Overrunning Alternator Pulley

Transcription

Schaeffler Automotive Aftermarket
INA Overrunning Alternator Pulleys
REMATEC 2009 June 9th.
26 Locations – 1.000 Employees – Acting Globally
D. Wolff
Headquarters in Langen, Germany
D. Wolff
INA Overrunning Alternator Pulley
(OAP)
Variety of applications
D. Wolff
Overrunning Alternator Pulleys
Volumes
Evolution since Market Introduction
10.000.000
9000000
9.000.000
8.400.000
8.000.000
sales pcs. per year
7.470.000
7.000.000
6.000.000
5.000.000
>100 Mio. since 1995!
5.560.000
4.232.000
4.000.000
2.850.000
3.000.000
1.956.000
2.000.000
952.000
1.000.000
495.000
30.000
0
1995
1996
D. Wolff
1997
1998
1999
2000
2001
2002
prog.2003
forecast 2004
Overrunning Alternator Pulleys
Market Position - Product Range
Ø INA/Schaeffler is the #1 OEM/OES supplier worldwide with 85% market share!
Ø Every 2nd. vehicle in Europe is equiped with an INA OAP
Ø More than 140 different INA OAP´s available
Ø INA OAP´s are patented products
Ø Applications for all major Alternator manufacturers such as:
D. Wolff
Motivation
Decoupling of alternator mass
from torsional vibrations resulting
from the combustion process
à Improved behaviour of FEAD
D. Wolff
Motivation
I
II
Benefits
nmot
nmot
ignition causes
acceleration
compression causes
deceleration
belt:
- reduction of belt vibrations / force level
- avoid slipage at deceleration (gear shift 1-2)
tensioning system:
alternator shaft
- reduced forces and displacement
alternator:
- reduced load on alternator bearings
- rotor is uncoupled
alternator pulley
D. Wolff
system:
- extended system life
- improved NVH
- reduced consumption and emissions
Reason for decoupling the alternator
• alternator has the highest inertia moment in FEAD
• ratio of approx. 2.5 to 3 between engine and alternator speed
• increasing electrical power consumption
alternators with higher inertia moment
functional limit of the belt drive is exceeded
Solution: decoupling by Overrunning Alternator Pulley
D. Wolff
OAP Installation Example
Locating bearing
Shaft
•
Dust cover
Overrunning
alternator pulley
D. Wolff
Design
cross section: clutch unit
pulley
drawn outer
ring
cage
hub
spline for
assembly
drawn inner ring
with ramp profile
protection
cap
contact seal
washer
with seal
clamping roller
radial needle
roller bearings
D. Wolff
spring
Modular design
sealing ring
hub
clutch unit
pulley
sealing frontside
cap
outer sleeve
support bearing
clutch cage
needle rollers
support bearing 2
inner sleeve with
ramp profile
D. Wolff
Function
inner and outer
sleeves with clamping
needles
speed [rpm]
alternator
shaft
alternator
pulley
time [s]
D. Wolff
Advantages
- Reduced effect of alternator on belt drive
- Use of alternators with increased mass inertia
- Stabilisation of belt vibrations
-Reduced force level on the belt
- Reduced tensioning forces
and travel on tensioner
-Increased service life on
belt and tensioner system
- Extended system life
- Cost-effective solution compared to crankshaft-decoupling - Improved noise behavior
- Reduced consumption and emissions
- OAP protects the alternator bearings
D. Wolff
OEM Trends
Economy
♦ diesel engines, DI/TDI
♦ gasoline direct injection engines
♦ reduction of consumption and emissions
♦ reduced idle speed
→ high crankshaft torsional vibrations
Comfort
application of dual-mass flywheel
→ high crankshaft torsional vibrations
u
Electrical power consumption
♦ liquid-cooled alternators
