Hydraulic clutch and method of manufacturing the same

Abstract

A hydraulic clutch and its manufacturing method are disclosed, belonging to the field of clutch technology. The aim is to solve the technical defects of existing friction clutches (rapid wear), gear clutches (large impact), and unstable operation), and to provide a highly efficient, stable, and durable hydraulic clutch and a standardized manufacturing method. The hydraulic clutch includes components such as a base shell, middle shell, upper shell, driving gear, driven gear, high-pressure valve, pressure ring shift fork, and hydraulic oil pipes. The opening of the high-pressure valve is adjusted by pushing the pressure ring shift fork to control the flow of the hydraulic medium, thereby achieving precise switching between three working states: closed, disengaged, and semi-engaged. Each gear and housing is fitted with a micro-clearance and equipped with sliding bearings. Sealing rings are installed at the connections between the housings, and a return spring is installed between the pressure ring shift fork and the end cover to ensure smooth transmission, sealing, and service life. The manufacturing method achieves standardized production through theoretical parameter calculation, preliminary determination of structural parameters, precise parameter verification, component processing and assembly, and testing and debugging, ensuring product consistency and compatibility. This invention features smooth transmission, precise control, low wear, and good sealing. It is manufactured using a standardized process and can be widely applied to various mechanical devices that require power transmission and separation, as well as semi-linkage control. It is especially suitable for engineering operations and heavy-duty transport vehicles.

Description

Technical Field

[0001] This invention belongs to the field of clutch technology, and in particular to a hydraulic clutch and its manufacturing method. Background Technology

[0002] The clutch is located in the flywheel housing between the engine and the transmission. During vehicle operation, the driver can depress or release the clutch pedal as needed to temporarily separate and gradually engage the engine and transmission, cutting off or transmitting power from the engine to the transmission. Therefore, the clutch is a commonly used component for changing the mechanical transmission path. Existing clutches are mainly of two types: gear-type and friction-type. In the automotive industry, the most commonly used clutch is the friction clutch. This type of clutch transmits torque through physical friction. The clutch friction plates are prone to wear, especially in engineering and heavy-duty transport vehicles, where they typically need to be replaced every tens of thousands or even thousands of kilometers. This is not only time-consuming and labor-intensive but also quite expensive. Gear clutches, on the other hand, generally experience greater impact and unstable operation when changing between disengagement and engagement. Summary of the Invention

