Belt Drive System

April, 2014
Belt Drive System
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Liaison Offices
Global Structure
Canadian Headquarters
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Commercially Confidential
April, 2014
April, 2014
Belt Drive System
ISO / TS 16949 REGISTERED • ISO 14001 REGISTERED • www.litens.com
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Belt drive systems
Belt drive systems in motor vehicles perform two tasks:
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The timing belt drive controls the valves by means of
a toothed belt which transmits the radial movement of
the crankshaft to the camshaft with a ratio of 2:1, thus
ensuring that piston motion and valve timing are
perfectly synchronised.
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The so-called accessory drive is used to drive
auxiliary equipment, such as alternator, coolant
pump, power steering pump or A/C compressor. This
function used to be performed by the V-ribbed belt
which ensured a nonpositive transmission of the
torque from the crankshaft to the alternator and the
coolant pump.
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4 June 2014
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Accessory Drive Systems – Low Tension (“Lean”) FEAD
Overrunning Alternator
Decoupler (OAD)
Accessory Drive Tensioner
or
Idler
TorqFiltr®
• Innovative technology pioneered by Litens
• High value approach to improve fuel economy and reduce emissions
• Friction reduced drive systems
• CO2 reductions from 1 – 5 gm/km
• Fuel economy improvement of ~ 1%-2%
• Well correlated predictive tools save time and money in development process
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Accessory Drive Tensioners
Benefits
Litens Automotive Group
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Global production platforms
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Design flexibility for all applications
Stable and reliable damping over time
Long life and wear resistance
Optimized belt life, wear compensation
Light weight
•
Optimized cost and quality
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TorqFiltr®
Benefits
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•
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Reduce dynamic and static belt tensions
Fuel economy improvement of ~ 1%
CO2 reduction by 1 – 5 g/km
Lower loads on front crank shaft bearing at
startup
•
Improved durability
Reduce system hub loads
Improved NVH
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Overrunning Alternator Decoupler
Benefits
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•
•
•
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•
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Eliminates inertia based resonance
Reduces dynamic and static belt tensions
Fuel economy improvement of ~ 1%
CO2 reduction by 1 – 5 g/km
Improved NVH
Can reduce belt slip, chirp and flutter
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Summary
Accessory Drive Vibration Control:
• Wide ranging benefits for modern engines.
• Cost effective.
• Fuel economy improvement tool.
• OAD when the alternator dominates the system.
• TorqFiltr® for entire system isolation.
• 3 and 4 cylinder high powered engines.
• Isolate the FEAD from the engine.
• TorqFiltr® does not require OAD or OAP
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Page 10
Alternator Pulley Evolution
V-Belt
Poly V-Belt
 Common pre 1979
system
 Limited drive capability
 Several belts used
 High maintenance lock
center systems
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 Introduced on the 1979
Mustang and quickly
became the new
standard in the
automotive industry
 Capable of driving all
accessories with one
belt
 Perfectly suited for
FWD transverse
engines
 Perfect match for
automatic tensioners
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OAP
 Overrunning Alternator
Pulley
 Industry trend to use
larger alternators with
more mass caused belt
chirp noises during
shifting and engine
shutdown
 A one-way clutch inside
the alternator pulley
allows the alternator
rotor to overrun during
these conditions
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OAD
 Industry trend continued
with larger alternators
and smaller engines
(including more diesels)
 Carmakers reduced idle
speed requirements to
improve fuel economy
 These trends caused
new problems such as
belt slip, belt wear,
component bearing
durability and NVH
 Only the Litens OAD
provides the isolation
required to solve the
new challenges
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4 June 2014
Page 11
OAD Design
OAD transfers torque from the engine
to the alternator via the belt, provide
overrunning function and absorb
engine vibrations. They have two
differentiating components over solid
pulleys:
Adapter
Pulley
1) One-way clutch
2) Tuned steel torsion spring
Ball Bearing
Thrust Plate
Thrust Washer
Clutch Assembly
Spring
Shaft
The spring is the
key to the energy
absorbtion!
