise and those vibration not actually throughout transmitting the vehicle. torque), The making effect them is reduced rattle against proportionally each other by at increasing high frequency the number - generating of cylinders uncomfortable in the engine. noise and vibration throughout the vehicle. The effect is reduced proportionally by ln the diagram below you can see the measurement results increasing the number of cylinders in the engine. taken from a 3-cylinder tractor with no torsion damper fitted. The blue line reveals that, when idling, the engine speed ln the diagram below you can see the measurement results taken fluctuates between 735 and 775 RPM. Because of the excitation, from a 3-cylinder tractor with no torsion damper fitted. The blue the transmission input speed is fluctuating between 73O and line reveals that, when idling, the engine speed fluctuates between 78O RPM. 735 and 775 RPM. Because of the excitation, the transmission input speed is fluctuating between 73O and 78O RPM. LuK: Analysis for exact solutions Analysis LuK LuK has has developed developed sophisticated computerised computerised measuring measuring equipment, equipment which precisely which precisely records the records speed the of the speed engine of the crankshaft engine and crankshaft the drive and train the at various drive train points at between various points the gearbox between input the and gearbox final drive. input Following and final analysis drive. of Following these measurements analysis of and these the measurements transmission design and the on transmission a particular tractor, design LuK on engineers a particular were tractor, able LuK to design engineers a torsion were damper able to which design is mounted a torsion directly damper into which the flywheel is mounted to transmit directly the into engine the torque flywheel to the to transmission transmit the and/or engine conventional torque to the PTO transmission or from the and front / of or the conventional engine to drive PTO or a front from PTO the unit. front of the engine to drive a front PTO unit. These dampers smooth out all of the engine torque peaks These dampers smooth out all of the engine torque peaks and and eliminate excitation in the drive train under all operating eliminate excitation in the drive train under all operating conditions conditions including engine idling, full load and overrun including engine idling, full load and overrun (engine braking). (engine braking). Good driving characteristics Result: Good driving characteristics n the diagram below you can see the results from the same In tractor, the diagram but now below fitted you can with see a LuK the results torsion from damper. the same Whilst tractor, the but engine now fitted exhibits with a the LuK same torsion fluctuation damper. Whilst in speed, the engine the exhibits damper the has same almost fluctuation completely in speed, eliminated the damper the has fluctuations almost completely in the eliminated transmission the fluctuations input speed, in the making transmission the tractor input quiet, speed, vibration making the free, tractor and quiet, a pleasure vibration to drive. free, and a pleasure to drive. Variations in torque Speeding up. And slowing down Unlike electrical motors and turbines, internal combustion engines do not deliver a continuous torque. Instead, the crankshaft is continuously both accelerating and decelerating as each engine cylinder fires. These variations in torque and crankshaft speed are passed into the transmission causing both noise and unpleasant vibration throughout the tractor. Torsion dampers are designed to minimise both the noise and vibrations and provide a comfortable driving environment. Piston movement The 4-stroke diesel engine used in today s tractors mixes air and fuel in a combustion chamber where it burns and creates heat energy, which rapidly expands the trapped gas, creating pressure energy. The piston is forced down the cylinder by the expanding gas and, through the mechanism of the connecting rod and crankshaft, the linear mechanical energy in the piston is converted into rotational mechanical energy through the transmission, thus turning the wheels. Although fuel starts being injected into the combustion chamber before the piston reaches the top of its stroke, the piston is already on its way down the power stroke before the really high cylinder pressures are reached. As the piston continues down the cylinder, the gas above it is cooled by the cylinder walls and the pressure reduces rapidly. Of course, the engine designer tries to create the maximum pressure in the cylinder at the point where the connecting rod and the crankshaft are at the greatest angle which will generate the maximum turning moment (torque) in the crankshaft. ln reality, the length of time that the high pressure gas is doing real work on the piston is often less than 7O degrees in a full cycle of 72O degrees. A 3-cylinder 4-stroke engine generates 3 short torque peaks in each full cycle, each peak being 24O degrees rotation apart. Each torque peak causes the engine to speed up momentarily, before slowing down again. 3-cylinder engine without LuK damper 1 = Engine 2 = Transmission 3-cylinder engine with LuK damper 1 = Engine 2 = Transmission During this cycle, the crankshaft will turn through 2 complete revolutions (72O degrees), to complete the induction, compression, power and exhaust strokes. lf we examine the complete cycle carefully, we will find that it is only the power stroke which is creating power and, although we think of this as representing 18O degrees of the complete cycle, the real work is being done in a much shorter time. 4 5

