clutch systems industrial aerospace - schaeffler group · targeted investments in research and...

Clutch Systems

Innovative Solutions for All Roads

Schaeffler Brasil Ltda.

Av. Independência, 3500 A

18087-101 – Sorocaba – SP

Vendas Automotivas OEM LuK

Tel.: 15 3335-1500

www.schaeffler.com.br

All data have been carefully elaborated and checked.

However, we are not liable for any errors or omissions.

We reserve the right to introduce modifications due

to technology improvements.

Any reproduction, even partial, may be only carried

out with our prior consent.

As a family business, we realize that we have a responsibility

to keep moving forward in a world, which is developing at a

faster and faster rate and on which the half-life of forecasts

is becoming increasingly shorter. As the Schaeffler Group,

we must be competitive and work together to achieve our

goals. We have worked hard to get to the top; and INA, FAG

and LuK have grown together to form the Schaeffler Group.

We are committed to succeeding, to ensuring sustainability

in our actions and to being passionate about our company:

“Together we move the world.” We further the competence of our employees and rely on

targeted investments in research and development. We

base our decisions on customers' expectations and our

customers demand proximity in growing and newly

developing markets. Technical and business expertise and

the dedication of our excellent employees have always been

a basis for our success, as have been our regional ties that

have never lost sight of the global picture.

Not only has our development been characterized by

responsible management and consistent company

development, we have also actively designed the connection

between the company history and the corporate culture. We

cultivate commitment, trust and reliability, striving for

powerful and sustainable results.

Maria-Elisabeth Schaeffler

Partner

Georg F. W. Schaeffler

Partner

Dr. Jürgen M. Geissinger

President & CEO

AutomotiveEngine SystemsTransmission SystemsChassis SystemsAutomotive Aftermarket

IndustrialHeavy IndustryProduction MachineryPower TransmissionRailway IndustryConsumer Products and Distribution

AerospaceAirplanes, Helicopters and Special Applications

S c h a e f f l e r G r o u p

Modern dual-clutch transmissions increase drivetrain efficiency by combining the fuel economy of a manual transmission with the comfort of an automatic. They offer an excellent foundation for progressively hybridizing the drivetrain on modular basis - from mild to full hybrid.

Clutch Systems

Tel.: 15 3335-1500

Partner

President & CEO

Clutch Systems

Tel.: 15 3335-1500

Partner

President & CEO

Project Tuning

Testing

ExpertiseExpertise

Prototyping

StampingMachining

P r o d u c t i o n P r o d u c t s a n d S e r v i c e s D e v e l o p m e n t

Gearing up for Tomorrow Global Presence, Local Solutions1.

Engine Flywheel Technology –

Dual Mass Flywheels (DMF)

The current development on

internal combustion engines lead

the new projects for systems, which

operates at lower rotations, higher

compression rates and less mass.

New eco-friendly fuels change the

systems’ torsional features.

Vehicles are constantly optimized

by reduction of running and wind

noises. As a consequence, internal

noise sources are increasing and

system dampers diminishing. As

per the theories of physics, the

solution is to increment the

transmission inertial mass, without

increasing the coupling system

inertial mass. Thus, the rotation

responsible for the system excita-

tion and which provokes a reso-

nance, reduces below the idling

shift speed.

Centrifugal Burst Trial of

Cylindrical Parts.

Searching for quality excellence and

perfection in product durability, LuK

has developed proceeding trials and

test rigs for the accelerated

evaluation of centrifugal and

centripetal forces on complex

cylindrical components and

products, thus allowing the

continuous improvement of our

projects and the projects of our

partners and customers. In our R&D

Center in Sorocaba we are able to

perform component trials, such as

engine flywheel systems, clutches

and brake discs at high safety and

reliability levels. With local knowl-

edge and expertise, the R&D Center

in Sorocaba has become a world

LuK has always been present and close to

its customers by locally developing,

testing and manufacturing its products in

order to meet the markets needs and

overcome its partners’ expectations. The

operations in Sorocaba, Brazil, count on a

comprehensive structure to attend new

projects requirements, from its conception

to the serial production.

