Hybrid Clutch

Assignment Working
BSc(Hons) in Mechanical Engineering/BTEC HND in

Mechanical Engineering
Task 1
Initial proposal briefing.
Hybrid clutch system for automobiles.
Introduction.
Clutch systems are available in almost every automobile around the world. Basically
clutch is a device used to couple two rotating shafts. In automobiles clutch is used to couple
and decouple the engine output shaft or the fly wheel to the gear box input shaft which will
engage and disengage in changing gears.
In vehicle clutches, it uses friction as the coupling method. Friction between two
rotating disks holds the coupling and keep the shafts rotating.
Main drawback of this friction coupling is ''wear". Due to the friction the rubbing
surfaces tends to wear with the time or with heavy use of the clutch in a bad manner, because
of this wearing slip between two coupling surfaces occur resulting the coupling to fail.
In this hybrid clutch system old conventional friction coupling is replaced by
magnetic and fluid coupling. Therefore Wearing between two faces have reduced drastically
ensuring the clutch system more reliable.
Concept.
A concept can be defined as a solution for an existing problem. So lets check what is
the reason for this newer clutch system or the problem with the old clutch system.
Initial problem: Conventional clutches depend on friction coupling. Friction between the
materials will wear the rubbing surfaces. In this case friction surface on the flywheel and
clutch plates as shown below.
Fly wheel friction surface
Figure 1: Fly wheel friction surface
Assignment Working
Therefore with the time this wearing effect due to friction cause slip between clutch plate and
the flywheel friction surface. So power losses will occur and performance of the vehicle get
Clutch plate friction

surface
Figure 2: Clutch plate friction

surface
Reduced. Also maintenance cost will increase due to the wearing of clutch plats and parts. So
this will arise two main problems,
1.) Reducing or preventing the wearing of clutch plates.
2.) Reducing energy losses due to friction and slip.
Solution: From the above given facts it is proven that reason for the above two problems are
mainly friction. So reducing the friction will reduce the wearing and also the slip and energy
losses. So following solution methods can be given.
1.) Power transmission without friction coupling.
As mentioned earlier in a clutch, power transmission occurs due to friction
coupling. Therefore if we replace this friction coupling from some other type
of coupling method such as fluid coupling, magnetic coupling and etc. these
frictional losses and slip can be prevented.
Assignment Working
Rationale.
This project involve about automobile power transmission. Automobile is known as a
sub part of mechanical engineering. All the mechanical engineering related fields such as
thermodynamics, mechanical principles & physics, electronics, energy management and
mechatronics are used in this project. As an examples, reducing energy losses belongs to
energy management and thermodynamics, power transmission methods are belong to
mechanical principles fields can be given. So this project is much related to mechanical
engineering.
Conducting literature review.
Before doing each and every project works it is obvious to read some quality literature
reviews. By reading them you can grab so many ideas and implement them in your way to
make your project a success. Therefore even for this project also it is a must to read a
literature review. So I can get the detailed knowledge about the functionality and the
integration of the parts associated with the clutch system.
After going through some literature reviews I could pin point the weak spots in
conventional clutch system and adjust them in my new design to get the maximum
performance out of the new design and achieve the goals of this project.
Benefits and Positive outcomes.
Benefits and positive outcomes can be listed as follows.
1.) Reducing maintenance costs for clutch system.
2.) Improved power transmission from engine output shaft to gear box input shaft.
3.) Cheap and reliable clutch system.
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Feasibility or the likelihood of the project being a success.
If any system which is already available in the automobile industry can be replaced by
a newer technologically advanced, reliable most importantly cheap, is much more favorable
to be a success system or a project. So with the newer design much reliable, cheap clutch
system can be identified and made.
Also the main fact is it can be used with an existing vehicle without doing costly
modifications. Implementation for a particular vehicle is easier. Not only on the conventional
combustion engine vehicles it can be used in modern hybrid vehicles as well. The most
supportive facts is the synergistic nature of the design easily support for implementation on
hybrid vehicles as well. Hybrid vehicle can be named as a mechatronic system. So the new
design is also a mechatronic system, therefore the two systems can be combined together to
make the overall system a success.
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Approach.
Reading of the automobile clutch systems, there mechanisms, operation, parts

involved and etc. will be carried out initially.
After getting a well understanding about the clutch, its operation different types of
clutch systems will be carried out.
Tabulation of the main problematic area of the conventional clutch system
Designing the new system to provide new solutions for conventional clutch issues.
Discuss about the new design with the field experts, engineers and technicians.
Getting the feedbacks and doing the refinements for the initial design.
Finalizing the new design.
Discuss about the final design with the field experts, engineers and technicians
Carry out the refinements and completing the new design.
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Cost.
Though this is a research and all the designing tasks were carried out virtually using CAD
softwares. Cost or the budget for the overall project can be negligible.
Timeline.
I was able to follow the agreed timeline accordingly and complete the project on time. The
timeline is shown below in the form of Gantt chart.
Table 1: Gantt chart
Standards
Though it is a mechatronic system it should be according to the correct standards. For this
kind of a system personal safety and the equipment safety is the major issue. So the wiring
and the other electronic systems needs to be done according to the corrects standards.
Probability for a power surge should be minimized. All these factors are considered during
the design phase of the new system. Other standards used can be given as,
ISO 3006:2015
Road vehicles -- Passenger car wheels for road use -- Test methods
ISO 10597:2012
Road vehicles -- Flat attachment fixing nuts for commercial vehicles -- Test methods
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Legislative issues
This project is heavily dependent on existing work done by other people and therefore
it was extremely important to use references and acknowledge the original authors so
that any legislative issues can be prevented.
On the design aspect of the project, since this is a system proposed for an automobile,
all the suggestions and findings of this projects should comply with current
automobile safety legislations if the project is to be recognized in the industry.
Ethics and social issues.