4 Functional Description of the of the Tractor Torsion System Front PTO damper Different dampers for different engines Every Every damper damper can can be simply be simply described as having as having two two separate Simple Simple axial axial dampers use use a series a series of small of small coil coil springs springs mounted Every damper can be simply described as having two separate Simple axial dampers use a series of small coil springs mounted parts parts which which are are effectively connected through through the the damping within within a clutch a clutch disc disc centre centre which which are are compressed by by each each parts which are effectively connected through the damping springs. within a clutch disc centre which are compressed by each torque axial springs. springs. With With transmission dampers, the the first first part, part, or primary or torque torque axial axial spring spring damper damper peak, peak, smoothing the the torque torque flow flow With transmission dampers, the first part, or primary as it is often spring damper peak, smoothing the torque flow into the transmission. as it as is it often is often called, called, is usually is usually connected directly directly to the to the engine engine into into the the transmission. called, is usually connected directly to the engine flywheel using flywheel flywheel using using bolts bolts around around the the outer outer flange flange of the of the damper. damper. bolts around the outer flange of the damper. The second part, or Using 2 or 3 The second part, or is directly to the Using different 2 or strengths 3 of springs can of accommodate springs can the The second part, or secondary, is connected directly to the Using 2 or 3 different strengths of springs can accommodate secondary, is connected directly to the transmission input shaft full torque output input shaft via a splined hub or flange in the the full of the torque engine output between of idling the engine and maximum engine transmission input shaft via a splined hub or flange in the the full torque output of the engine between idling idling and and via a splined hub or flange in the centre of the damper. output. This centre of the type of damper engine frequently output. This has an type articulation of damper of between centre of the damper. maximum engine output. This type of damper frequently has has an an 10 and 25 articulation degrees. of between of between 10 and 10 and 25 degrees. 25 degrees. Front PTO Front dampers Front PTO PTO dampers may be bolted may may be directly bolted be bolted between directly directly between the between engine the the engine engine crankshaft crankshaft and the and front and the PTO the front unit. front PTO The PTO unit. secondary unit. The The secondary part of the part part of the of At the other At the At end other of other end scale end of the is of the the scale LuK scale is designed the is the LuK LuK Long designed Travel Long Long Travel Travel damper damper is then damper driven is then is then by driven the driven primary by the by the primary through primary through the through damping the the damping coil coil Damper coil Damper which Damper uses which arc which uses springs uses arc to arc provide springs springs exceptional to to provide provide damping exceptional springs springs or other springs or energy other or other absorbing energy energy absorbing elements elements which are which able which to are are able able to ability to under damping all operating ability ability under conditions. under all operating all This damper conditions. design This particularly design suited design is to particularly higher is powered suited suited engines to higher to and higher powered can have engines an engines articu- and and can can This damper damper compress compress and damp and and out damp damp all out of the out all torque of all the of the torque peaks torque and peaks peaks eliminate and and eliminate excitation excitation in the transmission. in the in the transmission. lation in have excess have an of articulation an 4O degrees. in excess in excess of 4O of degrees. 4O degrees. Flywheel Flywheel damper damper The LuK product range With With the the growing growing trend trend from from tractor tractor manufacturers towards towards power- powershifshift type type transmissions, the the requirement for damping for between between the the engine engine and and transmission has has grown grown considerably in in the in the the last last last few few years. years. LuK LuK has has led led led the the the way way way and and and today today is able is is able to offer to offer a range a range of of of products specifically designed designed to suit to suit the characteristics the of each of of each each tractor, tractor, including including axial axial spring spring dampers, long long travel travel dampers, flywheel flywheel PTO PTO dampers and and front front PTO PTO dampers. All of All these of these dampers are are designed to absorb to absorb the the engine s engine s torque torque peaks peaks and and provide provide a smooth, a smooth, constant and and quiet quiet drive drive from from the the engine engine into into the the transmission and and front front PTO PTO unit. unit. Front Front PTO PTO damper damper A normal process: wear-off As with As with any any moving moving part part the part the the damper damper will, will, over will, over time, over time, begin time, begin to begin wear to to in wear accordance wear in accordance in with the with nature with the the nature of the nature work of the of that the work the work that vehicle that the the vehicle is undertaking, is undertaking, is and as a and result and as will a as result be a result less will effective will be less be less in effective damping effective the damping engine output. the the engine engine output. vehicle output. Whilst Whilst the the tractor tractor will will continue to to run run to with run with a with worn a worn a and worn and poorly and poorly poorly functioning damper, damper, it will it will not not only only be noisy be noisy and and uncomfortable to drive, to drive, but but the the risk risk of accelerated of wear wear and and possible possible damage damage to to to the the transmission and and front front PTO PTO will will be considerably be increased. Without Without these these technically advanced dampers the the the tractor tractor would would be noisy be noisy be and noisy and and uncomfortable the for the for operator. the operator. Transmission Front Front PTO PTO