LuK’s concept is based on a customer-

oriented work, systematically participating

in the definition and development phases

of the systems to uphold its products. The

multidisciplinary teamwork, which

involves professional people from

Sorocaba and the branch offices from

Clutch Release System Assembly

Heat Treatment

Clutch Assembly

reference in trial technology and

supplies analysis and expert reports

for all other operations of the LuK

Group.

Conventional and Self-Adjusting

Clutches (SAC)

The trend of increasing the engine

torques and the growing demands

on comfort require clutches capable

to transmit a high torque on one

hand, but featuring low operation

power on the other hand. The

diaphragm spring development was

the first step taken by LuK to meet

such demands. Where as a clutch is

a wearing component in vehicles,

LuK has been investing great efforts

to continuously develop and

improve compensation systems to

minimize those wear effects. In

1995, LuK started the production of

the self-adjusting clutch (SAC),

which uses a system based on a

load sensor to actuate the wear

compensation system and, conse-

quently, the effort on the clutch

pedal.

Besides the clutch cover, the disc

plays an important role in the

coupling between engine and

transmission. As core element of

this connection, LuK has specialized

itself in tuning of axial characteris-

tics system, which provides modula-

tion and clutch pedal actuation

comfort.

As secondary function, but not less

important, clutch discs of modern

developments allow the implemen-

tation of torsional dampers in its

core part, which dampen the

vibrations produced by the internal

combustion engines, improving the

users’ comfort and avoiding the

premature wear of the transmission

gears.

LuK clutches provide excellent

operating comfort, long operating

life, compact solutions by means of

function integration, strength and

misaligning compensation between

the engine and the transmission.

Virtual Development

Already during the first development

phase, LuK applies the virtual

development concept on its pro-

jects, anticipating the products' final

behavior, even before the first

physical prototype. By means of

computer methods, such as virtual

analysis and simulations to optimize

the project, the research cycles of

the vehicle components are reduced.

In other words, LuK anticipates the

definitions involving the develop-

ment of geometry and shapes,

durability, vibrations and noises,

temperature distribution in opera-

tion conditions, as well as manufac-

turing process details.

Vehicle Testing Technology

Sustained by LuK's values, the

Experimental Engineering

Department is composed of a

specialized team, which is highly

qualified in testing and analyzing

clutch systems and their interfaces

with the vehicle. Aiming to support

its partners in development and

solutions of technical obstacles,

that may hinder the comfort and

durability of the vehicles, LuK

performs and develops testing

technologies for its products and

the systems they are fit in. Thus, the

tests are made on combustion

engines, transmission noises and

stresses, as well as on comfort and

durability of the clutch pedal

actuation systems.

Clutch Release Systems

Knowledge is the key to success in

clutch release systems. Vehicle

drivers may evaluate the clutch and

the release system comfort feeling

the smooth coupling and decoupling

behavior, the load-travel ratio and

the absence of vibrations and noises

during pedal actuation. When

actuating the clutch pedal, the

driver notes the release system

response. To satisfy the require-

ments on the clutch pedal, the

system components must be

adjusted as for the tribology

parameters, rigidity and mechanical

relations LuK keeps high technologi-

cal competence level in clutch

release systems.

The Future of Cylinders

LuK supplies master cylinders for

the clutch release system with

complete plastic project technology.

In different dimensions, connection

and fixing systems, the cylinders use

piston, seal and lubricant material

combinations, which keep the

actuation process smooth and

silent.

In the same manner, the develop-

ment of slave cylinders applies

plastic materials integrating

functions, assuring low weight and

innovating in the use of such

materials.

Piping-Easy Installation with

Innovation

On request, LuK coordinates the

development of pipe installation

and the supply of components.

Besides, with the use of rubber /

steel and plastic pipes, LuK, in

association with technical partners,

has developed a new polymer

technology that allows flexibility in

the installation, making easy the

quick fixing and allowing similar

routes as the cable route, with low

volumetric expansion, reducing

hydraulic losses at reduced applica-

tion costs.

Expertise in Clutch Pedal System

Projects

Always concerned to offer the best

technical solutions to meet the

current demands on comfort, and

approaching the pedal actuation

load as well as noises and vibrations

during actuation, LuK has created

and has been continuously enlarg-

ing its professional team with

experts specialized in pedals and

load compensation springs.