It is a common and general fact on society that when any principle or mechanism
sustain for a long period of time the people tends to think that it the correct mechanism or the
principle and they tend to forget downside of it by accepting it as the perfect solution.
Automobile clutch is also something that last for many decades. So people might
think that the new system can be much complex and generate issues with usage. But this
mindset can be rectified only by providing them the evidence for accept it. So to use this new
system proper information about the new system should be given for the people with practical
examples.
Sustainability.
Though the new system improves the vehicle performance and reduce the cost for
periodic and non-periodic maintenance of the available clutch system, it will make the people
to use it. Also it reduces the fuel consumption and increase the fuel efficiency as well. So
from these facts we can predict that the new design can sustain in the automobile industry.
Hardware requirements. (For the actual system)
Inductors or solenoids.
RPM sensor.
Ferromagnetic disk.
Torque converter.
Peltier devices.
Hoses.
Control circuit for the peltier device and for the inductors.
Power cutoff switches.
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Metal plates and mounts.
Task 2
HYBRID CLUTCH.
Project proposal.
Ramesh Jayashan Warusavitharana KTB/A-00061

BSc (Hons) in Mechanical Engineering/BTEC HND in Mechanical Engineering
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Assignment Working
INDEX
1. INTRODUCTION.
1.1 CONCEPT & INITIAL PROBLEM 10
1.2 SOLUTION.................11
2. AIMS & OBJECTIVES.
2.1 AIMS & OBJECTIVES..12

2.2 DELIVERABLES...13
2.3 TECHNICAL SPECIFICATION....13
3. PROJECT PLAN & TIMELINE.
3.1 GANTT CHART.14
3.2 MILESTONES .. 14
4. DISCUSSION AND CONCLUSION.
4.1 CURRENT STATE OF THE PROJECT.... 15
4.2 IMPLICATIONS OF THE REMAINDER OF THE PROJECT.20
4.3 PRACTICAL PROBLEMS AND UNSOLVED ISSUES...20
Assignment Working
INTRODUCTION.
Clutch systems are available in almost every automobile around the world. Basically clutch is
a device used to couple two rotating shafts. In automobiles clutch is used to couple and
decouple the engine output shaft or the fly wheel to the gear box input shaft which will
engage and disengage in changing gears.
In vehicle clutches, it uses friction as the coupling method. Friction between two
rotating disks holds the coupling and keep the shafts rotating.
Main drawback of this friction coupling is ''wear". Due to the friction the rubbing
surfaces tends to wear with the time or with heavy use of the clutch in a bad manner, because
of this wearing slip between two coupling surfaces occur resulting the coupling to fail.
In this hybrid clutch system old conventional friction coupling is replaced by
magnetic and fluid coupling. Therefore Wearing between two faces have reduced drastically
ensuring the clutch system more reliable.
1.1 CONCEPT AND INITIAL PROBLEM
A concept can be defined as a solution for an existing problem. So lets check what is
the reason for this newer clutch system or the problem with the old clutch system.
Initial problem: Conventional clutches depend on friction coupling. Friction between the
materials will wear the rubbing surfaces. In this case friction surface on the flywheel and
clutch plates as shown below.
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surface
Figure 4: Clutch plate friction surface
Therefore with the time this wearing effect due to friction cause slip between clutch plate and
the flywheel friction surface. So power losses will occur and performance of the vehicle get
reduced. Also maintenance cost will increase due to the wearing of clutch plats and parts. So
this will arise two main problems,
1.) Wearing of clutch plates.
2.) Reducing energy losses due to friction and slip.
1.2 SOLUTION
From the above given facts it is proven that reason for the above two problems are mainly
friction. So reducing the friction will reduce the wearing and also the slip and energy losses.
So following solution methods can be given.
2.) Power transmission without friction coupling.
As mentioned earlier in a clutch, power transmission occurs due to friction
coupling. Therefore if we replace this friction coupling from some other type
of coupling method such as fluid coupling, magnetic coupling and etc. these
frictional losses and slip can be prevented.
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2. AIMS AND OBJECTIVES.

2.1 AIMS & OBJECTIVES.
1. Study about vehicle clutch systems and understanding the drawbacks.
Before doing an engineering project it is a must to study about a similar project or a
research that has been done earlier by different communities, peoples or individuals. By
doing that we can get the idea of the way doing it.
In my project also I must learn as much as I can about vehicle clutch systems and
parts associated with it. By learning about them I can get to know their configurations or how
they work and operating principles as well as the theories behind them. After learning them I
can understand and pinpoint where the problems occur and what are the reasons for them. So
with better understanding of the problems I can provide solutions for that. Which is a main
objective of the project.
2. Learn about different type of sensors.
For this project RPM sensors and position sensors are needed therefore before
applying them in to the project I must know about the working principle of them, Accuracy,
Range, working environment properties and etc. to get the maximum performance out of
them without damaging other equipments and these sensors.
3. Designing a mechatronic system to get the work done with desired efficiency
levels.
In this project conventional clutch friction coupling is replaced by magnetic and fluid
coupling. Even though the methods have changed the work done by the clutch should also be
done with the new system. To do that work sensors, actuators and magnets and control
methods are used. Therefore to completely do the clutch action control system is also needed.
The actual coding is done on the engine ECU. But here only the flow diagram and the design
will be provided.
4. Minimizing the energy wastage and take the maximum energy from the wasting
energy such as heat and etc.
As mentioned earlier, the magnetic coupling is based on eddy currents. Therefore due
to eddy current formation the materials get heat up. So this heat goes away as waste energy.
But my idea is to capture this waste heat and use it to produce current using thermoelectricity
theories.
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5. Learn about thermoelectricity and apply them on this project.

In every automobile main energy wastage occur as heat. But in basic physics
principles such as seebeck effect, it denotes that with heat energy we can produce electricity.
So in this project my idea is to capture that waste heat and produce electricity to power up the
new system actuators as well as the other vehicle equipments.
2.2 DELIVERABLES.
The deliverable of this project will be a final project report thoroughly discussing how all the
above mentioned aims and objectives were achieved and the advantage of using the proposed
solution to overcome the initial problem.
2.3 TECHNICAL SPECIFICATIONS.
Following technical detail will be discussed in the project as follows.
Clutch assembly: The mechanism of the clutch assembly and the parts related to it
such as pressure plates, clutch plates, bearing will be discussed.
Torque converter: Operating principle of a torque converter, its mathematical and

fluid dynamic characteristics will be discussed.
Magnetic coupling: Theories related to magnetic coupling such as eddy currents will
be discussed. Implementation of the RPM sensor and its principles are discussed.
Thermoelectricity: Generation of electricity from heat and also about the peltier
devices and its operation principles are discussed.
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3. PROJECT PLAN AND TIMELINE

3.1 GANTT CHART
3.2 MILESTONES.
Studying and identification of issues with conventional clutch systems.

Designing of the new system.
Sensors and actuator selection.
Completion of the new design.
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4. DISCUSSION AND CONCLUTIONS.

