Release bearing travel control to avoid clutch pressure

Title
plate breakage on 709/909/1109BSII/BSIII vehicles
Doc no DFSS 282

IDENTIFY Project Champion Mr.Sarang Kavishwar Date

Project Sponser Mr.Garg
Mr.Kavishwar(VEH-I)
Mr.Peshwe(QA)
CFT members
Mr.shirodkar(QA)
Mr.panse(service)
clutch release bearing travel control between 10-13mm
Scope of work
during clutch disenguagement
Target outcome Release brg travel control 10-13mm,pedal effort

Required time 1month

start date 1/2/2011
No major modifications
easy of retrofitment in field if required
Constraints No disturbance to Booster as a feature

15
14
13
Engineering parameters

12
11
10

House of Quality
DEFINE

9
8
7
6
5
4
3
2
1
behaviour
Pneu. piston dia
Customer priority

Hydraulic ratio
Pedal Travel

Air pressure
Pedal ratio
Fork ratio

Free play

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Engineering parameters 5
 Release brg travel
5
control10-12mm

Customer requirement Pedal effort <15kg 4

Target parameters Customer voice

1
2
3 benchmarking
4
5
 DFSS 28212901

customer response

Loss function
2.5

OK OK

2
House of Quality

rlz brg travel C.R

1.5 9.8 0
10 2
Border case
10.2 2
1
10.4 2
10.6 2
10.8 2
0.5
11 2
not acceptable not acceptable
11.2 2
11.4 2
0
9 9.5
11.6
10 10.5
2
11 11.5 12 12.5 13 13.5
11.8 rlz brg
2 travel
12 2
12.2 1
12.4 1
12.6 1
12.8 1
4 3 2 1 13 1
 13.2 0

Customer voice

benchmarking
 BASE DESIGN Concept1

Base design

Pedal ratio 5.78

Hydraulic ratio 1.35
Criteria Fork ratio 0.96 Adjustable push rod length
Pedal Travel 110
Floor stopper
release brg travel between 10-12mm fixed push rod length +
easy to implement solution for
production and in field
+
No additional chassis line activity -
Cost effective +
short implementation time +
solution effective in buses after body
building
+
No adjustment/setting by
customer/service
-
Possibility of clutch life deterioration -
Free play adjustment -
Σ─ 4
Σ+ 5
ΣS 0
 Final selected
Concept2 Concept3 Concept4 Concept5 Concept6 concept Hybridation

rlz brg travel

increased
stopper Stopper controlled indicator Stopper on pedal
accuracy Stopper on pedal
on fork on pedal pneumatic with support+stopper for
on floor support
ball end support stroke adjustment free play adjustment
stopper
of stroke
+ + + + + + +
- + - + - + +
- + + + - + +
+ + - - - + +
+ + - - - + +
+ + - + + + +

- + + + - + +
- + + + - + +
- - - - - + +
5 1 5 7 2 1 1
4 8 4 2 6 8 8
0 0 0 0 0 0 0
 Ideal function

release
brg
force
O/P x
travel
kgxmm

pedal
I/PforceXpedal travel
kgxmm

PARAMETER DIAGRAM
Mechanical
1] Mechanical Linkages.
2] Hydralic assistance.
3] Material and mount location.
4] Piping , connectors & joints .
5] Part design parameters.
6)Pneumatic assistance
Error states :-
A] Functional
1] Complete loss of Clutch control.
2] Engaugement and
Disengaugement not smooth.
3] Clutch pedal sticky.
4] Driver needs to push clutch pedal
all time whenever shifting the gears.
5]Clutch pedal free play incorrect.
6]Clutch control lever fouling.
7] Spring for thrust link broken.
B] Non-Functional
1] Noise.
2] Vibration/Shimmy.
3] Ergonomics

Control Factors

Signal
Response :-
Energy:-
Mechanical A] Response of the
input
(moment/force) CLUTCH output vehicle to clutch input
Hydraulic energy meeting the regulatory
CONTROL requirements.
Mass:-
Oil at required flow rate B] Feedback to driver
and pressure giving feel of the road.
Signal
Response :-
Energy:-
Mechanical A] Response of the
input
(moment/force) CLUTCH output vehicle to clutch input
Hydraulic energy meeting the regulatory
CONTROL requirements.
Mass:-
Oil at required flow rate B] Feedback to driver
and pressure giving feel of the road.

