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轻型货车离合器及操纵机构与传动轴设计

轻型货车离合器及操纵机构与传动轴设计【优秀汽车离合器全套课程毕业设计含3张CAD图纸】

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轻型货车离合器及操纵机构与传动轴设计.doc

轻型货车设计（离合器及操纵机构与传动轴设计）

摘要

在这三个月的时间里，我的最重要的任务之一就是设计汽车离合器、其操纵机构，以及传动轴的设计。

众所周知汽车底盘包括传动系、行驶系和转向系，传动系部件包括离合器、变速器、传动轴、驱动桥、半轴及驱动轮。在传动系的这些部件中，离合器和变速器无疑是两个最为重要的部件。驾驶员通过操纵离合器既可以在变速器换档时使发动机与离合器暂时分离，也可以在汽车起步时使发动机与离合器平稳接合。离合器的设计采用膜片弹簧压紧机构，液压式操纵机构。在国外，常采用液压操纵机构的离合器以减轻驾驶员的疲劳，

通过对传动轴的传动类型分析，对传动方式和传动轴进行了选型；通过对传动轴的类型与结构分析，选择了传动轴的十字轴滚针轴承的密封形式——盖板式密封。通过对万向节的十字轴、滚针轴承、万向节叉的设计计算，确定了所设计车辆使用的这些部件的具体尺寸。

综合各部分的设计及校核结果，所设计的离合器、传动轴能满足所设计的轻型货车的传动要求。

关键词：离合器，传动轴，十字轴，操纵机构

THE DESING OF A LIGHT TRUCK

(THE CLUTCKAND THE MANIPULATION

OF INSTITUTIONS AND SHAFT DESIGN)

ABSTRACT

In these two month-long time, one of my most vital duties is designs the automobile clutch ,Its control mechanism, as well as drive shaft design.

The well known motor car chassis including the power transmission, the travel is and the steering system, the power transmission part including the meeting and parting Transmission gearbox, drive shaft, driving axle, rear axle and driving gear. In power transmission these parts, to Gathering and the transmission gearbox are two most important parts without doubt. The pilot through operates the coupling already to be possible in The transmission gearbox shifts gears when causes the engine and the coupling separates temporarily, also may starts when the automobile cause the engine and Coupling steady joint. The coupling design used the disk spring to contract the organization, hydraulic control organization. In overseas, often uses the hydraulic control organization the coupling by to reduce pilot's weariness.

Through to the drive shaft transmission type analysis, has carried on the shaping to the type of drive and the drive shaft; Through to the drive shaft type and the structure analysis, chose the drive shaft cross axle needle bearing seal form to cover the board style seal. Through to the universal joint cross axle, the needle bearing, the universal joint sliding yoke design calculation, had determined designs these parts concrete sizes which the vehicles uses.

Synthesizes each part of designs and the check result, designs the coupling, the drive shaft can satisfy skin truck which designs to use the transport vehicle the transmission request.

KEY WORDS: Coupling drive shaft cross axle control mechanism

目　录

前　言 ………………………………………………………1

第一章离合器设计分析与方案选择………………………3

§1.1 概述……………………………………………………3

§1.2 离合器结构方案分析…………………………………4

§1.2.1　从动盘数的选择 …………………………5

§1.2.2 压紧弹簧和布置形式的选择 ……………6

§1.2.3　膜片弹簧支承形式 ………………………7

§1.2.4　压盘驱动方式的选择 ……………………8

第二章离合器基本参数和主要尺寸选择…………………8

§2.1 离合器基本参数计算………………………………10

§2.2 膜片弹簧主要参数的选择…………………………12

§2.3 扭转减震器的设计…………………………………13

§2.4 离合器压盘的设计…………………………………18

§2.5 离合器从动盘毂花键的强度校核…………………19

§2.6 离合器操纵机构的设计计算………………………20

第三章传动轴的设计与计算……………………………23

§3.1 概　述………………………………………………23

§3.2 万向节结构方案分析………………………………24

§3.3 万向节的设计计算…………………………………24

§3.3.1 万向节设计 ……………………………24

§3.3.2 传动轴的设计 …………………………27

第四章结论 ………………………………………………30

参考文献 …………………………………………………31

致　谢 ……………………………………………………32

前言

自从十九世纪末期诞生第一辆汽车以来，汽车工业经历了100年的发展过程。由于社会需求的不断增长和科学技术发展的推动，汽车设计日臻精巧，其运输生产率和各项性能都有很大提高。因此，现在汽车已成为世界各国国民经济和社会生活中不可缺少的的一种运输工具。汽车工业规模和其产品的质量也成为衡量一个国家技术水平的重要标志之一。