4.1 CURRENT STATE OF THE PROJECT.
Study about vehicle clutch systems and understanding the drawbacks.

Conventional clutches depend on friction coupling. Friction between the materials will
wear the rubbing surfaces. In this case friction surface on the flywheel and clutch plates
as shown below.

surface
Figure 6: Clutch plate friction

surface
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Different types of clutch assemblies

Multi plate clutch.
In this assembly it has many clutch disks so it can transfer
power more precisly
while reducing the slip energy between the friction surfaces.
Figure 7: Multi plate clutch
Conical clutch
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1 Cones
2 Input shaft
3 Friction surface
4 Spring
5 Clutch control
mechanism
6 Rotating direction
Figure 8: Conical clutch
These clutches use conically shapped friction surface to transfer

power.Mostly they are used in racing cars.Because it has higher
surface area and you dont have to press the clutch pedal to it
maximum limit to shift gears.Therefore the gear changing action is
much faster and energy saving.
Centrifugal clutch
Figure 9: Centrifugal clutch
These clutches work based on centrifugal force. When the driving

shaft reached a specific speed, due to centrifugal force the friction
lining get contact with the driven shaft casing causing it to rotate
ultimately rotating the driven shaft or output shaft.
Now lets talk about what are the drawbacks or problems are occurred with conventional
clutches which were the reason for my new clutch design.
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What are the drawbacks of a conventional clutch system ?
Mainly there is a major drawback.As shown in the above different

clutch assemblies it uses the principles of friction to transfer
power.Thereforewhen the clutch get engagged and disengagged the
friction surfaces get rubbed against each other resulting the
material to wear easily.So when these friction surfaces are weared
the clutch assembly cannot perform its duty accurately and
precisely.So after some time you have to replace the clutch plates or
clutch packs, which means the maintainance cost is bit high for this
friction clutch assemblies. Also due to frictional wearing of the
materials the durability of the clutch assembly is also low. In most
automobiles clutch plates have to be replaced in every 1000020000 km. A vehicle which travels long distances have to spend
more expenses for clutch repairements and also if the driver is using
the clutch abruplty in a bad manner the wearing of the clutch is
high, therefore it reduces the life time of the clutch as well.
With the engagement and disengagement of the clutch the pressure

plates are also undergo cyclic forces. Eventually due to this cyclic
forces fatigue failures are occured in this pressure plates.
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Study about different type of rpm sensors.

RPM sensors: It can be inductive, Capacitive and Hall Effect sensor. But it is best to use a
Hall Effect sensor. Because as we know when at high speed operation Hall Effect sensors are
much more reliable though the other two sensor types which begins to distort in high speeds
or frequencies. Also capacitive sensors can get trigged by the dust. Hall Effect sensor
operating range is also high but they are bit costly than the other two sensor types. But Hall
Effect sensor system maintenance cost is low and you can get best performance too.
Figure 10: hall Effect RPM Sensor
Purpose of using this RPM sensor is to cutoff the power to the inductive coils during high
torque converter output shaft RPMs. The magnetic coupling system on the design provides
additional torque for the torque converter output shaft during the low RPMs because the
torque generated from the torque converter is not enough during the low rpms. Also it
increases the overall efficiency of the torque converter and the magnetic coupling system as
well.
So from the above details and facts it is obvious that the study of automobile clutch systems
are carried out according to the time line and also the study and the identification of the
needed sensors are also being carried out successfully.
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4.2 IMPLICATIONS OF THE REMAINDER OF THE PROJECT.

I have understood that the conventional systems has many drawbacks which can be reduced
or diminished by the new design. But the new design is a fully mechatronic system. So to
design the system further knowledge about mechatronic systems, actuators and sensors which
takes more time than intentioned. So after thoroughly going through the system design of a
mechatronic system the implementation of the new design should be initialized.
4.3 PRACTICAL PROBLEMS AND UNSOLVED ISSUES.
It is a common fact deigning of a new system in a physical world is challenging due to the
lack of physical resources we have and the testing methods to test and analyze the system. So
to test and analyze the design feedback from the field experts, engineers and technicians are
used. But due to the busy nature of the above mentioned people it has become hard to meet
and discuss with them. But I have already arranged some workshop visits and also meet them
in their homes as well so I can discuss and get the feedback from them. Its still being carried
out.
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Task 3
Hybrid Clutch.
PROJECT REPORT.
Ramesh Jayashan Warusavitharana KTB/A-00061

BSc (Hons) in Mechanical Engineering/BTEC HND in
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INDEX
1. INTRODUCTION AND THEORY.
1.1 INTRODUCTION 24
1.2 MECHANISM AND PARTS ...26
1.3 DIFFERENT TYPES OF CLUTCH
ASEMBLIES............................................31

2.1 AIMS & OBJECTIVES...35
2.2 DELIVERABLES36
2.3 TECHNICAL SPECIFICATIONS..36
3. PROJECT METHODOLOGY.
3.1 OVERALL DESIGN.37
3.2 METHODOLOGY....38
3.3 REDUCTION OF ENERGY WASTE AND INCREASING EFFICIENCY47
4. MATCHING AND UTILIZING THE RESOURCES.
4.1 ALLOCATED BUDGET 49
4.2 HARDWARE RESOURCES...49
4.3 HUMAN RESOURCES INVOLVED.49
4.4 TIME AGAINST AGREED TIMELINE.50
5. RESULTS AND FINDINGS.
5.1 PROJECT OUTCOMES. 51
5.2 ANALYSIS OF OUTCOMES.52
6. MEETING THE SPECIFICATIONS.
6.1 TECHNICAL SPECIFICATIONS..53
6.2 COST/BUDGET..53
6.3 TIMELINE...54
6.4 STANDARDS..54
6.5 LEGISLATIVE ISSUES AND REQUIREMENTS....55
6.6 ETHICS AND SOCIAL ISSUES....55
6.7 SUSTAINABILITY.55
7. DISCUSSION AND CONCLUSIONS
7.1 EVALUATION...56
7.2 RECOMMENDATIONS AND FUTURE WORK.....56
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INDEX
8. BIBILIOGRAPGHY..57
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1. INTRODUCTION AND THEORY.

1.1 INTRODUCTION.
Basically we talk about automobile clutch. Before we go into more detail lets talk
about what is a clutch, purpose of it, different clutch types and problems with the
conventional clutches.
What is a clutch in a automobile?
Basically clutch is a mechanical device having the main purpose of engaging and
disengaging the driven shaft from the drive shaft.In a automobile the clutch engage and
disengage the transmission or simply the gear box input shaft (Driven shaft) from the engine.
Parts of the clutch can be shown as below.
Figure 11: Clutch system
What is the purpose of having a clutch?

