Experiencing Dynamics – Reliably Commercial Vehicle Powertrain Modules

Contents Powertrain innovations beyond tomorrow Clutch systems Clutch Disc Torsional damper InLine® Clutch Cover Twin-Disc Clutch XTend® Wear Compensation Power Take-Off Clutch ConAct®/XAct Pneumatic Clutch Actuation Clutch Facings Dual Mass Flywheel Torsional Damper HRTD – Belt Pulley Torsional Damper Clutch for Auxiliary Drives EVERYTHING IN SIGHT: ZF OVERALL EXPERTISE FOR COMMERCIAL VEHICLES THE RELIABLE PARTNER. In all regions of the world the amount of goods as well as the number of people being transported day by day is rapidly increasing. Clutch systems, transmissions and other ZF components...

Performance - comfort - environmental protection. Powertrain components and systems for commercial vehicles, developed and delivered by ZF, meet the wide-§ spread challenges of the highly complex interface between engine and transmission — ~ ~ n, . POWERTRAIN SOLUTIONS FOR ALL PURPOSES The demands placed on suppliers are undergoing change at a fundamental level. Suppliers are increasingly expected to integrate components into complex systems - a task that can only be mastered in close developmental partnerships with the vehicle manufacturers. In the future, fuel consumption, emissions, weight,...

Clutch Systems Clutch systems “Made by ZF”, always the right partner No matter which application, a ZF clutch system, sold under the traditional and renowned brand name “Sachs”, is designed to offer the perfect solution for the very different needs in the transportation industry across the globe. The ZF commercial vehicle modu- to many highly dynamic influences. lar clutch system offers the perfect clutch for every vehicle from light- wear of the clutch facing leads to duty delivery trucks through buses changes in the force and travel con- and coaches up to heavy automated ditions, which must...

Clutch Disc Torsional Damper 285 The clutch disc, at the interface between engine and Modern powertrains more and more use down- transmission, is one of the most heavily stressed com- speeding as a measure to increase fuel efficiency and ponents in the powertrain and consists of the toothed reduce CO2 emission. But operating a vehicle at a lower sliding hub, the torsional damper, and the clutch fac- engine speed automatically increases the workload ings with cushion springs. The cushion springs ensure of the torsional damper in the clutch disc by shifting a prolongation of the engagement travel...

The clutch cover is screwed to the flywheel and, when engaged, transmits the engine torque to the clutch disc via the housing, the tangential leaf springs and the pressure plate. For the dimensioning of the clutch cover, important factors such as the heat capacity of the pressure plate as well as the clamp load and release load of the diaphragm spring are considered. Diaphragm springs are belleville springs with integrated actuating levers, the diaphragm spring fingers. The housing and the pressure plate are connected by riveted leaf springs, the so-called tangential leaf springs. Due to their...

XTend® WEAR COMPENSATION Heavy vehicles, rough terrain - the clutch is subject to extreme loads here, where drive-o s on extreme gradients and frequent maneuvering can be part of the daily routine. Long slipping times of the clutch generate heat, which increases wear on the facings to a disproportionate degree. With twice the number of friction surfaces and a greater heat absorption capacity, a twin-disc clutch can “keep cool” and protect its friction facings even under di cult conditions. The intelligent ZF intermediate-plate control mechanism ensures reliable interruption of the power flow...

POWER FOR EVERY MISSION ■ For use with gearboxes with engine-dependent auxiliary drives, e.g. ZF NMV 221 ■ The auxiliary drive can be operated independently of clutch actuation, both in stationary and moving vehicles ■ Power take-off via the auxiliary drive possible up to maximum engine torque ■ Integrated, two-stage torsional damper in auxiliary drive reduces vibrations ■ Also available as a twin-disc clutch ■ Also available in other sizes Auxiliary drives allow the engine torque to be used for other jobs than just driving the vehicle. Typical use cases are drives for cement mixer drums, fire...

ConAct® pNEUMATIC cLUTCH aCTUATION ZF has replaced the common fork type actuation with ConAct® is suitable for fully automatic operation and the clutch booster, the fork, and the releaser by a pneu- clutch-by-wire applications. In the application with matic release cylinder concentric with the transmission automatic transmissions, the system automatically de- input shaft. This permits the elimination of all mechani- termines the ideal release position – even for challeng- cal and hydraulic connections as well as the clutch ing driving situations such as maneuvering, starting on booster, saving...

Releaser The classic releaser transmits the force of the static release fork to the diaphragm spring, which is rotating at engine speed. The release bearing must absorb high axial forces. In push-type actuation systems, the releaser rests on the tips of the diaphragm spring, but in pull-type systems, the releaser must be locked accordingly, which makes assembly somewhat more complex. Dust and deposits are a particular hazard for the highly Clutch Facings MAINTENANCE FREE CLUTCH ACTUATION For pull- and push-type clutch actuation systems The bearings are equipped with contact seals as well as a...

Dual Mass Flywheel Dual Mass Flywheel System Design A-A Higher torques and stricter emission controls are lead- A highly efficient, grease-filled spring and damping ing to an increasing excitation of the powertrain by system operates between the two masses. This means rotational irregularities. At the same time, the demands that the resonance speed of the Dual Mass Flywheel – are increasing for noise reduction and comfort as well in contrast to conventional clutch discs with torsional as the protection of the transmission and vibration-sen- dampers – lies below the engine’s idle speed. Secondary...