Modification of the dry clutch mechanism of the truck
As we all know, container trucks play a vital role in port logistics companies, serving as the bridge between terminal operations and on-site production. However, the Clutch system of Hongyan container trucks has long been a major pain point for operators. Traditionally, these trucks use dry friction plates, which are prone to rapid wear due to frequent starts and stops in the busy port environment. On average, each truck requires a clutch replacement every two to three months, making the maintenance process both time-consuming and costly. Every time the Gearbox needs to be removed, numerous auxiliary components must also be taken apart, and in some cases, two trucks are serviced at once, significantly disrupting daily operations.
Additionally, drivers reported that operating the clutch pedal was physically exhausting, increasing their workload and contributing to fatigue. The clutch bearing and guide seat often overheated and burned, while the clutch plates were worn down quickly. In severe cases, the flywheel even failed, leading to more serious mechanical issues. From both an economic and operational standpoint, it became clear that a significant overhaul of the clutch system was urgently needed.
To address this, we conducted extensive research into related technical manuals and thoroughly analyzed the clutch transmission mechanism and control system. Based on our findings, we decided to modify the clutch design to better suit the demanding conditions of the port environment.
The first step in the redesign involved re-evaluating the return spring. After long-term observation, we found that the main cause of bearing failure was the incomplete return of the separation bearing, which would then hit the pressure claw and rotate along with the plate. This led to excessive heat buildup and eventual burning. Additionally, when the vehicle was idling, the clutch plates were often in a semi-engaged state, accelerating wear. To solve this, we redesigned the guide seat, replaced the return spring with one having a higher elastic coefficient, and implemented regular lubrication of the guide seat shaft. This ensured the bearing returned quickly to its original position, preventing unnecessary contact and reducing wear on both the bearing and the clutch plates.
Next, we transitioned from an air-assisted system to a hydraulic control system. Initially, the air-assisted clutch still felt heavy during gear shifts, even when the air pressure reached 0.7MPa. This was due to issues such as insufficient spool stroke or poor valve closure. Replacing the booster cylinder only provided temporary relief, as the spool wore out quickly due to frequent use in the port. After careful analysis, we decided to switch to a hydraulic system. We modified the original air path and removed the assist cylinder and button valve. Instead, we installed a master cylinder under the clutch pedal in the cab and added a working cylinder next to the gearbox. We also rerouted the oil lines accordingly.
When the driver presses the clutch pedal, the master cylinder pushes the piston, forcing oil into the working cylinder. This creates hydraulic pressure that moves the piston rod, pushing the separation fork forward. The fork then rotates the separation bearing, which in turn pushes the pressure plate away from the clutch disc, disengaging the power transmission. When the driver releases the pedal, the return spring pulls the piston back, allowing the oil to flow back into the master cylinder. This brings the separation fork and bearing back to their original positions, reapplying pressure to the clutch disc and restoring power transfer.
After implementing these changes, the results were impressive. Clutch failures, particularly the burning of the separation bearing, were completely eliminated. The lifespan of the clutch plates increased significantly, from an average of three months to nine months. Based on calculations, this transformation saved a considerable amount of maintenance time and labor. Each truck now saves nearly 10,000 yuan annually in repair costs, and the risk of sudden breakdowns is greatly reduced. Overall, the modifications have made the operation of the container trucks more efficient, reliable, and driver-friendly.
Oshan Z6
Oshan Z6 PARTS
Chongqing Zhongheng Chuangxin Auto Parts Co., Ltd , https://www.zhcx-autoparts.com