Assume that you are driving a vehicle and you want to shift to the next gear First u press the
clutch peddle and then put the gear selector to the correct position and release the clutch then
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the vehicle moves smoothly.If there was no clutch when u pulling the gear shifter respective
gears get violently collide with each other resulting broken gear teeth and ultimately causing
a tranmission failure.So the clutch basically disconnects the gear box input shaft from the
engine to change the gears smoothly without damaging the gear box.
How does the clutch work?
Mainly due to friction between two rubbing surfaces.The engine fly
wheel friction surface and clutch plate surface are bought into contact to
roatate the gear box input shaft. Main parts of the clutch can be shown as below.
Pressure Plate.
Clutch plate
Fly wheel friction

surface
Pivoted
Figure 13: Friction fork

Figure 12 : Pressure plate, clutch
plate and fly wheel friction surface.
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Secondary push rod

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Main push rod
1.2 MECHANISM AND PARTS.
Clutch peddle
Diaphragm spring
Figure 14: Clutch mechanism
When clutch pedal is not pressed.

When the clutch peddle is pressed it pulls the main push rod backward resulting more
clutch fluid to flow from the master cylinder. Due to this the pressure on the secondary push
rod increases and it tends to move away from the slave cylinder. This motion will move the
release bearing into the diaphragm spring breaking the contact between the clutch plate and
the friction surface on the fly wheel ultimately disengaging the driven member from the
driving member.
When clutch pedal is pressed
Engine power is not

transmitted to the
tranasmission unit
Fly wheel
Clutch Plate
Pressure plate
Figure 15: Clutch peddle
pressed
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After releasing the clutch peddle the trapped fluid flows back in to the master cylinder
reducing the pressure on the secondary push rod causing the release bearing to move away
from diaphragm spring and ultimately making the contact between clutch plates and the
friction surface on the fly wheel. Then again the driving member and the driven member is
coupled for power transmission.
When clutch pedal is not pressed .
Engine power is
transmitted to the
tranasmission
Fly wheel unit
Clutch Plate
Pressure plate
Figure 16: Clutch peddle
not pressed.
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Shift fork
The shift fork moves the release bearing back and forth resulting the diaphragm
spring to move back and forth ultimately engaging and disengaging the clutch plates with the
fly wheel. Movement of the shift fork is like a cantilever.
Pivoted
Figure 17: Shift fork
Clutch plate
Figure 18: Clutch plate
Clutch plate consists of frictional surfaces which are used to couple the transmission
input shaft with the fly wheel. Various materials have been used for the disc-friction facings,
including asbestos in the past. Modern clutches typically use a compound organic resin with
copper wire facing or a ceramic material. Ceramic materials are typically used in heavy
applications such as racing or heavy-duty hauling, though the harder ceramic materials
increase flywheel and pressure plate wear.
Clutch plates also have spring attached on to it. During abrupt clutch engagement and
disengagements the stress on the clutch plates heavily increases. So thee springs are
introduced to absorb that hazardous stress while enhancing the hardness and durability of the
clutch plates.
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Pressure plate.
Figure 19: Pressure plate
The clutch plate assembly is mounted on to the back of this pressure plate and the pressure
plate assembly is mounted on to the fly wheel though it is rotating with the fly wheel. This
pressure plate engages and disengages the contact between clutch plate and the fly wheel with
the aid of release bearing or thrust bearing. There are three major types of clutch plates are
used such as
1.) The Long style contains nine coil springs for pressure against the flywheel and
three thin fingers for release. It is used mainly for drag racing.
2.) The Borg & Beck style also contains nine coil springs and three fingers. The
fingers are wider, however, and the plate has the more robust materials and design
necessary for street driving.
3.) The diaphragm pressure plate is best suited for street use and is, therefore, the
most common type found on later-model automobiles. It contains a single
Bellville-style spring that applies a more even load from clutch plate to flywheel.
Because the single-spring diaphragm is more effective over-center, there is also
less effort needed by the driver to hold the clutch pedal in the depressed position
at a stop.
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Fly wheel friction surface.
Fly wheel friction

surface
Fly wheel
This fly
wheel 20:
friction
surface
is used of
to couple
with the clutch disks ultimately
Figure
Friction
surface
fly
wheel.
coupling the driving member and the driven member. As from the name this surface consists
with frictional materials. Mostly compound organic resins and ceramics.
1.3 DIFFERENT TYPES OF CLUTCH ASEMBLIES.

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Multi plate clutch.

In this assembly it has many clutch disks so it can transfer
power more precisly
while reducing the slip energy between the friction surfaces.
Figure 21: Multi plate clutch
Conical clutch
1
2
3
4
Cones
Input shaft
Friction surface
Spring
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Assignment Working
5 Clutch control
mechanism
6 Rotating direction
Figure 22: Conical clutch
These clutches use conically shapped friction surface to transfer

power.Mostly they are used in racing cars.Because it has higher
surface area and you dont have to press the clutch pedal to it
maximum limit to shift gears.Therefore the gear changing action is
much faster and energy saving.
Centrifugal clutch
These clutches work based on centrifugal force. When the driving

shaft reached a specific speed, due to centrifugal force the friction
Figure 23: Centrifugal clutch
lining get contact with the driven shaft casing causing it to rotate
ultimately rotating the driven shaft or output shaft.
Now we have known what is a clutch, its purpose, its mechanism and different clutch types.
Now lets talk about what are the drawbacks or problems are occurred with conventional
clutches which were the reason for my new clutch design.
What are the drawbacks of a conventional clutch system ?
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Assignment Working
Mainly there is a major drawback.As shown in the above different

clutch assemblies it uses the principles of friction to transfer
power.Thereforewhen the clutch get engagged and disengagged the
friction surfaces get rubbed against each other resulting the
material to wear easily.So when these friction surfaces are weared
the clutch assembly cannot perform its duty accurately and
precisely.So after some time you have to replace the clutch plates or
clutch packs, which means the maintainance cost is bit high for this
friction clutch assemblies. Also due to frictional wearing of the
materials the durability of the clutch assembly is also low. In most
automobiles clutch plates have to be replaced in every 1000020000 km. A vehicle which travels long distances have to spend
more expenses for clutch repairements and also if the driver is using
the clutch abruplty in a bad manner the wearing of the clutch is
high, therefore it reduces the life time of the clutch as well.
With the engagement and disengagement of the clutch the pressure

plates are also undergo cyclic forces. Eventually due to this cyclic
forces fatigue failures are occured in this pressure plates.
Solutions for the stated problems

So how can we overcome this problem ?
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If we can find a new way to tranfer power between driving and

driven members without involving any friction surfaces or friction we can
overcome this problem. Also this kind of a new method can reduce the
energy losses due to friction as well.

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2.1 AIMS AND OBJECTIVES.