[0003] To address the aforementioned problems, this invention provides a hydraulic clutch and its manufacturing method. It enables efficient and stable control and transmission of power, while maintaining long-term durability. To achieve the above-mentioned objectives, the present invention provides a hydraulic clutch, the core technical solution of which is as follows: A hydraulic clutch includes a bottom housing (1) that carries the entire clutch, a middle housing (2) that encloses the gears, and an upper housing (3) through which a high-pressure valve (13) for performing separation and an output shaft (23) protrudes; it includes a drive gear (4) and a driven gear (5, 6), a hydraulic oil pipe (12) and a high-pressure ball valve (13), and a pressure ring fork (10) for controlling the opening of the high-pressure valve; by pushing the pressure ring fork (10) with an external force to control the opening of the high-pressure valve (13) to control the flow of hydraulic oil, the rotational resistance of the gears (4, 5, 6) is controlled. When the high-pressure valve (13) is closed, the circuit between the high-pressure chamber and the low-pressure chamber formed by the driving gear (4) and the driven gear (5, 6) is closed, the hydraulic oil cannot flow, the driving gear (4) and the driven gear (5, 6) are locked at the same time, the output shaft (23) rotates with the housing, and the clutch is in the closed state; when the high-pressure valve (13) is open, the hydraulic medium pumped out by the driving gear (4) and the driven gear (5, 6) flows back to the low-pressure chamber (22) through the oil pipe (12) of the high-pressure chamber (21) to form a circuit, the output shaft (23) does not rotate with the housing, and the clutch is in the disengaged state; when the high-pressure valve (13) is half open, the hydraulic medium pumped out by the driving gear (4) and the driven gear (5, 6) from the high-pressure chamber (21) flows back to the low-pressure chamber (22) with resistance, the speed of the output shaft (23) is lower than the speed of the housing, and the clutch is in the semi-engaged state. The larger the opening of the high-pressure valve (13), the greater the flow of the hydraulic medium, and the lower the speed of the output shaft (23). Furthermore, the drive gear (4), driven gear (5, 6), bottom shell (1), middle shell (2) and upper shell (3) are all fitted with micro-clear gaps. The size of these micro-clear gaps is precisely calculated and determined based on the material, flow rate and gear speed of the hydraulic medium. This ensures the normal flow of the hydraulic medium, effectively prevents hydraulic medium leakage, and reduces wear between components. Furthermore, sliding bearings are provided between the drive gear (4), the driven gear (5, 6) and the bottom shell (1) and the upper shell (3). The sliding bearings are made of wear-resistant and high-temperature resistant materials, which can effectively reduce the frictional resistance between the gears and the shell, reduce component wear, and extend the service life of the clutch. Furthermore, the working state of the clutch is controlled by controlling the opening and closing state of the high-pressure valve (13). Specifically, the opening degree of the high-pressure valve (13) is adjusted by the thrust of the pressure ring shift fork (10), so as to achieve precise switching between the three working states of closing, disengagement, and semi-clutching, and meet the power transmission requirements under different working conditions. Furthermore, sealing rings are provided between the bottom shell (1) and the middle shell (2), between the middle shell (2) and the upper shell (3), and between the upper shell (3) and the end cover (9). The sealing rings are made of oil-resistant and high-temperature resistant elastic material, which can effectively enhance the sealing performance of the clutch, prevent hydraulic medium leakage, and ensure the normal operation of the clutch. Furthermore, a reset spring (11) is provided between the pressure ring fork (10) and the end cover (9). The reset spring (11) is always in a pre-tightened state. When the external force is removed, it can push the pressure ring fork (10) to automatically reset, ensuring that the high pressure valve (13) returns to its initial state and improving the reliability of the clutch working state switching. The present invention also provides a method for manufacturing the above-mentioned hydraulic clutch, specifically including the following steps: A1: Calculate the theoretical torque and speed that the hydraulic clutch needs to transmit based on the requirements. Calculate the output shaft diameter and the theoretical torque that the spline hole on the output shaft can withstand, taking into account the output shaft material. Calculate the peak flow velocity of the hydraulic medium based on the pressure it can withstand and the clutch speed. Calculate the micro-clearances between gears and between the gears and the housing based on the material of the hydraulic medium. Calculate the gear module based on the flow velocity of the hydraulic medium and the maximum speed of the gears. A2: Preliminary determination of the structural parameters