Clutch Construction Operation Theory Support

1.
Clutch Construction Operation Theory Support
Clutch Construction and Operation

Automotive – Transmission Systems
This presentation will explore:

 Clutch Components and Construction
 Basic Clutch Operation
 Clutch Operating Mechanisms
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1. Clutch Construction Operation Theory Support
Reason For Clutches

Clutches are required in

automobiles that use a
manual transmission system.
They are used to provide a

drive link between the
engine and the transmission
system and are also used to
separate this link (disengage
the transmission).
Clutches allow a smooth take up of drive

so that the vehicle can be gradually
moved away from rest. This is done by
moderately slipping the clutch, as the
engine speed is increased.
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Reason For Clutches

The clutch also allows for a brief

disengagement between the
engine and gearbox for gear
changing, when in motion. This
must be done when changing up
or down through the gears.
The clutch also has to give a

temporary disconnection when
the vehicle is stopped in gear.
This situation may arise when
waiting at stop (traffic) lights or at
a road junction.
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Clutch Action
The action of a clutch can be simply Drive disc

demonstrated by the use of two discs. Input shaft to
transmission
One disc (drive disc) is attached to

the engine and is rotated by its
action. The other disc (driven disc)
is attached to the transmission
input shaft.
Engine Driven disc
When the driven disc is disconnected, no

drive is applied to the transmission.
However, if the driven disc is brought into
contact with the drive disc, friction between
the two discs causes the driven disc to
rotate. Therefore, power is transferred from
the engine to the transmission.
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Clutch System Parts

The clutch system consists

of five major components:
Release Clutch plate
the Flywheel, Clutch
(Friction or Driven) Plate, bearing
Pressure Plate Assembly, Clutch
Release (Throw-Out) housing
Bearing and Clutch Fork.
As the clutch system is Flywheel

situated between the engine
and the transmission, a clutch Pressure plate
housing is used to join the assembly
Clutch
transmission to the engine and fork
protect the clutch components
from the outside elements.
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Clutch System Parts - Clutch Plate

Also known as a clutch (or friction) Rivets

disc, the clutch plate is found Friction
material
between the flywheel & pressure Splined
plate and provides the friction hub
material required between these
two components.
The splines in the center of the

clutch plate mesh with the splines of
the transmission system's input shaft.
The diagram shows two discs of

frictional material. These are riveted to
the cushion spring plate on either side
of the friction ring. The friction discs
sometimes have grooves cut into them
to aid cooling of the material. 6 of 14
Clutch System Parts - Clutch Plate

The friction material is riveted to Cushion

cushioning springs that have a springs
slight curve in them. These
springs cushion the force as the
pressure plate pushes the clutch
plate onto the flywheel. Torsional
spring
The torsional (damping) springs

soften the torsional load applied to
the clutch plate as it first begins to
turn, so allowing a smooth take up
of drive. If this did not occur, a
juddering effect may be felt in Cushion
the vehicle. springs
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Clutch System Parts - Pressure Assembly

The pressure plate assembly is the

component used to push the clutch Pressure plate
plate onto the flywheel.
Cover
There are two types of pressure plate:
Coil Spring and Diaphragm Spring.
Both types of plate assembly have a

pressure plate, which is the part that
presses on to the clutch plate, and is
housed within a cover.
The coil spring type uses a number of

coil springs in order to push the
pressure plate against the clutch plate.
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Clutch System Parts - Pressure Assembly

The diaphragm spring pressure Cover

plate assembly uses a single dish-
shaped spring that is made of
several fingers.
These fingers connect to the outer

edge of the spring with an
opening at the center.
As the spring is pushed toward

the engine, the inner pivot ring Diaphragm
causes its outer edge to bend Pivot rings
spring
away from the engine and release
pressure from the pressure plate
and clutch plate. As the spring is
released, pressure is returned to
the pressure plate and clutch plate Pressure plate
via the outer pivot ring. 9 of 14
Clutch System Parts - Release Bearing