Noise Factors

Customer Usage
1] Mishandling.
Piece to piece Variation
2] Service damage.
1] Material
Assembly-
1] Dimension.
2] Misbuild.
System interactions
1]Chasis Frame.
External Environment 2] Gearbox.
1] Road load. 3] Cab system.
2] Salt /water.
3] Temperature
 Noise Factors affecting rlz brg travel Nominal Upper lim Lower limit
stopper location
1 Pedal Travel 100 .+3 .-3
variation
absence of rubber
10 NA
gromet
free play setting
8.67 17.37 5.79
variation
pedal initial height
279 2 -2
setting variation
2 Pedal ratio pedal length variation 5.789 5.83 5.75
3 Hydraulic ratio CMC dia variation 1.358 1.330 1.387
slave cylinder dia
1.334 1.383 1.334
variation
4 Mechanical ratio fork length variation 0.96 0.98 0.95
fork deflection 0.568 na

Control factors Pedal Travel variation

absence of
stopper locatn free play Pedal initial
1 Pedal travel rubber
variatn setting variation ht variation
gromet
N1 N2 N1 N1 N2 N1 N2
102
110
105
Pedal ratio Hydraulic ratio Mechanical
variation variation ratio variation

N1 N2 N1 N2 N1 N2
Beta (dB)

3.0
Beta Response Plot

2.8

2.5
 Beta (dB)
3.0
Beta Response Plot

2.8

2.5

2.3

2.0
A1 A2 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G

25
S/N Response Plot
S/N (dB)

20

15

10

5
A1 A2 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F
 S/N Beta

A1 0.00 0.00 0.00 0.00

A2 0.00 0.00 0.00 0.00

B1 0.00 0.00 0.00 0.00

B2 0.00 0.00 0.00 0.00
B3 0.00 0.00 0.00 0.00

C1 0.00 0.00 0.00 0.00

C2 0.00 0.00 0.00 0.00
C3 0.00 0.00 0.00 0.00

D1 0.00 0.00 0.00 0.00

D2 0.00 0.00 0.00 0.00

D3 0.00 0.00 0.00 0.00

E1 0.00 0.00 0.00 0.00

E2 0.00 0.00 0.00 0.00
E3 0.00 0.00 0.00 0.00

F1 0.00 0.00 0.00 0.00

F2 0.00 0.00 0.00 0.00
F3 0.00 0.00 0.00 0.00

G1 0.00 0.00 0.00 0.00

G2 0.00 0.00 0.00 0.00
G3 0.00 0.00 0.00 0.00
a Response Plot
a Response Plot
H1 0.00 0.00 0.00 0.00
H2 0.00 0.00 0.00 0.00
H3 0.00 0.00 0.00 0.00

2 D3 E1 E2 E3 F1 F2 F3 G1 G2G3 H1 H2 H3

Response Plot

E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3
 Predicte
d Actual
Tick mark Results results
Verification CAE analysis
Design
calculation
Assembly
Rig testing
Vehicle testing
Corelation
Measurement
other method

DESIGN REVIEW RECOR

TATA MOTORS PROJECT:

Design Review Stage :
ERC, Pune, Review Team :
Sl. Review points Expecte Decision
No. d taken
output /
 REVIEW RECORD Page No. 1 Of 1

Date of review completion:

tage :

Actions Constraints Target date Responsibility

planned
 LP709/42
Pedal Travel 100
Pedal Ratio 5.79
CMC Free play 1.5
Pedl travel lost due to free play 8.68
effective pedal travel 91.32
Master cylinder size 19.05
Slave cylinder size 22.2
Area of master cylinder 284.88
Area of Slave cylinder 386.88
Hydraulic ratio 1.36
distance pivot to rlz brg(x2) 146
distance pivot to fork end(x1) 151
Clutch release fork-ratio 0.97
Fork deflection 0.54
Master cylinder stroke 15.77
slave cylindr stroke 11.50