Bushing
Cap
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OAD Overrunning Function
• Allows the alternator to gently coast to
stop at engine shut down
• Overrunning feature also occurs during
transmission shifting
• Allows the rotor of the alternator to
actually spin faster (or play catch up to
the engine deceleration rate)
• Eliminates chirp noise
Thanks to the internal clutch the alternator gently coasts to a stop
when the engine is shut off!
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Torsional Vibration
rpm
• Each time a cylinder fires, the
crankshaft speeds up and slows
down a little bit. These firing pulses
are known as Torsional Vibration.
• The lower the RPM, the higher the
Torsional Vibration will be.
• It is these firing pulses that act on the
alternator rotor, trying to speed it up
and slow it down several times
during every revolution of the engine.
Torsional Vibration
torsional vibration
amplitude;
rpm (max-min)
engine rotation
speed; rpm
time
Pulse Amplitude:
• Increases with Engine Power.
• Decreases as Engine rpm Increases.
• Without the Litens OAD, these
pulses cause the belt tensioner to
exhibit increased movement.
• Increased tensioner movement
equals less durability for the
tensioner and belt, as well as all the
other components within the belt
drive system.
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OAD Isolating Function
• The Litens OAD has a patented steel
torsion spring inside. This is the secret
to the higher level of function that the
Litens OAD is world famous for. This
spring connects the alternator pulley to
the rotor. Think of it as a “suspension
system” for the alternator.
This
“suspension system” is needed
because of something called Torsional
Vibration (TV). TV, acting on the
alternator inertia, will seriously affect
the belt drive system durability as well
as the NVH felt by the driver.
Thanks to the internal steel torsion spring, the Litens OAD is able to
effectively absorb the torsional vibrations created by the combustion
cycle of the engine!
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Visnova OAP vs. Litens OAD
Litens durability test with alternator loading
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Page 16
Why Use an OAD?

Litens Overrunning Alternator Decoupler (OAD) is a unique engine belt drive tuning
device that can provide numerous significant benefits in a variety of engine and vehicle
applications. These include:
• Provide wide ranging benefit to the FEAD system
• Control resonance of alternator below the operating speed range
• Extended belt life and increased drive system component durability, by up to 2x
• Reduce dynamic torque and belt tension fluctuation= Extended tensioner life
• Quieter accessory drive system operation
• Smoother accessory drive system operation
• Reduced vibrations in passenger compartment
• Can improve fuel mileage 1-2%, depending on application.
• Proven in production
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Comparison Test OAP vs. OAD
Ford Transit 2.4D (Puma engine), MY 2001, Bosch Alternator, Litens OAD 920574
Test setup: lugging, full alternator load, A/C on, steering pump working
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Are you using the correct alternator pulley?
• A Litens OAD is similar in appearance to other pulley designs but plays a vital
role in absorbing vibration within the belt drive system. When replacing an
Litens OAD equipped alternator, the only acceptable choice is another Litens
OAD equipped unit.
Always replace Original Equipment (OE) design with OE design. After all,
your reputation is stake.
• Always decide on OE quality, independently if it is an OAD or an OAP – never
replace with a low cost replacement part.
• Using the correct OE technology and quality will extend bearing life, add to
tensioner durability, control belt noise and vibration and increase fuel
economy.
• To protect the accessory drive and your reputation… Always replace the
alternator pulley with the exact product type.
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Page 19
The Accessory Drive as a System
Observation:
• Extremely worn ADT (relation wear/part mileage)
• Broken ADT (tensioner arm/housing)
Conclusion:
• Usage of solid pulley instead of correct alternator technology
• Usage of OAP instead of OAD on OAD applications
• Missing maintenance/check of worn out OAP/OAD
Comment:
• OAP/OAD is a wearable item, which has to be regularly checked for
proper function
• The accessory drive is an engineered system, in which all components
are dependent on one another
• Replace alternator pulley with the proper OE technology (OAP  OAP
and OAD  OAD)
INA OAP
Litens OAD
Broken ADT due to wrong Alternator Pulley Technology or missing Maintenance/Check of worn out OAP or OAD
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Thank you for your attention!
Thank you
Questions and Answer?
Visit us at our booth no. 24
www.litens-aftermarket.com
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4 June 2014