参考文献

[1] 陈家瑞主编. 汽车构造（第3版）. 北京：机械工业出版社2001

[2] 刘惟信编著. 汽车制动系的结构分析与设计计算. 北京：机械工业版社，2004

[3] 刘惟信主编. 汽车设计（第3版）. 北京：清华大学出版社， 2001

[4] 余志生主编. 汽车理论（第3版）. 北京：清华大学出版社， 2002

[5] 王望予主编. 汽车设计（第3版）. 北京：机械工业出版社， 2002

[6] 张则曹主编. 汽车构造图册(底盘) . 北京：人民交通出版社，1998

[7] 张洪欣主编. 汽车设计（第2版） . 北京：机械工业出版社，1995

[8] 邓楚南主编. 轿车构造 . 北京：人民交通出版社， 2001

[9] 王巍，钱可强主编. 机械工程图册 . 北京：机械工业出版社， 2000

[10]李传禹主编.汽车设计标准资料手册 . 长春: 吉林科学技术出版社,1992

[11]甘永立主编.几何量公差与检测 . 上海: 上海科学技术出版社,2001

[12]汪卸建主编.汽车底盘简明教学图解 . 北京：电子工业出版社，1993

[13]刘世桤主编.汽车的传动系 . 北京: 人民交通出版社,1978

[14]羊拯民主编.传动轴于万向节 . 北京: 人民交通出版社,1986

[15]藏新群主编.汽车滚动轴承应用手册 . 北京: 机械工业出版社,1997

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内容简介：: CLUTCH The engine produces the power to drive the vehicle. The drive line or drive train transfers the power of the engine to the wheels. The drive train consists of the parts from the back of the flywh eel to the wheels. These parts include the clutch, the transmission, the drive shaft, and the final drive assembly (Figure 8-1). The clutch which inc ludes the flywheel, clutch disc, pressure plate, springs, pressure plate cover and the linkage necessary to operate the clutch is a rotating mechanis m between t he engine and the transmission (F igure 8-2). It operates through fr iction which comes from contact between the parts. That is the reason why the clutch is called a frict ion mechanism. After engagement, the clutch must continue to transmit all the engine to rque to the transmission depending on the friction w ithout slippage. The clutch is also used to disengage the engine from the drive train whenever the gears in the transmission are being shifted from one gear ratio to another. To start the engine or shift the gears, the driver has to depress the clutch pedal with the pur pose of disengagement the transmission from the engine. At that time, the driven members connected to the transmission input shaft are either stationary or rotating at a speed that is slowe r or faster tha n the driving members connected to the engine crankshaft. There is no spring pressure on the clutch assembly parts. So there is no frict ion between the driving me mbers and driven me mbers. As the driver lets loose the clutch pedal, spring pre ssure increases on the clutch parts. F riction between the parts also increases. The pressure exerted by the springs on the driven me mbers is controlled by the driver through the clutch pedal and linkage. The positive engagement of the driving and driven me mbers is made possible by the friction between the surfaces of the me mbers. When full spring pressure is applied, the speed of the driving and driven me mbers should be the same. At the ntsmoment, the clutch must act as a solid coupling device and transmit al l engine power to the transmission, without slipping. However, the transmission should be engaged to the engine gradually in order to operate the car smoothly and minimize torsional shock on the drive train because an engine at id le just develops litt le power. O therwise, the driving me mbers are connected with the driven members too quickly and the engine would be stalled. The flyw heel is a major part of the clutch. The flyw heel mounts to the engines crankshaft and transmits engine torque to the clutch assembly. The flywheel, when coupled with the clutch disc and pressure plate makes and breaks the flow of power from the engine to the transmission. The flywheel provides a mount ing location for the clutch assembly as well. When the clutch is applied, the flyw heel transfers engine torque to the clutch disc. Because of its weight, the flywheel he lps to smooth engine operation. The flywheel also has a large ring gear at its outer edge, which engages with a pinion gear on the starter motor during engine cranking. The clutch disc fits between the flywheel and the pressure