Modification of the dry clutch mechanism of the truck
Container trucks are essential in port logistics operations, serving as a vital link between terminal frontiers and production sites. However, the Clutch system of Hongyan container trucks, which uses dry friction plates, has proven problematic due to the high frequency of starts and stops in the busy port environment. This leads to excessive wear on the clutch plates, requiring replacement every two to three months. The replacement process is cumbersome, involving the removal of numerous auxiliary components and often requiring two trucks to be serviced at once, significantly impacting production efficiency. Additionally, drivers find it physically exhausting to operate the clutch pedal during each shift, increasing their workload. Issues such as burned clutch bearings, damaged guide seats, ablated clutch plates, and even flywheel failures have become common, making an urgent need for improvement.
To address these challenges, we reviewed relevant technical literature and thoroughly analyzed the clutch transmission mechanism and control system. We decided to modify the clutch system to better suit the demanding conditions of the port area.
First, we re-evaluated the return spring mechanism. Long-term observation revealed that the main cause of bearing failure was incomplete return of the separation bearing, leading to contact with the pressure claw and subsequent overheating. To solve this, we redesigned the guide seat and replaced the return spring with one having a higher elastic coefficient, increasing from two to four. Regular lubrication of the guide seat shaft was also implemented to ensure quick and complete return of the bearing, reducing the risk of burning and minimizing clutch plate wear.
Second, we transitioned from air-assisted to hydraulic control. Initially, after replacing the booster cylinder, the problem was only temporarily resolved. Due to frequent clutch use in the port, the booster valve spool wore quickly, causing the pedal to remain heavy. Through detailed observation and analysis, we decided to implement a hydraulic control system. We modified the original air path and removed the booster cylinder and button valve. A master cylinder was installed at the bottom of the clutch pedal in the cabin, while a working cylinder was added next to the Gearbox. The oil lines were rerouted accordingly.
When the driver presses the clutch pedal, the master cylinder pushes the piston, forcing oil into the working cylinder. This increases the oil pressure, moving the piston and rod of the working cylinder, which in turn rotates the separation fork, pushing the bearing forward. This action separates the pressure plate from the clutch disc, cutting off power transmission. When the pedal is released, the return spring pulls the piston back, allowing oil to flow back to the master cylinder, and the system returns to its original position, reapplying pressure to the clutch disc.
After implementing these changes, the results were significant. The clutch no longer experienced bearing burnout, and the life of the clutch plates was extended from an average of three months to nine months. Based on calculations, this transformation saves a considerable amount of maintenance time and reduces repair costs by nearly 10,000 yuan per vehicle annually, eliminating previous concerns about reliability and performance.
Auto Body Parts
Auto Body Parts
Chongqing Zhongheng Chuangxin Auto Parts Co., Ltd , https://www.zhcx-autoparts.com