Release brg travel 11.89

mean 13.19 13.19
stopper location variation 13.6 12.82
rubber gromet absence 14.51 13.21
free play setg variatn 12.08 13.59
pedal ht variation 13.47 12.95
pedal ratio variatn 13.11 13.31
hyd ratio vartn due to cmc 13.49 12.93
hyd ratio vartn due to slave 12.97 13.45
fork ratio vartn 13.03 13.45
fork deflection 13.71

mean 11.89 11.89

stopper location variation 12.28 11.5
rubber gromet absence 13.19 11.89
free play setg variatn 12.27 10.76
pedal ht variation 12.15 11.63
pedal ratio variatn 11.8 11.98
hyd ratio vartn due to cmc 12.14 11.64
hyd ratio vartn due to slave 11.64 12.11
fork ratio vartn 11.73 12.1
fork deflection 12.37

mean 11.89 11.89 11.89

stopper location variation 12.28 11.5
free play setg variatn 12.27 11.89
pedal ht variation 12.15 11.63
pedal ratio variatn 11.8 11.98
14.26
 14.26
hyd ratio vartn due to cmc 12.14 11.64
hyd ratio vartn due to slave 11.64 12.11
fork ratio vartn 11.73 12.1
fork deflection 12.37
11.89

11.29
11.29
 100 pedal travel

13.5

13
rlz brg travel

12.5

12

upper
11.5 limit
lower limit

11

10.5

10

9.5
mean stopper rubber free play pedal ht pedal ratio hyd ratio hyd ratio fork ratio fork
location gromet setg variation variatn vartn due vartn due vartn deflection
variation absence variatn to cmc to slave
paramter vartn
 15
1
pedal travel
variation
1

14.5 1
1

1
1

total ratio
14 variation

4
4

13.5
44

44 fork deflection
13

pedal 5
5

6
6

travel 5
12.5 6
5

variation 5
6
5

2
2
3
12
3

2 3
100-1-27
2 3

2
2
3
3

11.5 total ratio 100-1.5-27.25

variation
100-1.-27.5
11
100-1.5-27
10.5
100-1.5.-27.5

10
100-1.25-27.25
0.8 1.8 2.8 3.8 4.8 5.8 6.8
 Noise factors 1 2 nom T1 T2
stopper location variation A +3 -3 130
free play setg variatn B -5.79 .-8.69 -0.869
15 .-5
pedal ht variation C +2 -2 279
absence of rubber stopper D 10 0 0
pedal ratio variatn E 5.83 5.75 5.79
hyd ratio vartn due to cmc F
1.412 1.306 1.36 8.07 7.13
hyd ratio vartn due to slave G
fork ratio vartn H 0.98 0.95 0.97
fork deflection I 0.568 0.49 0.53 0.568 0.49

Control factors 1 2 3
1 Pedal Travel A 100 105 110
2 free play stopper B 1 1.5 1.25
3 fork dia C 27 27.25 27.5

ORTHOGONAL ARRAY
Control Factors
Run A B C D E
1 1 1 1 1 1
2 1 1 2 2 2
3 1 1 3 3 3
4 1 2 1 1 2
5 1 2 2 2 3
6 1 2 3 3 1
7 1 3 1 2 1
8 1 3 2 3 2
9 1 3 3 1 3
10 2 1 1 3 3
11 2 1 2 1 1
12 2 1 3 2 2
13 2 2 1 2 3
14 2 2 2 3 1
15 2 2 3 1 2
16 2 3 1 3 2
17 2 3 2 1 3
18 2 3 3 2 1

Noise factors 1 2 nom T1 T2

stopper location variation A +1 -1 130

3 .-3
 free play setg variatn B -5.79 .-8.69 -0.869
3 .-3
pedal ht variation C +2 -2 279
absence of rubber stopper D 0 0 0
pedal ratio variatn E 5.83 5.79 5.79
hyd ratio vartn due to cmc F
1.412 1.306 1.36 8.07 7.13
hyd ratio vartn due to slave G
fork ratio vartn H 0.98 0.98 0.97
fork deflection I 0.568 0.49 0.53 0.568 0.49

