Poor clutch life is a major issue for some light commercial vehicle models. Clutch overheating is the primary cause for clutch failure. Some of the reasons include inappropriate gear selection by the driver, poor low-end dynamic torque availability from an engine, heavy stop and go traffic, vehicle overloading resulting in excessive clutch slippage especially in gradients, riding of the clutch pedal by the customer etc. These situations lead to a high thermal energy dissipation at the clutch, increasing clutch wear and in extreme conditions leading to not only poor shift quality but also eventual clutch failure. Unfortunately, it is not practical to monitor clutch temperature in a production vehicle due to high costs or technical challenges involved. This paper describes 1-D thermal modeling of single plate dry clutch typically used in passenger car/truck and bus applications. The objective of simulation is to estimate the temperature rise on the clutch facing and clutch housing. This can be used in conjunction with supplier provided data (facing temperature vs facing wear ratio) for different clutch materials to estimate clutch life at an early design stage. Drive cycle data collected in Chennai city (India) are used for the analysis. The simulation results for clutch housing temperature shows a good correlation with the test results (>90%). The prediction of clutch life/wear using clutch facing temperature shows good match with test results for both accelerated and regular vehicle level testing. The clutch life is analyzed for different facing materials and RWUP test cycle. Finally, DOE evaluation (effect of first gear ratio, final drive ratio, engine torque, clutch size, tire size, vehicle weight, and road grade) is carried out from the correlated model in GT SUITE. Clutch temperature modeling can be used as a tool to optimize designs and reduce testing efforts.
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机译：贫困的离合器生活是一些轻型商用车型的主要问题。离合器过热是离合器故障的主要原因。其中一些原因包括驾驶员的不适当的齿轮选择，从发动机，重型停止和去交通的低端动态扭矩可用性，车辆超载导致过多的离合器滑动，特别是梯度，由客户骑行踏板。这些情况导致离合器的高热能量耗散，增加离合器磨损和极端条件，这不仅是差的换档质量，而且最终的离合器故障。遗憾的是，由于所涉及的成本或技术挑战，监测生产车内的离合器温度并不实用。本文介绍了乘用车/卡车和总线应用中的单板干式离合器的1-D热建模。模拟的目的是估计离合器面向和离合器壳体上的温度升高。这可以与供应商结合使用，为不同的离合器材料提供数据（面向温度Vs面向磨损比率），以在早期设计阶段估算离合器寿命。 Chennai City（印度）收集的驱动周期数据用于分析。离合器壳体温度的仿真结果显示出与测试结果（> 90％）的良好相关性。使用离合器面向温度的离合器寿命/磨损的预测显示出与加速和常规车辆水平测试的测试结果良好匹配。分析离合器寿命，针对不同的面对材料和RWUP测试循环分析。最后，从GT套件的相关模型中，执行DOE评估（第一传动比，最终驱动比，发动机扭矩，离合器尺寸，轮胎尺寸，车辆重量和道路等级）。离合器温度造型可用作优化设计的工具，减少测试工作。
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