plate. The clutch disc has a splined hub that fits over splines on the transmission input shaft. A splined hub has grooves that match splines on the shaft. These splines fit in the grooves. Thus, t he two parts are held together. However, back-and- forth movement of the disc on the shaft is possible. Attached to the input shaft, At disc turns at the speed of the shaft. The clutch pressure plate is generally made of cast iron. It is round and about the same dia meter as the clutch disc. O ne side of the pressure plate is machined smooth. This side will press the clutch disc facing are against the flywheel. The outer side has various shapes to facilitate attachment of spring and release mechanisms. The two primary types of pressure plate assemblies are coil spring assembly and diaphragm ntsspring (Figure 8-3). In a coil spring clutch the pressure plate is backed by a number of coil springs and housed with them in a pressed-steel cover bolted to the flywheel. The springs push against the cover. Neither the driven plate nor the pressure plate is connected rigidly to the flywh eel and both can move either to wards it or away. When the clutch pedal is depressed a thrust pad riding on a carbon or ball thrust bearing is forced towards the flywheel. Levers pivoted so that they engage with the thrust pad at one end and the pressure plate at the other end pull the pressure plate ba ck against its springs. This re leases pressure on the driven plate disconnecting the gearbox from the engine (Figure 8-4). Diaphragm spring pressure plate assemblies are widely used in most modern cars. The diaphragm spring is a single thin sheet of metal which yie lds when pressure is applied to it. When pressure is removed the metal springs back to its original shape. The centre portion of the diaphragm spring is slit into numerous fingers that act as release levers. When the clutch assembly rotates with the engine these weights are flung outwards by centrifugal forces and cause the levers to pre ss against the pressure plate. During disengagement of the clutch the fingers are moved forward by the release bearing. The spring pivots over the fulcrum ring and its outer rim moves away from the flywheel. The retracting spring pulls the pressure plate a way from the clutch plate thus disengaging the clutch (Figure 8-5). When engaged the release bearing and the fingers of the diaphragm spring move towards the transmission. As the diaphragm pivots over the pivot ring its outer rim forces the pressure plate against the clutch disc so that the clutch plate is engaged to the flywheel. The advantages of a diaphragm type pres sure plate assembly are its compactness, lower weight, fewer moving parts, less effort to engage, reduces rotational imbalance by providin g a balanced force around the pressure plate and less chances of clutch slippage. ntsThe clutch pedal is connected to the disengagement mechanis m either by a cable or, more commonly, by a hydraulic system. Either way, pushing the pedal down operates the dise ngagement mechanis m which puts pressure on the fingers of the clutch diaphragm via a release bearing and causes the diaphragm to release the clutch plate. With a hydraulic mechanism, the clutch pedal arm operates a piston in the clutch master cylinder. This forces hydraulic fluid through a pipe to the clutch release cylinder where another piston operates the clutch disengagement mechanis m. The alternative is to link the clutch pedal to the disengagement mechanism by a cable. The other parts includ ing t he cl utch fork, release bearing, bell- housing, bell housing cover, and pilot bushing are needed to couple and uncouple the transmission. The clutch fork, which connects to the linkage, actually operates the clutch. The release bearing fits between the clutch fo rk and the pressure