Moreover, LuK shows its compe-

tence in clutch release system and

components, minimizing noises and

vibrations, using technologies

grounded on innovative solutions by

means of plastics and polymers.

other countries and our headquarters in

Germany, provided a regular diffusion of

knowledge and allows the reduction of the

response time to technical challenges.

LuK stands for its special attention to its

partners and strives for local solutions

with global knowledge and technology.

Modern dual-clutch transmissions improve

the transmission system's efficiency and

combines the reduction in fuel

consumption of a manual transmission

with the comfort of an automatic

transmission. These transmissions offer an

excellent base to the progressive

hybridizing of a transmission on a modular

basis - from mild to full hybrid.

Definitionphase

Prototypephase

Optimizationphase

Productionprelaunch phase

Ramp-upphase

Develop product

Develop production process

Prepare production

Process quotation

Product Development Process (PEP)

Project Management PEP

Stableproduction

Define functions &processes

Inquiry Quotation Modificationfreeze

Internal SOP

Volume production

LuK supplies components and

systems for vehicle drivetrains

around the world. When Georg and

Wilhelm Schaeffler founded LuK in

1965, their objective was to produce

clutch cover with diaphragm spring

systems for the successor of the VW

Beetle. Today, LuK clutches are used

in one in four cars worldwide. With

innovative products and lean,

customer-oriented structures, LuK is

experiencing highly dynamic growth.

Almost all major automobile

manufacturers benefit from the

knowledge of LuK engineers.

Dedicated employees, innovation,

product development and

technological leadership are the

main factors of the company's

success. LuK makes project teams

available to all its customers to

ensure that specific requirements

are met.

As a technology leader in many

areas, LuK can look back on a legacy

of having developed many ground-

breaking innovations. In 1965, LuK

was the first company in Europe to

market a diaphragm spring clutch.

Twenty years later, LuK launched the

first dual-mass flywheel. This was

followed by the introduction of

components for CVTs that could

handle more than 300 Nm of torque,

as well as Auto Shift Gearbox (ASG)-

the world's first electromagnetically-

automated manual gearbox. In 1997,

LuK began engineering and

manufacturing torque converters in

the US; Germany followed in 2004.

LuK's current R&D efforts, in

addition to the continued

development of conventional

transmission systems, have a

particular focus on alternative

drivetrain concepts, such as

components for dual-clutch

transmissions and hybrid drivetrains.

LuK is also an important supplier of

many other products, such as

hydraulic cylinders.

OEM Automotive and Agricultural

Business focuses on new

developments and stands for

excellence in supply to

manufacturers. The Automotive

Aftermarket business unit, created

by LuK, is currently responsible for

the entire automotive aftermarket

business of the Schaeffler Group,

and supplies a large variety of

products of the INA, FAG and LuK

brands - about 20 thousand

different items of original

replacement parts, moreover

remanufactured products. The

company offers comprehensive

services to distributors,

wholesalers, repair shops and

exclusive car dealers, including a

strong technical assistance

program.

Project Tuning

Testing

ExpertiseExpertise

Prototyping

StampingMachining

shift speed.

Cylindrical Parts.

Heat Treatment

Clutch Assembly

Group.

Clutches (SAC)

pedal.

comfort.

gears.

Virtual Development

actuation systems.

release systems.

silent.

materials.

Innovation

tion costs.

Projects

Definitionphase

Prototypephase

Optimizationphase

Ramp-upphase

Develop product

Prepare production

Process quotation

Stableproduction

Internal SOP

Volume production

are met.

program.

Project Tuning

Testing

ExpertiseExpertise

Prototyping

StampingMachining

shift speed.

Cylindrical Parts.

Heat Treatment

Clutch Assembly

Group.

Clutches (SAC)

pedal.

comfort.

gears.

Virtual Development

actuation systems.

release systems.

silent.

materials.

Innovation

tion costs.

Projects

Definitionphase

Prototypephase

Optimizationphase

Ramp-upphase

Develop product

Prepare production

Process quotation

Stableproduction

Internal SOP

Volume production

are met.

program.

Clutch Systems

Tel.: 15 3335-1500

Partner

President & CEO

clutch systems industrial aerospace - schaeffler group · targeted investments in research and...

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