♦ application of additional electric accessories
→ alternators with high inertia and high ratio
D. Wolff
• avoiding belt vibrations
• reduction of tensioner
forces/displacements
• avoiding steering shudder
• eliminating squeak noise at
WOT shift on automatic
transmission
→ reduced force level in
whole belt drive
→ extended belt/system life
→ improved NVH
(idle / start - stop)
References - Car Makers
Worldwide > 100 million INA OAPs
since start of mass procution
D. Wolff
Production Applications - Diesel Engines
Vehicle
Engine
Alternator
Alternator
supplier
SOP
9-5
3.0 V6
140A
Polo
1.9 SD / SDI
90A
Sharan,
Golf Variant / Cabriolet
1.9 TDI
Europe
A4
A3
1.9 TDI
1.9 TDI
90/120A
90/120A
Bosch
(F-225653.10)
Bosch
(F-226804.4/F-227628.6)
IV/95
II/96
Bravo / Brava / Marea
Multipla / New Punto
145/146/156/166
1.9 DS / 1.9 JTD
2.4 JTD
110A
Denso Italy
(F-230866.7)
120A
(EA180)
Plattform AB
Golf/Bora/Passat/
Oktavia/Felicia
1.9SDI/TDI
70/90/120A
Transport T4
2.5 TDI
150A
S40 / V40
F9Q 2000
120A
S60
2.4 D
140A
III/98
Lybra / Kappa
Focus
Fiesta
A-class
1.8 D
1.4 D
1.7 CDI
(OM668)
80A
90A/100A
(F-233608.1)
Visteon
(F-235492)
Valeo
(F-232030.5)
190A
Delphi
(OM611/612)
FGG
(F-229363.5)
V8 CDI
150A
Bosch
(OM628)
LIF
(F-230825.3)
Sprinter
CDI
(OM611)
120A
Viano (Van)
CDI
143A
D9, Z8, U6
2.0D-4cyl.
150A
Laguna
F9Q
120A
Laguna/Megane/Clio
F9Q euro 96
(TDI)
120A
C-class / E-class
S-class
2.2/2.7 CDI
90A
Denso Italy
D. Wolff
Bosch
(F-228824.6)
Bosch
(F-228824.6)
Valeo
(F-229603.7)
Valeo
(F-229643.7)
Valeo
(F-228881.2)
III/97
Avante XD,
Trajet XG, Santa Fe
2.0l D-Engine
90A/120A
Verna, Avante XD,
Lavita
1.5D-3cyl.
2.0D-4cyl.
90A/120A
Teracan
J3 - 2.9TDI
90A
Starex
2,5/2,9l A-Engine
110A
Carnival (KV-II)
J3 - 2.9TDI
90A
II/00
II/00
IV/95
Bosch
(F-226556.4/ F-230147.1)
Bosch
(F-225355.6)
Bosch/Hitachi/Valeo
(F-227628.6)
Bosch
(F-227820.8)
Valeo
(F-234637)
Bosch
(F-230401.8)
III/01
IV/95
II/96
II/97
II/98
I/00
IV/01
Asia
I/01
II/01
Bosch
(F-234563.1)
Istana
2.3D-4cyl./2.9D-5cyl.
Musso/Korando/Y200
(OM601/602)
II/96
I/99
P729
3.0 V6
140A
Carisma
F9Q 1999
120A
Terrano
ZD, L4 - 3L
100A
I/99
I/00
90A
Denso PS Korea
(F-233970)
Denso
(F-233106.1)
Denso PS Korea
(F-231618.1)
Valeo Mando
II/00
II/01
II/01
(F-232774.1)
IV/01
Denso PS / Valeo Mando
(F-231618.1)
III/99
KDAC
(F-225643.6)
Denso
(F-228411.2)
Valeo
(F-234637)
Hitachi
(F-228751.3)
III/98
II/00
I/00
III/98
America
Blazer S10
2.8D - 4cyl.
100A
Valeo
(F-233593)
I/00
Production Applications - Gasoline Engines
Vehicle
Engine
Alternator
Alternator
supplier
SOP
Europe
A3, A4, A6
B6
1.6/1.8L-5V
(EA113)
Asia
120A
(F-234739)
NG4
90/120A
Ferrari /
Maserati M138
4,2L F-136
150
Mondeo
1.8L / 2.0L
115A
Transit
2.3L DOHC
115A
X200
3.0L - V6
120A
1.9L
(M166 E19)
90A
Boxster (986),
Carrera (996)
3.2L / 3.4L
120A
Clio / Megane
1.4L / 1.6L
125A
Jetta, Passat
VR5 - 2.3L
120A
Sharan
1.8-5V Turbo
(EA113)
120A
V70 / S70
N2 - 5cyl.
120A
V40 / S40
N1 - 4cyl.
120A
D. Wolff
(F-226322.10)
Valeo
1.8L - 4cyl. -5V
316/318 ti
A-class
Bosch
Bosch/Valeo
(F-236528)
Denso
(F-233372.2)
Visteon
(F-232854.3)
Denso-Italy
(F-234359)
Denso
(F-230051)
Valeo
(F-230759.1)
Bosch
(F-233525.1)
Valeo
(F-235152.3)
Bosch
(F-230846.2)
Bosch
(F-227628.6)
Bosch
(F-230401)
Denso
(F-231108)
II/97
Altima
2.0/2.5 GDI
110A
Hitachi
(F-232288.1)
I/00
America
III/00
III/01
II/01
III/00
III/00
II/98
I/99
III/99
IV/00
III/97
IV/97
III/98
I/99
Navigator,
Falcon
DEW 98
3.0L V6
115A
Intrique
3.5L-V6 LX5