ORTHOGONAL ARRAY
Control Factors
Run A B C D E
1 1 1 1 1 1
2 1 1 2 2 2
3 1 1 3 3 3
4 1 2 1 1 2
5 1 2 2 2 3
6 1 2 3 3 1
7 1 3 1 2 1
8 1 3 2 3 2
9 1 3 3 1 3
10 2 1 1 3 3
11 2 1 2 1 1
12 2 1 3 2 2
13 2 2 1 2 3
14 2 2 2 3 1
15 2 2 3 1 2
16 2 3 1 3 2
17 2 3 2 1 3
18 2 3 3 2 1
 B1
B1

L ARRAY
ctors Control Factor Level Engineering Units
F G H Run A B C D
1 1 1 1 100 1 27.0
2 2 2 2 100 1.5 27.3
3 3 3 3 100 1.25 27.5
2 3 3 4 105 1 27.0
3 1 1 5 105 1.5 27.3
1 2 2 6 105 1.25 27.5
3 2 3 7 110 1 27.3
1 3 1 8 110 1.5 27.5
2 1 2 9 110 1.25 27.0
2 2 1 10 100 1 27.5
3 3 2 11 100 1.5 27.0
1 1 3 12 100 1.25 27.3
1 3 2 13 105 1 27.3
2 1 3 14 105 1.5 27.5
3 2 1 15 105 1.25 27.0
3 1 2 16 110 1 27.5
1 2 3 17 110 1.5 27.0
2 3 1 18 110 1.25 27.3

13.5
Row
66
13 Row
67
Row
68
serie
12.5 4
serie
5
 13.5
Row
66
Row
13 67
Row
68
serie
12.5 4
serie
5

12

11.5

L ARRAY
11
ctors Control Factor Level Engineering Units
1 2 3 4 5 6
F G H Run A B C D
1 1 1 1 100 1 27.0
2 2 2 2 100 1.5 27.3
3 3 3 3 100 1.25 27.5
2 3 3 4 105 1 27.0
3 1 1 5 105 1.5 27.3
1 2 2 6 105 1.25 27.5
3 2 3 7 110 1 27.3
1 3 1 8 110 1.5 27.5
2 1 2 9 110 1.25 27.0
2 2 1 10 100 1 27.5
3 3 2 11 100 1.5 27.0
1 1 3 12 100 1.25 27.3
1 3 2 13 105 1 27.3
2 1 3 14 105 1.5 27.5
3 2 1 15 105 1.25 27.0
3 1 2 16 110 1 27.5
1 2 3 17 110 1.5 27.0
2 3 1 18 110 1.25 27.3
 Pedal Travel 110
Pedal Ratio 5.79
CMC Free play 1.25
Pedl travel lost due to free play 7.24
23.20
effective pedal travel 102.76
Master cylinder size 19.05
23.00 B3
Slave cylinder size 22.2
Area of master cylinder 284.88
22.80
Area of Slave cylinder 386.88

S/N db
Hydraulic ratio 1.36 D1
22.60 C1 C2
distance pivot to rlz brg(x2) 146
distance pivot to fork end(x1) 151 22.40 B2 D
Clutch release fork-ratio 0.97 +3 -3 130 15 .-5 C3
Fork deflection 0.47 -5.79 .-8.69
22.20 -0.869
Master cylinder stroke 17.75 +2 -2 B1 279
slave cylindr stroke 13.39 10 22.000 0

Release brg travel 13.80 5.83 5.75

21.80 5.79
8.07 7.13
1.412 1.306 1.36
21.60
C2 D3 0.98 0.95
B1 0.97 B3
B2 C1 C2 C3 D1 D2
C2 D3 0.568 0.49 0.53 0.568 0.49
0.535
15 .-5 8.07 7.13 0.568
ontrol Factor Level Engineering Units PEDAL TRAVEL TOTAL RATIO FORK DEFLECTION
Noise
E F N1 N2 M1 M2 O1
14.76 12.15 12.09 13.63 12.79
14.31 11.71 11.72 13.22 12.39
14.47 11.88 11.88 13.4 12.56
15.34 12.75 12.7 14.32 13.44
14.95 12.36 12.33 13.91 13.04
15.12 12.53 11.88 13.4 12.56
15.98 13.38 13.3 15 14.06
15.58 12.99 12.93 14.5 13.67
15.8 13.2 13.14 14.81 13.9
14.66 12.07 12.06 13.6 12.75
14.32 11.7 11.73 13.23 12.41
14.49 11.9 11.9 13.42 12.58
15.33 12.74 12.82 14.01 13.01
14.7 12.18 12.27 13.41 12.85
14.85 12.33 12.42 13.57 12.99
15.48 12.96 13.02 14.23 13.62
15.14 12.63 12.7 13.88 13.71
15.79 13.2 13.13 14.8 13.88