plate assembly. The bell housing covers the clutch assembly. The bell housing c over fastens to the bottom of the bell housing. This removable cover allows a mechanic to inspect the clutch wit hout removing the transmission and bell housing. A pilot bushing fits into the back of the crankshaft and holds the transmission input shaft. Torque Converter The Basics Just like manual transmission cars, cars with automatic transmissions need a way to let the engine turn while the wheels and gears in the transmission come to a stop. Manual transmission cars use a clutch, which completely disconnects the engine from the transmission. Automatic transmis sion cars use a torque converter. A torque converter is a type of fluid coupling, which allows the engine to spin somewhat independently of the transmission. If the engine is turning slowly, such as when the car is idling at a stoplight, ntsthe amount of torque passed through the torque converter is very small, so keeping the car still requires only a light pressure on the brake pedal. If you were to step on the gas pedal while the car is stopped, you would have to press harder on the brake to keep the car from moving. This is because when you step on the gas, the engine speeds up and pumps more fluid into the torque converter, causing more torque to be transmitted to the wheels. Inside a Torque Converter There are four components inside the very strong housing of the torque converter: 1. Pump; 2. Turbine ; 3. Stator; 4. Transmission fluid. The housing o f the torque converter is bolted to the flyw heel of the engine, so it turns at whatever speed the engine is running at. The fins that make up the pump of the torque converter are attached to the housing, so they also turn at the same speed as the engine. The cutaway below shows how everything is connected inside the torque converter (Figure 8-6). The pump inside a torque converter is a type of centrifugal pump. As it spins, fluid is flung to the outside, much as the spin cycle of a washing machine flings water and clothes to the outside of the wash tub. As fluid is flung to the outside, a vacuum is created that draws more fluid in at the center. The fluid then enters the blades of the turbine, which is connected to the transmission. The turbine causes the transmission to spin, which basically moves the car. The blades of the turbine are curved. This means that the fluid, which enters the turbine from the outside, has to change direction before it exits the center of the turbine. It is this directional change that causes the turbine to spin. ntsThe fluid exits the turbine at the center, moving in a different direction than when it entered. The fluid exits the turbine moving opposite the direction that the pump (and engine) is turning. If the fluid were allowed to hit the pump, it would slow the engine down, wasting power. This is why a torque converter has a stator. The stator resides in the very center of the torque converter. Its job is to redirect the fluid re turning from the turbine before it hits the pump again. This dramatically increases the efficiency of the torque converter. The stator has a very aggressive blade design that almost completely reverses the direction of the fluid. A one -way clutch (ins ide the stator) connects the stator to a fixed shaft in the transmission. Because of this arrangement, the stator cannot spin with the fluid - it can spin only in the oppos it e dire c t i o n, forc i n g the flui d to chang e dire c t i o n as it hit s the stato r blade s . Something a little bit tricky happens when the car gets moving. There is a point, around 40 mph (64 kph), at which both the pump and the turbine are spinning at almost the same speed (the pump always spins slightly faster). At this point, the fluid returns from the turbine, entering the