1. Study about vehicle clutch systems and understanding the drawbacks.
Before doing an engineering project it is a must to study about a similar project or a
research that has been done earlier by different communities, peoples or individuals. By
doing that we can get the idea of the way doing it.
In my project also I must learn as much as I can about vehicle clutch systems and
parts associated with it. By learning about them I can get to know their configurations or how
they work and operating principles as well as the theories behind them. After learning them I
can understand and pinpoint where the problems occur and what are the reasons for them. So
with better understanding of the problems I can provide solutions for that. Which is a main
objective of the project.
2. Learn about different type of rpm sensors.
For this project RPM sensor and a position sensor is needed therefore before applying
them in to the project I must know about the working principle of them, Accuracy, Range,
working environment properties and etc. to get the maximum performance out of them
without damaging other equipments and these sensors.
3. Designing a mechatronic system to get the work done with desired efficiency
levels.
In this project conventional clutch friction coupling is replaced by magnetic and fluid
coupling. Even though the methods have changed the work done by the clutch should also be
done with the new system. To do that work sensors, actuators and magnets and control
methods are used. Therefore to completely do the clutch action control system is also needed.
This has been done using programming the ATmega 2560 microcontroller which is on the
Arduino mega board.
4. Minimizing the energy wastage and take the maximum energy from the wasting
energy such as heat and etc.
As mentioned earlier, the magnetic coupling is based on eddy currents. Therefore due
to eddy current formation the materials get heat up. So this heat goes away as waste energy.
But my idea is to capture this waste heat and use it to produce current using thermoelectricity
theories.
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Assignment Working
5. Learn about thermoelectricity and apply them on this project.

In every automobile main energy wastage occur as heat. But in basic physics
principles such as seebeck effect, it denotes that with heat energy we can produce electricity.
So in this project my idea is to capture that waste heat and produce electricity to power up the
new system actuators as well as the other vehicle equipments.
2.2 DELIVERABLES.
The deliverable of this project will be a final project report thoroughly discussing how all the
above mentioned aims and objectives were achieved and the advantage of using the proposed
solution to overcome the initial problem.

Thermoelectricity: Generation of electricity from heat and also about the peltier
devices and its operation principles are discussed.
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Assignment Working
3. PROJECT METHODOLOGY.
3.1 OVERALL DESIGN.
Figure 24: Overall design
37
Assignment Working
And the parts can be named as below.
Figure 25: Parts of the new design
3.2 METHODOLOGY.
Design can be divided into two main parts as given below.
Figure 26: New design
Torque converter redesign.

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Assignment Working
What is a torque converter?

Torque converter is a mechanical device which uses the principles of fluid coupling to
connect driving and driven member. Mainly used in automatic transmission vehicles. It
consists of a turbine, impeller and a stator.
Figure 27: Torque converter.
The impeller of the torque converter is connected with the engine output shaft with the aid of
the fly wheel. So when the engine output shaft or fly wheel rotates the impeller also rotes
with the same rpm rate. This impeller guides the trapped fluid on the converter to the turbine
while increasing the pressure in the fluid. The direction of the fluid flow in the impeller is
shown below.
Figure 28: Impeller
As you can see from the above image it is evident that with the geometrical dimensions of the
impeller blades or vanes the pressure increases. If we take the geometry of the vanes it is
basically a diverging passage. As shown below,
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Assignment Working
Fluid flow
According to the nervier -stokes continuity equations the velocity in the vanes reduces. This
means the pressure on the fluid increases.
So this pressure increased fluid is send over the stator to the turbine as shown below,
Figure 29: Turbine
In the turbine section the fluid is entered from the top of the turbine and exit from the bottom
of the turbine. The geometry of the turbines blades or vanes is a converging type. This means
that with the fluid flow through the turbine blades the velocity of the fluid increases and
pressure decreases.
Then this released fluid enters the stator of the converter. As the name denotes this stator
cannot rotate with the fluid flow. It just guides the fluid in to the entering point of the
impeller. But the blades of the stator accelerate the fluid, and then send it back into the
impeller at a higher pressure, where it is then accelerated again, and sent back to the turbine
at an even higher pressure. (This is called vortex flow), and it is what creates the torque
multiplication that gives automatic equipped vehicles such strong low speed torque. One way
roller clutches in the stator prevent it from spinning backwards ruining the vortex effect.
Roller clutch
Figure 30: Roller clutch
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Assignment Working
Redesign
As mentioned earlier torque converters are used in automatic transmission vehicles.
Automatic vehicles do not use clutch systems. They use planetary gear systems, continuously
variable transmission methods with these torque converters to change gears of the vehicle.
Therefore as mentioned earlier clutch is basically used to disconnect the drive train from the
engine for smooth gear shifting. Therefore if we are using a torque converter for manual
transmission vehicles we should find a way to disconnect the drive train from the engine
because the torque converter couples the engine and the dive train using fluid coupling.
Therefore it can be done as follows,
The spline connector is connected between the converter output shaft and the
transmission input shaft. By moving that spline connector back and forth the
connection between the drive train and the torque converter can be removed and
replaced. The spline connector is shown below.
Figure
31: Spline
connector
The diameter of the spline
connector
is smaller
than the converter output shaft
diameter and the transmission input shaft diameter. Therefore it can move back and
forth inside of the converter output shaft and the transmission input shaft. The back
and forth movement mechanism is based on the clutch engage disengage mechanism
as explained earlier.
When the clutch peddle is pressed it moves the spline connector backward
disconnecting the converter output shaft and the spline connector ultimately
disconnecting the drive train from the engine.
Inside of the converter output shaft and the outside of the spline connector is consist
with spherical surfaces. These spherical surfaces are made for smooth movement of
the shafts. Within these spherical shafts pressurized oil layer is made to smoothen the
movement of the spline connector to reduce wear and tear and between the spline
connector spherical surfaces and converter output and transmission input shaft
spherical surfaces a sealed layer of oil is placed to reduce the frictional forces thus
reducing the energy wastage and wearing of the materials.
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Assignment Working
Figure 32: Spherical surfaces
The spline connector is connected using two fixed bearings these bearings do not
rotate or move linearly parallel to the spline connector axis. But the spline connector
rotates inside these bearings.
Now we have found a way to install a torque converter to a manual transmission
vehicle. But this assembly is not enough to compensate the work done by the clutch.
Because due to the heating of the converter fluid, fluid friction, friction between
materials and other resistances the efficiency of the torque converter lies between 90
-92%. Which means that engine rotating speed is slightly higher than the torque
transmission input shaft rotating speed.
So to minimize this this speed different and make the overall efficiency of the system
much closer to 95% - 97% additional magnetic drive or magnetic coupling system is
introduced.
Magnetic drive or magnetic coupling system.
This magnetic drive system is based on magnetic coupling. It uses following