Baseline
Row design 15.65 13.06 13 14.66 13.71
66
Row
67
Row
68
series
4
series
5
 Row
66
optimised
Row design 14.28 11.69 12.09 11.7 12.37
67
Row
predicted
68 gain
series
4
series 27 0.56 0.49
5 27.25 0.54 0.47
27.5 0.52 0.45

3 .-3 8.07 7.13 0.568

ontrol Factor Level Engineering Units PEDAL TRAVEL TOTAL RATIO FORK DEFLECTION
3 4 5 6 Noise
E F N1 N2 M1 M2 O1
13.14 12.36 12.09 13.12 12.66
12.75 11.97 11.72 12.85 12.39
12.93 12.14 11.88 13.03 12.56
13.78 13.01 12.7 13.93 13.44
13.4 12.62 11.96 13.12 12.65
13.57 12.79 12.49 13.7 13.21
14.21 13.44 13.1 14.38 13.86
14.03 13.25 12.93 14.18 13.67
14.24 13.47 13.14 14.41 13.9
13.1 12.33 12.06 13.22 12.75
12.76 11.98 11.73 12.86 12.86
13.13 12.35 12.08 13.24 12.77
13.77 13 12.69 13.92 13.42
13.38 12.6 12.31 13.5 13.02
13.6 12.82 12.52 13.73 13.25
14.4 13.62 13.28 14.57 14.6
14.03 13.25 12.93 14.18 14.21
14.23 13.46 13.13 14.4 13.88

Baseline design 15.65 13.06 13 14.66 13.71

optimised design 14.28 11.69 12.09 11.7 12.37

predicted gain
 14.20
14.00 3

Average
13.80
13.60
5
13.40 10
7 9
D1 2 11 Colum
13.20 6
C1 C2 n AU
13.00
D2 D3 12.80 1
C3
12.60
12.40
12.20
0 2 4 6 8 10 12
27
27.25
27.5
C1 C2 C3 D1 D2 D3

0.535
0.49
FORK DEFLECTION
O2 σ2 S/N Average stdev
12.72 1.03 22.15 13.023 1.0163 3.5 5.5
12.32 1.00 22.02 12.612 0.999668
12.49 1.00 22.14 12.780 0.9993
13.36 1.03 22.58 13.652 1.014464
12.97 1.02 22.38 13.260 1.008563
12.49 1.32 21.08 12.997 1.147461
13.99 1.06 22.84 14.285 1.030645
13.6 1.02 22.77 13.878 1.009107
13.82 1.05 22.79 14.112 1.024039
12.67 1.01 22.23 12.968 1.002944
12.34 1.00 22.00 12.622 1.002306
12.51 1.00 22.15 12.800 0.9993
12.94 1.04 22.42 13.475 1.019701
12.78 0.87 22.93 13.032 0.930407
12.92 0.87 23.01 13.180 0.93218
13.55 0.88 23.34 13.810 0.939745
13.64 0.84 23.43 13.617 0.917925
13.8 1.05 22.78 14.100 1.023269
22.50 13.34