120A
Opel Astra
4-cyl.
120A
Visteon
(F-229974)
Delphi
(F-230753)
Bosch
(F-226962.5)
III/98
I/98
II/01
Belt Drive Systems
Overrrunning Alternator Pulleys Special Tools
INA 400 0201 10 Torx
INA 400 020 10 Muli-Teets
D. Wolff
Auxiliary Drive – Engine under Full Load WITHOUT OAP
D. Wolff
Auxiliary Drive – Engine under Full Load WITH OAP
D. Wolff
Wrong and right way to proceed
Use only
original
INA OAP
Wrong way to proceed
D. Wolff
Design comparison
INA
Competitor 1
Competitor 2
Competitor 3
Clamping needle
rollers: 19
Clamping needle
rollers: 6
Clamping needle
rollers: 6
Clamping needle
rollers: 6
Support bearings:
needle roller
Support bearings: ball
Support bearings: ball
Support bearings:
ball and plain
D. Wolff
Competitors – general durability results
1200
100%
100%
600
INA
INA
INA
800
INA
run time [h]
100%
100%
Target
July 2006
100%
INA
100%
1000
INA
GDT tests are stopped
at 100% of req. time
October 2008
400
Competitors
16,3%
200
11,2%
11,2%
4,6%
part number
status
specimen
5374
5378
5406
5406
slippage
slippage
slippage
rough
overrunning
functional
functional
functional
functional
functional
functional
H481
H482
K012
K013
G937
G938
G939
G940
G941
G942
D. Wolff
F-233197.07 F-233197.07 F-233197.07 F-233197.07 F-233197.07 F-233197.07
Competitors – after 4,6% run time - findings
Service life of the grease reached
Deep wear depressions and fatigue failure
D. Wolff
Competitors - after 16,3% run time - findings
Tribocorrosion on the inner ring
ball bearing – additive discoloration grease service life reached
clutch raceway: indentations,
fatigue
D. Wolff
Clutch needles - indentations and
fatigue
Competitors - Results of functional test at high speed
l No torque transmission at 8500 rpm
l Sudden torque impact at 6500 rpm
Alternator load: 80 Amp.
Alternator speed ( with INA OAP)
Alternator speed (Competior)
Pulley speed
* Alternator speed = engine speed x ratio (2,85)
D. Wolff
INA in Comparison to Copies
INA
Concept
Copies
Needle roller clutch with ramps on inner ring :
Good clamping security at higher rotational speed of
alternator (clamping needles are pressed into the
clamping ramps due to centrifual force)
Needle roller clutch with ramps on outer ring :
Bad clamping security at higher rotational speed of
alternator (clamping needles are pressed out of the
clamping ramps due to centrifual force).
The result is slippage and in consequence the failure of
the OAP
JJ
L
Continuous series-accompanying tests have been
Durability test at INA
showing a durability higher than 70% over OE
test bench
requirement
(GDT test)
(tests are stopped after this 70%)
Target run time:
600h
Several parts have been testet:
All tested parts failed (approx. 5% to 15%)
JJ
Max. alternator speed: 20.000 rpm
Maximum alternator/ Max. engine speed: 6.666 to 8.000 rpm (depending on
engine speed
ratio)
(average ratio: 2,5-3)
L
Max. alternator speed: about 9.000 rpm (slippage at
about 8.000 - 9000 rpm)
Max. engine speed: 3.000 to 3.600 rpm (depending on
ratio)
JJ
slippage =
no drive of the alternator (charging light on)
blockage =
Emergency running
operation like stiff pulley
properties in case of
failure of OAP
Field experience
L
J
L
Mass production experience since 1995
Approx. 100 millions OAPs in the field
No field experience known
JJ
D. Wolff
L
Service. Power. Partnership.
D. Wolff

Overrunning Alternator Pulley

Transcription

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