5 Torsion Dampers Fault Diagnosis A worn or defective damper may be recognised by the following: LuK torsion dampers are specifically designed and manufactured to fit a particular engine and transmission group, and will provide a long service life under all normal tractor operating conditions. This will include all types of pulling work together with PTO driven machines. The maximum torque that the torsion damper can transmit is higher than the maximum engine output torque by a considerable safety margin. However, if the tractor experiences exceptional load conditions from external sources, the torsion damper can be subjected to accelerated wear, and possibly irreparable damage. Rattling in the transmission at any speed, or at engine start up and shut down. lncreasing noise from the transmission either in a specific gear or all gears or loads. Unusual noises from the area between the engine and transmission. A loss of drive to the wheels and PTO. It is difficult to accurately predict when a torsion damper will require replacement due to the wide variety of work each tractor undertakes. Typically, a LuK torsion damper will provide between 4,OOO and 6,OOO hours of service under normal operating conditions. lf the engine/transmission housing is opened for any reason, the damper can be visually inspected for obvious wear and damage. However testing the damper against its design parameters requires specialist equipment so precautionary replacement of the torsion damper is often the preferred option if any doubt exists as to its continued effectiveness. Under normal use, LuK strongly recommends that torsion dampers are replaced well before the more serious signs of imminent failure (like excessive noise and rattling or loss of drive) are evident. This will ensure that the tractor transmission continues to be fully protected and that the tractor continues to be as comfortable and quiet to operate as it was when new. Therefore, rely on the genuine LuK portfolio and trust on our original equipment manufacturing quality when replacing torsion dampers. LuK torsion dampers are cost-effective and guarantee the best results. They ensure a long operating life that will support you in the best possible way. In other words: You will have the freedom to work your field 24/7. For example: If the tractor is working with a heavy PTO driven machine and the PTO shaft has simple 2 piece universal joints then whenever the PTO shaft is not straight, it will accelerate and decelerate the drive train during each revolution. lf, due to the tractor turning, or the machine being raised, the PTO shaft joints reach a severe angle, the acceleration and deceleration resonance can destroy the torsion damper very quickly. Incorrect transmission downshifting whilst towing a heavy load can generate substantial inertial reverse torque loads through the drivetrain, possibly in excess of the torsion damper safety limits, resulting in severe damage. Torsion damper wear and fractures If oil leaks from either the engine or transmission and penetrates the damper, then the special friction elements within the damper hub assembly, which are designed to eliminate gear rattle at low power outputs, will become ineffective. This will result in transmission noise especially during periods of engine idling. Torsion damper contaminated with oil / grease 8 9

6 LuK Tractor Torsion Dampers quality parts from the innovation-leader Type Dia Spline Qty Clutch Part Number OEM OEM Part Number ZA Claas ZA Claas ZA Deutz ZA Hurlimann ZA Lamborghini ZA SAME ZA Claas ZA Claas ZA Claas ZA New Holland ZA Case-IH ZA Claas ZA BCS ZA Ferrari ZC 164 n/a Mercedes ZA Massey Ferguson M1 ZA Massey Ferguson M2 ZA Landini M91 ZA Massey Ferguson M2 ZA AGCO M3 ZA Challenger M3 ZA Massey Ferguson M3 ZA Landini M92 ZA McCormick M92 ZB Massey Ferguson M1 ZA Massey Ferguson M1 ZD Case-IH ZD New Holland ZA New Holland ZA Deutz ZA Hurlimann ZA Lamborghini ZA SAME ZA Case-IH ZA New Holland ZB Case-IH A1 ZB McCormick A1 ZB 354 n/a Case-IH A2 ZB 354 n/a McCormick A2 ZA Claas ZA Massey Ferguson M2 ZB Massey Ferguson M01 ZB McCormick A1 ZB 354 n/a McCormick A1 ZB Valtra ZC n/a n/a Claas ZC John Deere AL ZB Claas ZA Case-IH ZA New Holland ZA Steyr ZA Landini M91 Type Dia Spline Qty Clutch Part Number OEM OEM Part Number ZA Case-IH ZA New Holland ZA Steyr ZA Case-IH ZA New Holland ZA Steyr ZD Case-IH ZD New Holland ZC Case-IH ZC New Holland ZA BCS ZA Ferrari ZB John Deere RE ZD Massey Ferguson M1 ZB Challenger M1 ZB Massey Ferguson M1 ZB Claas ZB Massey Ferguson M1 ZA Deutz ZA Hurlimann ZA Lamborghini ZA SAME ZA Hurlimann /30 ZA Lamborghini /30 ZA SAME /30 ZA Hurlimann /10 ZA Lamborghini /10 ZA SAME /10 ZA Deutz ZA Hurlimann ZA Lamborghini ZA SAME ZA Case-IH ZA New Holland ZA Case-IH ZA New Holland ZA Steyr ZA Claas ZB Valtra ZC n/a n/a Claas ZE 288 n/a John Deere AL ZB Challenger M1 ZB Massey Ferguson M1 ZB Case-IH ZA New Holland ZB New Holland ZB Case-IH ZB New Holland ZB New Holland ZB Deutz /10 ZB Hurlimann /10 ZB Lamborghini /10 ZB SAME /

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