parts to complete the magnetic drive system.
Inductors or solenoid to create a magnetic field.
Ferromagnetic disk.
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Assignment Working
Setup of the magnetic drive can be given as follows.
This magnetic coupling uses principles of eddy current formation due to magnetic fields.
Figure 33: Magnetic drive system
Eddy currents.
Eddy currents occur due to electro magnetic induction.As from the basic chemistry
we know that every element on the earth is consist of electrons circuling around a nucleus
and these electrons are negetively charged, so an eddy current is a swirling current set up in a
conductor in response to a changing magnetic field. By Lenz's law, the current swirls in such
a way as to create a magnetic field opposing the change; to do this in a conductor, electrons
swirl in a plane perpendicular to the magnetic field.
In this case eddy currents are occurred on the ferromagnetic disk. This ferromagnetic disk can
be made of Iron, Nickel and Cobalt. The main reason to use a ferromagnetic material is to
form a strong induced magnetic field occurred due to eddy currents. Ferromagnetic materials
shows the highest magnetic properties than any other materials. So it creates a strong
magnetic field on the disk.
So when the clutch peddle is not pressed the current flows to the inductors or the
solenoids to activate the magnetic drive by creating a magnetic field. When this happens the
ferromagnetic disk is already rotating because of the torque converter participation. So this
external magnetic field induces an opposing strong magnetic field on the ferromagnetic disk
due to eddy current formations with the rotation of the ferromagnetic disk. But due to the
rotation of the ferromagnetic disk it induces North poles and South poles region of a
magnetic field on the disk respectively. So with the formation of this North Pole South Pole
arrangement it creates attraction forces with the external magnetic field created by the
inductors or solenoids. This attraction forces holds, rotates and provide extra torque for the
43
Assignment Working
torque converter output shaft. So even in the low RPM ranges on the engine the vehicle has a
high torque for the wheels to drive the car.
The radius of the ferromagnetic disk is taken 110% percent of the solenoid attached plate.
This has taken to match with the characteristics of the torque converter to work supportively
with the magnetic drive. Too large disk will induce and additional force and stress on the
torque converter output shaft.
Thickness of the ferromagnetic disk depends on the RPM range of the engine. With high
RPM ranges the induced the external magnetic field does not penetrate completely into the
interior of the disk. So with high RPM rated engines. The thickness of the disk can be
reduced to reduce cost as well. Reduction of thickness reduces the intensity of the induced
magnetic field or the eddy current as well. But with this automobile engine application it does
not matter because with the high engine RPMs the frequency needed to induce eddy currents
are also increased. So this will compensate and also increase the intensity of the induced
magnetic field or the eddy current as well. Thickness of the ferromagnetic disk can be found
as follows,
= f
Penetration depth or the thickness of the ferromagnetic disk.
f Frequency.
Magnetic permeability of the disk.
Electrical Conductivity of the disk.
For the magnetic system permanent magnets are not used due to the permanent magnetic
properties. As an example if permanent magnets are used the coupling between the driving
and the driven member cannot be easily separated, in a situation such as stopping the vehicle,
changing of gears an etc. So to create the magnetic field circular array of inductors or the
solenoids are used. The advantage of using a solenoid to generate a magnetic field is it can
44
Assignment Working
generate almost uniform magnetic field similar to that of a bar magnet. The magnetic field on
a current carrying conductor is shown as below.
The magnetic field intensity (B) on the center axis of the solenoid can be found from the
following equation.
B=
nI
Figure 34: Magnetic field
n- The number of turns per unit length

Permeability
I Current.
The intensity of the field is strongest on the center line axis. So this centerline axis is
arranged perpendicular to the ferromagnetic disk to induce eddy currents. Also the distance
between the ferromagnetic disk surface and the top of the solenoid is minimized into 1mm5mm to create strong eddy currents on the ferromagnetic disk. To generate a stronger eddy
current the field intensity should be increased. In this application it has been done by
increasing the number of turns per unit length. Also high permeability materials such as
Iron (99.95% pure Fe annealed in H), Cobalt-Iron and etc. are also used in the core to
increase the field strength as well.
45
Assignment Working
Figure 35: Solenoids and ferromagnetic disk.
For the disengagement of the magnetic coupling system below arguments should be achieved.
Clutch peddle pressed or vehicle is on neutral gear.

Torque converter output shaft RPM > 5500 rpm
Flow chart of the design can be given as follows.
Figure 36: Flow chart
To know the vehicle is on neutral gear a switch is attached to the gear liver which sends the
signal to the ECU that vehicle is on neutral gear. A potentiometer is attached to the clutch
peddle to end the signal to the ECU expressing the position of the clutch peddle. According to
the position of the clutch peddle the amount or the value of current sent to the solenoid is
controlled. As an example by pressing the clutch peddle the sent current is reduced ultimately
reducing the intensity of the magnetic field which results for a weaker eddy currents.
3.3 REDUCTION OF ENERGY WASTE AND INCREASING EFFICIENCY.
46
Assignment Working
Due to the eddy currents formation the ferromagnetic disk gets heated up. So with the as a
common factor for every material, with increasing temperature the magnetic properties of the
material tends to change. So it is much important and vital control the temperature rise of the
disk.
This temperature reduction is controlled by thermos-electric effect which is also known as
seebeck effect.
Seebeck-effect.
Seebeck effect is known as production of an electromotive force (emf) and consequently
an electric current in a loop of material consisting of at least two dissimilar conductors when
two junctions are maintained at different temperatures. The conductors are commonly metals,
though they need not even be solids. The German physicist Thomas Johann
Seebeck discovered (1821) the effect. The Seebeck effect is used to measure temperature with
great sensitivity and accuracy to generate electric power for special applications.
For this automobile application, a special device cold peltier device is used. IT consist with
diodes and transistor which uses the seebeck effect or the thermoelectric principle. This
peltier device has two surfaces. One surface is placed on a high temperature surface and the
other surface on a much cooler surface. The temperature difference on this surfaces generates
a heat flow from higher temperature surface to lower temperature surface. Though this heat
energy flow through the peltier device, it absorbs this heat energy to generate electromotive
force ultimately generating a DC current.
Figure 37: Peltier device
The variation of the temperature difference vs the induced electromotive force can be shown
as follows.
47
Figure 38: Temperature difference Vs EMF
Assignment Working
This peltier devices are made from semiconductor materials. Though they have properties of
semiconductor materials. Peltier devices are available with high quality semiconductor
material which can withstand higher temperature more than 600 . So this type of high
temperature peltier devices are used for this automobile application where the exhaust
temperature are more than 400 .
The hot surface of the peltier device is fixed onto the ferromagnetic disk. Which has a higher
temperature due to eddy currents. The other surface is fixed onto the turbine side torque
converter housing which has a low temperature due to the fluids on the torque converter. With
a temperature difference of 50 , a peltier device can induce an emf of 15V. This system
is planned to charge the 12 V battery from that induced emf. By using the voltage regulators
the induced emf can be used to charge the battery. Also it can be used to reduce the fuel
consumptions as well by using the induced emf to power the vehicles air conditioning
system which will reduce the load on the engine ultimately reducing the fuel consumption.
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Assignment Working
4. MATCHING AND UTILIZING THE RESOURCES.

