COBEM 2015 - Dynamic Coupling System Presented by Michelotti
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Transcript of COBEM 2015 - Dynamic Coupling System Presented by Michelotti
12/21/2015 1
DYNAMIC SIMULATION OF AN INNOVATIVE
PERMANENTLY ENGAGED MECHANISM FOR
STARTING SYSTEMS
Authors:
Alvaro Canto MichelottiZEN S.A. Indústria Metalúrgica, Brusque (SC), Brazil.
Jonny Carlos da SilvaUniversidade Federal de Santa Catarina (UFSC),
Florianópolis (SC), Brazil.
23rd ABCM International Congress of Mechanical Engineering
December 6-11, 2015, Rio de Janeiro, RJ, Brazil
12/21/2015 2
1. Introduction
2. Stop-Start Vehicles
3. Mechanical Interface for Starting Systems
4. Innovative DCS concept
5. Simulation Model
6. Results
7. Conclusions & Next Steps
Summary
12/21/2015 3
Alvaro Michelotti, M.Eng. – R&D Technical Specialist
Master degree in Mechanical Engineering – Univ. Federal de Santa Catarina (UFSC)
Doctorate (on-going) in Mechanical Engineering - UFSC
Research focus in Mechanical Systems, Lumped parameter Modeling & Simulation
Since 2003 works for ZEN S.A., in R&D area since 2012
+16 years of professional experience in the automotive market
Introduction - About the Author
12/21/2015 4
Annual carbon emissions from passenger vehicles are projected to climb +54% by 2030
Ref. Eichlseder & Wimmer (2005)
Upcoming technologies to replace current ICE (Fuel-Cell, Plug-in Electric and Hybrid)
New Technologies - infrastructure, fuel availability and cost level – Ref. Christidis (2003)
Continuity of ICE as the main propulsion system (Improved):
HCCI (Homogeneous Charge Compression Ignition), Carney (2008).
Engine Downsizing - DeCicco, et al. (2001)
Fuel Direct Injection - Leduc (2003)
IntroductionAutomotive Market Challenge
12/21/2015 5
Starting system remains basically the same for over a century
New Concepts => permanent connection by means of gear set or belt system
New requirements for SSV (Stop-Start Vehicles)
Potential SSV market share: 37 Mi in 2020 Ref. Pike Research (2012)
Objective:
propose and develop a new concept in Dynamic Coupling System (DCS), based on a permanently engaged connection between ICE and Starter Motor
IntroductionStarting Systems Evolution
12/21/2015 6
Stop Start Vehicles (SSV)Concept Overview
- Electronic Management SystemControls automatic stop and start of the ICE
- SSV 1st Generation:
To Shutdown engine:Vehicle is stationaryGear in neutralBattery has enough power for next engine start up... Any additional strategy
To turn engine back on:First gear engagedTemp inside vehicle...
12/21/2015 7
GR Starter PLGR Starter PMOSGR Starter
OSGR Starter
DD Starter
Main structure:
• Electric Starter Motor• Control systems (solenoid, relay, ...)• Battery• Wiring (control circuit, battery poles +/- )
Product design evolution / Application Specific
Stop Start Vehicles (SSV)Starting System Overview
12/21/2015 8
Starting failure (milling)Starting Engagement
Stop Start Vehicles (SSV)Starting System Overview
12/21/2015 9
Stop Start Vehicles (SSV)Dynamic Coupling System (DCS)
• Mechanical components
• Connecting Electric motor armatureto ICE crankshaft
• Power transmission
12/21/2015 10
Conventional Starter Improved Starter with Tamdem Solenoid
Permanently Engaged Starter
Belt Starter/Alternator (BAS)
Stop Start Vehicles (SSV)DCS Generic Types
PES – wet sprag clutch inside engine block PES – dry sprag clutch in
flywheel
Patent search
12/21/2015 11
New DCS Concept
Ring gear with internal or external gear teeth profile (1)
ICE flywheel (2)
Pinion gear (3) fixed in the armature shaft of the electric starter motor (4)
Permanently Engaged System between internal gear (5) and pinion (3)
Ring gear (1) has also na external ratchet or wedge profile (6)
Ratchet profile to engage to one or more pawls or mechanical diodes (7)
Pawl mounted in the flywheel subsystem (2) of the ICE crankshaft (8)
Damping system – CRITICAL DESIGN VARIABLE
Patent pending design in 2012 (INPI BR102012029979-8)
Patent Application
sketch
Innovative DCS Concept
12/21/2015 12
Subsystems
Assembly View
1) OWC Carrier System ( carrier / pawl / spring / pin)
2) Damping System ( arc springs / endstops / retainer / fasteners)
3) Flywheel System (Flywheel / Ring gear / Ratchet Profile / Bearing or Bushing)
4) Starter Motor Interface (armature shaft end / pinion)
Exploded View
Innovative DCS Concept - Subsystems / Components
12/21/2015 13
Innovative DCS Concept – Damping System
• Pawl-Ratchet OWC carrier (1) inside the flywheel (High Torque Capacity)
• Damping System for noise/vibration attenuation => arc springs (1) and carrier friction (2)
• Overrunning noise reduced by adjusted centrifugal effect and damping surface in pawl (3)
25
24
232122
20
1211
13
16
14
50
171840
(3)
(1)
(2)
Damping System for the Pawl-Ratchet OWC
12/21/2015 14
Simulation Model: Block Diagram
Fig 3 – Schematic of the Simulation Model for OWC damping performance
• Input / Output
• One-Way Clutch Model (simplified)
• Damping system effect in OWC
12/21/2015 15
Simulation Model: 1-D System
• 1st step: Lumped Parameter Sketch
• 2nd step: Mathmatical Models
• Model 1: OWC w/o damping system
• Model 2: OWC with damping system
(1)
(2)
Impulse = variation in quantity of movement
Pawl – Force (F) from torque TS;
TS => applied during t
Maximum distance X
Te to rotate flywheel (ICE crankshaft)
12/21/2015 16
• 3rd step: Parameter configuration
• 4th step: Simulation
• Simulation Results:
Simulation Results
CONCLUSION:with adjusted
damping system: 90% less impact
force!
12 kN peakimpact force
1.5 kN peakimpact force
12/21/2015 17
Proposed configuration
Current configuration
starter motor proposed changes:
lever – removed
solenoid plunger - removed
New positioning frame
Flywheel modification
Integrated OWC
Integrated damping system
Ring gear modification
Bearing support
External ratchet/wedge profile
Internal spur gear profile
Engine Test Bench VW EA111 – 1.6l/gasoline/4 cylValeo starter motor D7ES6
Current starter
Pinion - ModifiedModified Flywheel w/ ring gear
Experimental Results – Prototype Construction
12/21/2015 18
• DCS Prototype installed in ICE test bench
• Instrumentation (engine RPM)
• Succesful engine startup:
+100 starts during preliminary testing
• Noise evaluation:
DCS : 89 dB(A) max.
Conventional: 94 dB(A) max.
Experimental Results – Performance
12/21/2015 19
• Reduced starting cycle
DCS
~ 0.3s~ 0.8s
Conventional
Experimental Results – Cycle Time
12/21/2015 20
Aid of 1-D simulation to develop innovative products
Impact during engagement solved by a damping system => innovative DCS design
Experimental prototype confirmed system potential
NEXT STEPS:
Further refinement of the system – Durability targets
Both technical & economical validation of the system
Further research as a potential contribution to SSV emissions reduction
Conclusions & Further Research
12/21/2015 21
Thank you!
Alvaro Michelotti, M.Eng.R&D Technical Specialist
Tel +55-47-3255-2899www.zensa.com.br