of the hydraulic clutch, including: the module, diameter and thickness of the gears, the diameter of the output shaft, the diameter of the high-pressure oil pipe, and the effective inner diameter of the high-pressure valve. A3: Based on the rules of material mechanics, fluid mechanics, and safety factors of mechanical mechanisms, calculate accurate physical structure data to ensure that the structural strength and fitting accuracy of each component meet the usage requirements, while ensuring smooth flow of hydraulic medium and transmission efficiency that meets design standards. Attached Figure Description To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Figure 1 : A cross-sectional view of the overall structure of the hydraulic clutch of the present invention; Figure 2 : A schematic diagram of the gear engagement structure of the hydraulic clutch of the present invention; Figure 3 : Schematic diagram of the high-pressure valve and pressure ring shift fork cooperation structure of the hydraulic clutch of the present invention; In the diagram: 1-bottom shell, 2-middle shell, 3-upper shell, 4-drive gear, 5-drive gear, 6-drive gear, 7-sliding bearing, 8-sliding bearing, 9-end cover, 10-pressure ring shift fork, 11-reset spring, 12-hydraulic oil pipe, 13-high pressure valve, 14-oil pipe nut, 15-sealing ring, 16-sealing ring, 17-sealing ring, 18-oil seal, 19-spline hole, 20-screw, 21-high pressure chamber, 22-low pressure chamber, 23-output shaft. Detailed Implementation The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example 1: A hydraulic clutch like Figure 1-3 As shown, this embodiment provides a hydraulic clutch, including a bottom shell (1), a middle shell (2), and an upper shell (3). The bottom shell (1) is used to bear the weight of the entire clutch and to install the various components. The middle shell (2) is wrapped around the drive gear (4) and the driven gear (5, 6) to protect the gears and seal the hydraulic medium. A high-pressure valve (13) for performing the separation action is installed on the upper shell (3), and the output shaft (23) passes through the upper shell (3) to realize power output. The driving gear (4) meshes with the driven gears (5, 6) and is installed between the bottom shell (1) and the upper shell (3). The driving gear (4), driven gears (5, 6) and the bottom shell (1) and upper shell (3) are all fitted with a micro-clearance. The size of the micro-clearance is calculated and determined according to the material, flow rate and maximum speed of the hydraulic medium (such as hydraulic oil) used. In this embodiment, the micro-clearance is controlled at 0.02-0.05mm, which can ensure the normal flow of the hydraulic medium and effectively prevent leakage. At the same time, sliding bearings are provided between the driving gear (4), driven gears (5, 6) and the bottom shell (1) and upper shell (3). The sliding bearings are made of tin bronze, which has good wear resistance and high temperature resistance, and can effectively reduce the frictional resistance between the gears and the shell and reduce component wear. A hydraulic oil pipe (12) is also installed on the upper shell (3). One end of the hydraulic oil pipe (12) is connected to the high-pressure chamber (21), and the other end is connected to the low-pressure chamber (22). The high-pressure chamber (21) and the low-pressure chamber (22) are formed by the gap between the driving gear (4) and the driven gear (5, 6). The high-pressure valve (13) is a high-pressure ball valve, which is installed on the hydraulic oil pipe (12) to control the opening and closing of the hydraulic oil pipe (12) and the flow rate. The pressure ring fork (10) is installed on the end cover (9). One end of it is connected to the high-pressure valve (13), and the other end is used to receive external force. By pushing the pressure ring fork (10), the opening degree of the high-pressure valve (13) can be adjusted, thereby controlling the flow rate of the hydraulic medium. Sealing rings are provided between the bottom shell (1) and the middle shell (2), between the middle shell (2) and the upper shell (3), and between the upper shell (3) and the end cover (9). The sealing rings are made of fluororubber, which is oil-resistant and high-temperature resistant, and can effectively enhance the sealing performance of the clutch and prevent hydraulic medium leakage. A return spring (11) is provided between the pressure ring shift fork (10) and the end cover (9). The return spring (11) is a cylindrical helical spring, which is always in a pre-tightened state. When the external force is removed, the return spring (11) pushes the pressure ring shift fork (10) to automatically reset, so that the high-pressure valve (13) returns to the initial closed state, ensuring the reliability of the clutch working state switching. The working principle of the hydraulic clutch in this embodiment is as follows: 1. Closed state: When the high pressure valve (13) is in the closed state, the circuit between the high pressure chamber (21) and the low pressure chamber (22) formed between the driving gear (4) and the driven gear (5, 6) is closed, the hydraulic medium cannot flow, the driving gear (4) and the driven gear (5, 6) are locked due to the resistance of the hydraulic medium, and the output shaft (23) rotates together with the housing composed of the bottom shell (1), the middle shell (2) and the upper shell (3). At this time, the clutch is in the closed state, realizing the full transmission of power. 