4.1 ALLOCATED BUDGET.
4.2 HARDWARE REOURCES.
Following are the hardware resources for the actual system
Inductors or solenoids.
RPM sensor.
Ferromagnetic disk.
Torque converter.
Peltier devices.
Hoses.
Control circuit for the peltier device and for the inductors.
Power cutoff switches.
Metal plates and mounts.
4.3 HUMAN RESOURCES INVOLVED.
Since this was an individual project, the only human resource involved was myself. But
expertise of the technicians and the engineers were taken to analyze and get feedbacks for
necessary system refinements.
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Assignment Working
4.4 TIME AGAINST AGREED TIMELINE.

I was able to follow the agreed timeline accordingly and complete the project on time. The
timeline is shown below in the form of Gantt chart.
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Assignment Working
5. RESULTS AND FINDINGS.

5.1 PROJECT OUTCOMES.
A summary of the project findings and the outcomes are graphically illustrated below.
Figure 39 : Project Outcomes
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Assignment Working
5.2 ANALYSIS OF OUTCOMES.
A detailed analysis on the existing automobile clutch system and its components were done
on the previous topics. The findings and the knowledge gathered from them are highly
important to develop a new clutch system to replace the existing mechanical clutch system.
The synergistic work of the mechanical torque converter and the electronic magnetic
actuating system makes the overall project a mechatronic system. Due to the synergistic
nature of the implemented design, it is highly suitable for modern world hybrid vehicles.
Main purpose of a hybrid vehicle is to reduce the fuel consumption while full filling the
needs and desires of the driver or the owner. As a one outcome of the project the reduction of
fuel consumption is preferable for hybrid vehicles. With the introduction of new system to the
hybrid vehicles they can achieve much fuel economy than the existing hybrid vehicle.
Also it is a general fact that vehicles with low cylinder capacity have low torque and power
output from the engine. In conventional methods torque converters are used as torque
multiplier due to the operating nature of it. But it was a drawback that the efficiency of the
torque converters were low if they use independently. But with the new implementation of
magnetic coupling system efficiency of the overall clutch system has drastically improved
because energy waste is purely minimized by using different kind of techniques such as
thermoelectric power generation. Also with the additional torque from the magnetic coupling
system increases the overall torque of the engine even in low engine RPMs.
It can be mention that with the current trend of using hybrid vehicles, this kind of a
synergistic system is advantageous, but it is not limited for only hybrid vehicles due the
following facts it is preferable for any kind of vehicle.
1.
2.
3.
4.
Easy implementation for existing vehicles.

Reduction of maintenance costs and fuel consumptions.
Increase of overall torque during low engine rpms
Due to the synergistic nature damages and errors are reduced.
So with the above facts & analysis it can be said that the new design can be optimize the
overall performance of the vehicle and the efficiency of the overall system.
52
Assignment Working
6. MEETING THE SPECIFICATIONS.


Thermoelectricity: Generation of electricity from heat and also about the peltier devices and
its operation principles are discussed
6.2 COST/BUDGET.
53
Assignment Working
6.3 TIMELINE AND MILESTONES.

MILESTONES.
Studying and identification of issues with conventional clutch systems.

Designing of the new system.
Sensors and actuator selection.
Completion of the new design.
6.4 STANDARDS.
Though it is a mechatronic system it should be according to the correct standards. For this
kind of a system personal safety and the equipment safety is the major issue. So the wiring
and the other electronic systems needs to be done according to the correct standards.
Probability for a power surge should be minimized. All these factors are considered during
the design phase of the new system. Other standards used can be given as,
ISO 3006:2015
Road vehicles -- Passenger car wheels for road use -- Test methods
ISO 10597:2012
Road vehicles -- Flat attachment fixing nuts for commercial vehicles -- Test methods
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Assignment Working
6.5 LEGISLATIVE ISSUES
This project is heavily dependent on existing work done by other people and therefore
it was extremely important to use references and acknowledge the original authors so
that any legislative issues can be prevented.
On the design aspect of the project, since this is a system proposed for an automobile,
all the suggestions and findings of this projects should comply with current
automobile safety legislations if the project is to be recognized in the industry.
6.6 ETHICS AND SOCIAL ISSUES.

It is a common and general fact on society that when any principle or mechanism
sustain for a long period of time the people tends to think that it the correct mechanism or the
principle and they tend to forget downside of it by accepting it as the perfect solution.
Automobile clutch is also something that last for many decades. So people might
think that the new system can be much complex and generate issues with usage. But this
mindset can be rectified only by providing them the evidence for accept it. So to use this new
system proper information about the new system should be given for the people with practical
examples.
6.7 SUSTAINABILITY.
Though the new system improves the vehicle performance and reduce the cost for
periodic and non-periodic maintenance of the available clutch system, it will make the people
to use it. Also it reduces the fuel consumption and increase the fuel efficiency as well. So
from these facts we can predict that the new design can sustain in the automobile industry.
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Assignment Working
7. DISCUSSION AND CONCLUSION.

7.1 EVALUATION.
After developing the initial idea on friction less coupling clutch system, it was
obvious to further study and analyze about the existing clutch system, its parts, its operation
principles and the mechanism related to it. So further readings were carried out from history
of the conventional clutch systems to the modern hi-performance clutch systems. Also
difference clutch systems and there applications were also studied during the study phase.
The next phase was to model and design the new clutch system which covers the
every aspect of the conventional clutch system. So with my mechanical engineering
knowledge and the training and the knowledge I got during the industrial training process I
was able to design a new system which uses a torque converter and a spline connector which
used to couple and decouple the driving and driven members.
The next most important and vital step was to compare and analyze the new design
with conventional clutch system. So the initial design was analyzed by myself and well as the
field experts, technicians and engineers. So with the completion of the analysis it was obvious
that the initial design had few drawbacks such as poor performance, low efficiency, lack of
torque and complexity.
So it was back to the drawing board again. So from further and further readings I
understood that a secondary system coupled with the torque converter will surely reduce the
drawbacks of the initial design. So as a secondary system magnetic coupling system was
introduced. So the overall performance, lack of torque was improved.
Though the initial drawbacks were reduced, the efficiency of the overall system was
still on sake. Due to the principle used in magnetic coupling (Eddy current) lot of waste heat
was generated. This was an issue and to overcome this issue and to increase the efficiency
level of the system thermoelectric generation was introduced to generate electricity from the
waste heat.
So from the new refined design the issues with the conventional clutch system was
reduced and efficiency was improved as well.
7.2 RECOMMONDATIONS AND FUTURE WORK.