& Clutch Fork
The release (throw-out) bearing and Diaphragm spring

clutch fork are the components used to Clutch plate Release
move the pressure plate back and forth. bearing
As the clutch fork moves, it pivots and Gearbox

pushes the release bearing against the input shaft
diaphragm spring of the pressure
plate. This disengages the pressure
plate from the clutch plate and drive
is removed from the gearbox
(transmission) input shaft.
As the clutch fork moves in the other Clutch

direction, the release bearing removes fork
Flywheel
pressure from the diaphragm spring and
the clutch plate is engaged. Pressure plate
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Basic Clutch Operation

The clutch fork is operated by a pedal, which the driver presses with his/her
foot. As the driver presses on the pedal, a link (either mechanical or
hydraulic) moves the clutch fork, which in turn operates the release bearing
and disengages the clutch.
As the driver removes his/her foot from the pedal, the clutch is engaged
once more. The foot action should be smooth, especially when releasing
the pedal, otherwise a judder will be felt as the clutch is disengaged
and engaged.
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Basic Clutch Operation

Force at cable:
1 100N x 3 = 300N
4
3
1
Force at release bearing:
300N x 4 = 1200N 100N at pedal
The clutch must be easily operated from the driver's seat by a force low
enough to prevent the driver's leg from aching. This means that levers are
needed at both the pedal and release fork to increase the effort put on the
pedal by the driver.
The diagram to the right shows the driver applying a pressure of 100
Newtons (22.5 lb) to the clutch foot pedal.
This is multiplied by the pivot ratio of (3:1) on the pedal, to a force of 300
Newtons (67.5 lb) on the cable.
This leverage is then multiplied again by the pivot ratio on the clutch fork of
(4:1) to a force of 1200 Newtons (270 lb) at the release bearing. 12 of 14
Clutch Operating Mechanisms - Mechanical

The mechanically operated clutch

uses a multi-stranded steel wire Outer sheath
cable that is connected between
the clutch fork and clutch foot
pedal. The wire is protected by a
flexible outer sheath, which is
typically made of plastic.
As the clutch foot pedal is

depressed it pivots and pulls the
wire, which in turn pulls the clutch
fork. The clutch fork activates the
release bearing and the clutch is
disengaged. The return spring
Return spring
helps the clutch fork to return to its
rest position when the clutch foot Wire cable
pedal is released.
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Clutch Operating Mechanisms - Hydraulic

The hydraulically operated clutch

Master
has a pipe for fluid (usually brake cylinder
fluid) connected between the foot
pedal and clutch fork. It uses two
cylinders. At the clutch pedal is the
master cylinder, which incorporates Slave cylinder
a fluid reservoir and at the clutch
fork is the slave cylinder.
As the clutch pedal is depressed, Pipe

the master cylinder builds a
pressure in the system, activating
the slave cylinder. When the clutch
pedal is released, springs in the
cylinders and on the clutch pedal
(or clutch fork) help to return the
system to its rest position.
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Clutch Construction Operation Theory Support

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1.

Clutch Construction Operation Theory Support

Clutch Construction and Operation

This presentation will explore:

Reason For Clutches

Clutches are required in

They are used to provide a

Clutches allow a smooth take up of drive

Reason For Clutches

The clutch also allows for a brief

The clutch also has to give a

The action of a clutch can be simply Drive disc

One disc (drive disc) is attached to

When the driven disc is disconnected, no

Clutch System Parts

The clutch system consists

As the clutch system is Flywheel

Clutch System Parts - Clutch Plate

Also known as a clutch (or friction) Rivets

The splines in the center of the

The diagram shows two discs of

Clutch System Parts - Clutch Plate

The friction material is riveted to Cushion

The torsional (damping) springs

Clutch System Parts - Pressure Assembly

The pressure plate assembly is the

Both types of plate assembly have a

The coil spring type uses a number of

Clutch System Parts - Pressure Assembly

The diaphragm spring pressure Cover

These fingers connect to the outer

As the spring is pushed toward

Clutch System Parts - Release Bearing

The release (throw-out) bearing and Diaphragm spring

As the clutch fork moves, it pivots and Gearbox

As the clutch fork moves in the other Clutch

Basic Clutch Operation

Basic Clutch Operation

Clutch Operating Mechanisms - Mechanical

The mechanically operated clutch

As the clutch foot pedal is

Clutch Operating Mechanisms - Hydraulic

The hydraulically operated clutch

As the clutch pedal is depressed, Pipe

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