13.64 1.05 22.688 13.95333 1.023947

 12.34 0.93 22.2121 12.41167 0.962111

0.47591 1.541667

0.49
FORK DEFLECTION
O2 σ2 S/N Average stdev S/N Avg
12.59 0.17 29.68 12.660 0.415163 A1 0.00 0.00
12.32 0.19 29.02 12.333 0.436379 A2 0.00 0.00
12.53 0.20 29.01 12.512 0.443505
13.36 0.21 29.24 13.370 0.461563 B1 28.99 12.57
12.58 0.25 28.17 12.722 0.496887 B2 29.02 13.12
13.14 0.21 29.17 13.150 0.457777 B3 28.83 13.83
13.78 0.23 29.26 13.795 0.474963
13.6 0.22 29.26 13.610 0.468402 C1 29.08 13.34
13.82 0.22 29.33 13.830 0.472271 C2 28.57 12.98
12.67 0.20 29.15 12.688 0.442602 C3 29.19 13.20
12.75 0.25 27.94 12.490 0.5004
12.7 0.20 29.13 12.712 0.444406 D1 28.88 13.22
13.34 0.21 29.23 13.357 0.461331 D2 29.02 13.12
12.95 0.20 29.14 12.960 0.452504 D3 28.94 13.18
13.18 0.21 29.18 13.183 0.458025
14.53 0.32 27.91 14.167 0.56955 E1 0.00 0.00
14.14 0.31 27.91 13.790 0.554941 E2 0.00 0.00
13.8 0.22 29.33 13.817 0.472045 E3 0.00 0.00
28.95 13.17
F1 0.00 0.00
13.64 1.05 22.688 13.95333 1.023947 F2 0.00 0.00
F3 0.00 0.00
12.34 0.93 22.2121 12.41167 0.962111
G1 0.00 0.00
0.47591 1.541667 G2 0.00 0.00
G3 0.00 0.00

H1 0.00 0.00
H2 0.00 0.00
H3 0.00 0.00
11 Colum
n AU

S/N Avg
A1 0.00 0.00 0.00 0.00
A2 0.00 0.00 0.00 0.00
12

B1 22.12 12.80 -0.39 -0.54

B2 22.40 13.27 -0.10 -0.08
B3 22.99 13.97 0.49 0.62

C1 22.59 13.54 0.09 0.19

C2 22.59 13.17 0.08 -0.17
C3 22.32 13.33 -0.18 -0.02

D1 22.66 13.37 0.16 0.02

D2 22.43 13.42 -0.07 0.08
D3 22.41 13.24 -0.09 -0.10

E1 0.00 0.00 0.00 0.00

E2 0.00 0.00 0.00 0.00
E3 0.00 0.00 0.00 0.00

F1 0.00 0.00 0.00 0.00

F2 0.00 0.00 0.00 0.00
F3 0.00 0.00 0.00 0.00

G1 0.00 0.00 0.00 0.00

G2 0.00 0.00 0.00 0.00
G3 0.00 0.00 0.00 0.00

H1 0.00 0.00 0.00 0.00

H2 0.00 0.00 0.00 0.00
H3 0.00 0.00 0.00 0.00
 14.00

13.50
0.00 0.00 13.00
0.00 0.00
Colum
12.50 n AM
28.99 12.57
29.02 13.12 12.00
28.83 13.83
11.50
B1 B2 B3 C1 C2 C3 D1 D2 D3
29.08 13.34
28.57 12.98
29.19 13.20
29.40
28.88 13.22 29.20
29.02 13.12
28.94 13.18 29.00

28.80 Colum
0.00 0.00 n AL
0.00 0.00 28.60
0.00 0.00
28.40
0.00 0.00
28.20
0.00 0.00
B1 B2 B3 C1 C2 C3 D1 D2 D3
0.00 0.00

0.00 0.00
0.00 0.00 B1 C3 D3
0.00 0.00
B1 C2 D2
0.00 0.00 B1 C2 D1
0.00 0.00
0.00 0.00
26073.82
278.3505 0.966887
8.66E+08

1.64E+09 0.52
0.527358 0.51 0.52
0.49
0.49 0.54
0.56 0.62
27 0.56 0.49
27.25 0.54 0.47
27.5 0.52 0.45
 110 pedal travel

14.5 1

3
13.5

12.5 4 upper
limit
lower limit
2

11.5

10.5

9.5
mean stopper rubber free play pedal ht pedal ratio hyd ratio hyd ratio fork ratio fork
location gromet setg variation variatn vartn due vartn due vartn deflection
variation absence variatn to cmc to slave