Though the new design is a synergistic mechatronic system, by referring the flow chart it is
evident that the system is still an open loop system because there is no feedback from the
outputs. But for the reliability of the overall system feedback is necessary. Also with a correct
feedback the safety of the system will surely increase. So further design optimization
processes including converting to close loop system will be carried out in the future.
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Assignment Working
9. BIBILIOGRAPHY.
Clutch-Wikipedia, free encyclopedia. 2016. Clutch- Wikipedia, the free encyclodia.

[ONLINE] Available at: https:// en.wikipedia.org/wiki/Clutch.
Types of Clutches | Mechanical Booster . 2016. Types of Clutches | Mechanical

Booster . [ONLINE] Available at: http://www.mechanicalbooster.com/2014/07/typesof-clutches.html.
Types of Clutches - How Clutches Work | HowStuffWorks. 2016. Types of Clutches How Clutches Work | HowStuffWorks. [ONLINE] Available at:
http://auto.howstuffworks.com/clutch3.htm.
Torque converter - Wikipedia, the free encyclopedia. 2016. Torque converter Wikipedia, the free encyclopedia. [ONLINE] Available at:
https://en.wikipedia.org/wiki/Torque_converter.
How Does A Torque Converter Work? | Mister Transmission. [ONLINE] Available at:
http://www.mistertransmission.com/how-does-a-torque-converter-work.
How Does A Torque Converter Work? | Mister Transmission. 2016. POSITION

SENSOR | Types of Position Sensors & working - EngineersGarage. 2016.
POSITION SENSOR | Types of Position Sensors & working - EngineersGarage.
[ONLINE] Available at: http://www.engineersgarage.com/articles/position-sensors.
Hall effect sensor - Wikipedia, the free encyclopedia. 2016. Hall effect sensor Wikipedia, the free encyclopedia. [ONLINE] Available at:
https://en.wikipedia.org/wiki/Hall_effect_sensor.
Magnetic coupling - Wikipedia, the free encyclopedia. 2016. Magnetic coupling Wikipedia, the free encyclopedia. [ONLINE] Available at:
https://en.wikipedia.org/wiki/Magnetic_coupling.
Eddy current couplings and brakes - ThyssenKrupp Magnettechnik - englisch. 2016.

Eddy current couplings and brakes - ThyssenKrupp Magnettechnik - englisch.
[ONLINE] Available at: http://www.thyssenkruppmagnettechnik.com/index.php/eddy-current-couplings-and-brakes.html.
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Assignment Working
Task 4-Log book entries.

Date
07.05.2015
11.05.2015
20.05.2015
30.05.2015
15.06.2015
30.06.2015
16.07.2015
31.07.2015
12.08.2015
28.08.2015
30.10.2015
Tasks carried out.

Started Analysis of the initial problem
Started Analysis of the possible solutions that can be implemented to
Overcome the initial problem. The drawbacks of the solutions were
examined and the most suitable solution was selected
Discussed the project with the supervisor about the initial idea and its
drawbacks.
Started developing the initial system design. First I was focusing to use only a
torque converter. However, after further analysis it was understood that using
only torque converter has its drawbacks.
Further refinements for the torque converter implementation. Gathering
information for secondary system to support the torque converter.
Identified magnetic coupling as a secondary system and study about the
coupling methods and implementation.
Solidworks designing of the initial design and further studying about magnetic
coupling.
Completion of the Solidworks design and getting feedbacks for the design and
doing refinements.
Finalizing the design according to the standards and completing it.
Started writing the final report.
Completed the final project report and all submitted the project assignment.
58

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What problem does the conventional clutch system have?

What problem does the conventional clutch system have?

What solutions are proposed to overcome the problems with the conventional clutch system?

What solutions are proposed to overcome the problems with the conventional clutch system?

Assignment Working

BSc(Hons) in Mechanical Engineering/BTEC HND in

Fly wheel friction surface

Figure 1: Fly wheel friction surface

Clutch plate friction

Figure 2: Clutch plate friction

Feasibility or the likelihood of the project being a success.

Reading of the automobile clutch systems, there mechanisms, operation, parts

Tabulation of the main problematic area of the conventional clutch system

Finalizing the new design.

Carry out the refinements and completing the new design.

Ethics and social issues.

Metal plates and mounts.

Ramesh Jayashan Warusavitharana KTB/A-00061

2.1 AIMS & OBJECTIVES..12

Fly wheel friction surface

Figure 3: Fly wheel friction surface

Clutch plate friction

Figure 4: Clutch plate friction surface

2. AIMS AND OBJECTIVES.

5. Learn about thermoelectricity and apply them on this project.

Torque converter: Operating principle of a torque converter, its mathematical and

3. PROJECT PLAN AND TIMELINE

Studying and identification of issues with conventional clutch systems.

4. DISCUSSION AND CONCLUTIONS.

Study about vehicle clutch systems and understanding the drawbacks.

Fly wheel friction surface

Figure 5: Fly wheel friction surface

Clutch plate friction

Figure 6: Clutch plate friction

Different types of clutch assemblies

Figure 7: Multi plate clutch

Figure 8: Conical clutch

These clutches use conically shapped friction surface to transfer

Figure 9: Centrifugal clutch

These clutches work based on centrifugal force. When the driving

What are the drawbacks of a conventional clutch system ?

Mainly there is a major drawback.As shown in the above different

With the engagement and disengagement of the clutch the pressure

Study about different type of rpm sensors.

Figure 10: hall Effect RPM Sensor

4.2 IMPLICATIONS OF THE REMAINDER OF THE PROJECT.

Ramesh Jayashan Warusavitharana KTB/A-00061

2. AIMS AND OBJECTIVES.

1. INTRODUCTION AND THEORY.

Figure 11: Clutch system

What is the purpose of having a clutch?

Fly wheel friction

Figure 13: Friction fork

Secondary push rod

Main push rod

1.2 MECHANISM AND PARTS.

Figure 14: Clutch mechanism

When clutch pedal is not pressed.