pump already moving in the same direction as the pump, so the stator is not needed. Even though the turbine changes the direction of the fluid and flings it out the back, the fluid still ends up moving in the direction that the turbine is spinning because the turbine is spinning faster in one direction than the fluid is being pumped in the other direction. If you were standing in the back of a pickup moving at 60 mph, and you threw a ball out the back of that pickup at 40 mph, the ball would still be going forward at 20 mph. This is similar to what happens in the tur bine: The fluid is being flung out the back in one direction, but not as fast as it was going to start with in the other direction. ntsAt these speeds, the fluid actually strikes the back sides of the stator blades, caus ing the stator to freewheel on its one-way clutch so it doesnt hinder the fluid moving through it. Benefits and Weak Points In addition to the very important job of allowing a car come to a complete stop wit hout stalling the engine; the torque converter a ctually gives the car more torque when you accelerate out of a Stop. Modern torque converters can multiply the torque of the engine by two to three times. This effect only happens when the engine is turning much faster than the transmission. At higher speeds, the transmission catches up to the engine, eventually moving at almost the same speed. Ideally, though, the transmission would move at exactly the same speed as the engine, because this difference in speed wastes power. This is part of the reason why cars with automatic transmissions get worse gas mileage than cars with manual transmissions. To counter this effect, some cars have a torque converter with a lockup clutch. When the two halves of the torque converter get up to speed, this clutch locks them together, eliminating the slippage and improving efficiency. nts外文资料译文 1 离合器发动机产生动力用以驱动车辆。动力传动系将发动机动力传到车轮。传动系由飞轮后端到车轮之间的零件组成。这些零件包括离合器、变速器、传动轴和减速器总成。离合器是位于发动机和变速器之间的一个旋转装置，它包括飞轮、离合器（从动盘）磨擦片、压盘、压紧弹簧、离合器盖及操作离合器所需的连接杆件等。它通过零件间的接触磨擦工作。这是离合器为什么会称为磨擦机构的原因。离合器接合后，给变速器传递所有的发动机转矩磨擦没有打滑。离合器也被用于在变速器传动比变换时从传动系中分离发动机。为了起动发动机或换档，驾驶员必须踩下离合器踏板以便实现变速器和发动机的分离。在那时，与变速器输入轴相联的离合器从动件可能处于静止状态，也可能以一定的速度旋转，这一速度可能高于或低于与发动机相联的离合器主动件的旋转速度。没有弹簧压力作用于离合器总成器件上。因此在主动件和从动件之间没有磨擦。当驾驶员松开离合器踏板时，弹簧对离合件器件压力增加。各个器件之间的磨擦也会增加。弹簧对从动件所施加的压力由驾驶员通过离合器踏板和连杆机构来控制。主从动件的有效接合是通过其表面的摩擦来实现的。当弹簧压力全部应用时，主从动件的转速是相同的。此时，离合器充当一个刚性连接装置，没有滑转，将发动机全部功率传递给变速器。但是，为了使汽车操作平稳，变速器应该逐渐与发动机接合，并减小传动系的扭转冲击，因为发动机空转时的功率输出很小。否则，主动件与从动件连接过快，发动机会停转。飞轮是离合器的一个主要部件。飞轮安装在发动机的曲轴上，给离合器总成传递发动机转矩。飞轮与离合器摩擦片和压盘结合在一起来传递或中断发动机给变速器的功率流。飞轮也为离合器总成提供装配位置。当离合器作用时，飞轮将发动机转矩传递给离合器从动盘。飞轮重，所以有助于发动机的运nts外文资料译文 2 转平稳。飞轮外缘还有一个大齿圈，在起动发动机时，它与起动机的小齿轮啮合。离合器从动盘安装在飞轮和压盘之间，有一个花键毂套在变速器输入轴上的花键上。花键毂上的槽与输入轴上的花键配合。花键装配在槽内，因此，两个零件结合在一起。但是，从动盘可以在轴上前后移动。从动盘连接在输入轴上，与轴的转速相同。离合器压盘一般由铸铁制成。它是圆形，与（离合器）从动盘的直径相同。压盘一侧被加工平滑。这侧会把离合器摩擦衬面压到飞轮上。外侧有各种形状，以有利于弹簧与分离机构的连接。有两种主要的压盘总成分别是螺旋弹簧总成和膜片弹簧总成。螺旋弹簧离合器中，压盘背部有许多螺旋弹簧支撑（压紧），并和它们一起安装在一个通过螺栓连接到飞轮上的压制钢（离合器）盖中。弹簧推压离合器盖。从动盘和压盘都不是严格连接到飞轮上，两个都可以相对飞轮前后移动。当离合器踏板被踩下时，安放在碳质或滚珠推力轴承上的止推垫被压向飞轮。分离杠杆（在枢轴上）转动，使它们能够与一侧的止推垫和另一侧的压盘接合，然后将压盘拉向弹簧。这会释放施加在从动盘上的压力，变速器和发动机脱离。现代轿车普遍采用膜片弹簧压盘总成。膜片弹簧是一个薄金属片，在压力作用下会弯曲。当压力释放时，这个金属弹簧会回到原来的形状。膜片弹簧的中心部分有许多切开的分离指作为分离杠杆。当离合器总成随着发动机旋转时，由于离心力的作用，它们的重量会被甩到膜片弹簧的外缘，从而使分离杠杆对压盘释压。在离合器分离时，分离指在分离轴承作用下向前移动。支撑环（圈）上的弹簧枢轴和它的外缘从飞轮分离。弹簧收缩将压盘拉离离合器片，从而将离合器分离。当离合器结合时，分离轴承和膜片弹簧的分离指向变速器方向移动。当膜片枢轴越过支承环时，它的外缘将压盘压在离合器片上，使离合器片和飞轮接合。膜片式压盘总成的优点在于它的结构紧凑，重量轻，运动部件少，接合费力小（轻便），通过对压盘周围施加的平衡力来减小转动nts外文资料译文 3 时的不平衡现象，离合器滑转率小。离合器踏板可通过绳索或常见的液压系统连接到分离机构。无论采用哪种方式，踩下踏板，操纵分离机构，通过分离轴承对离合器膜片弹簧指施加压力，均可解除膜片弹簧对离合器盘的压紧。如果带有液压机构，由离合器踏板臂来操纵离合器主缸中的活塞，将液压油通过管道压入到离合器工作（分离）缸，此后由工作缸中的活塞操纵离合器分离机构。另外一种是由绳索将离合器踏板连接到分离机构的。其它零部件包括离合器（分离）叉、分离轴承、离合器壳、离合器盖和导轴衬（套），用来接合和分离变速器。分离叉连接到杠杆机构，实际用来操纵离合器。分离轴承安装在离合器分离叉和压盘总成之间。离合器壳用来封闭离合器总成。而离合器盖固定在离合器壳的底部。这个

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