2. Disengaged state: When the external force pushes the pressure ring fork (10) to fully open the high pressure valve (13), the hydraulic medium pumped out by the driving gear (4) and the driven gear (5, 6) flows smoothly back to the low pressure chamber (22) through the high pressure chamber (21) and the hydraulic oil pipe (12), forming a complete hydraulic circuit. The hydraulic medium flows smoothly, the resistance between the driving gear (4) and the driven gear (5, 6) disappears, and the output shaft (23) does not rotate with the housing. At this time, the clutch is in the disengaged state, and the power transmission is interrupted. 3. Semi-clutch state: When the external force pushes the pressure ring fork (10) to make the high pressure valve (13) half open, the flow area of ​​the hydraulic oil pipe (12) decreases. When the hydraulic medium pumped out by the driving gear (4) and the driven gear (5, 6) flows back to the low pressure chamber (22), it is resisted, the flow rate of the hydraulic medium decreases, there is a certain resistance between the driving gear (4) and the driven gear (5, 6), and the speed of the output shaft (23) is lower than the speed of the housing. At this time, the clutch is in a semi-clutch state. The larger the opening of the high pressure valve (13), the greater the flow rate of the hydraulic medium, and the lower the speed of the output shaft (23), which can realize stepless adjustment of power. Example 2: A method for manufacturing a hydraulic clutch This embodiment provides a method for manufacturing the above-mentioned hydraulic clutch, which specifically includes the following steps: A1: Preliminary parameter calculations: Based on the actual usage requirements of the hydraulic clutch, the theoretical torque to be transmitted is determined to be 500 N·m, and the speed is 1500 r / min; 45 steel is selected as the output shaft material, and the output shaft diameter is calculated to be 50 mm according to the material mechanics formula, and the theoretical torque that the spline hole on the output shaft can withstand is 480 N·m; 32 anti-wear hydraulic oil is selected as the hydraulic medium, and its maximum pressure is 10 MPa. Combined with the clutch speed, the peak flow velocity of the hydraulic medium is calculated to be 8 m / s; based on the viscosity, density, and other material parameters of the hydraulic oil, the micro-clearance between gears and between gears and housing is calculated to be 0.03 mm; based on the flow velocity of the hydraulic medium and the maximum speed of the gears (1800 r / min), the gear module is calculated to be 3. A2: Preliminary determination of structural parameters: Based on the calculation results of step A1, the structural parameters of the hydraulic clutch are preliminarily determined as follows: the gear module is 3, the diameter of the driving gear is 120mm and the thickness is 40mm, the diameter of the driven gear (5, 6) is 80mm and the thickness is 40mm; the output shaft diameter is 50mm and the length is 200mm; the diameter of the high-pressure oil pipe is 15mm; and the effective inner diameter of the high-pressure valve is 10mm. A3: Precise parameter calculation: Based on the principles of material mechanics, the wall thickness of the bottom shell (1), middle shell (2), and upper shell (3) is calculated to be 15mm to ensure that the structural strength meets the load-bearing requirements; Based on the principles of fluid mechanics, the length and bending angle of the hydraulic oil pipe (12) are optimized to ensure smooth flow of the hydraulic medium and that the pressure loss is controlled within 0.5MPa; Based on the safety factor rules of mechanical mechanisms (the safety factor is 1.5), the dimensions of key components such as gears, output shafts, pressure ring shift forks (10) are precisely calculated, and the precise physical structure data of each component are finally determined to ensure that the product quality meets the design standards. A4: Component processing and assembly: According to the precise parameters determined in step A3, process the bottom shell (1), middle shell (2), upper shell (3), drive gear (4), driven gear (5, 6), output shaft (23), pressure ring shift fork (10) and other components. After processing, perform surface treatment (such as rust removal and quenching). Install the sliding bearings in the corresponding installation positions of the bottom shell (1) and upper shell (3), and install the sealing rings at the connection of each shell. Install the drive gear (4) and driven gear (5, 6) on the bottom shell (1), and assemble the middle shell (2), upper shell (3) and end cover (9) in sequence. Install the return spring (11), pressure ring shift fork (10) and high pressure valve (13), connect the hydraulic oil pipe (12), inject hydraulic medium, and complete the assembly of the hydraulic clutch. A5: Inspection and Debugging: Perform sealing tests, transmission efficiency tests, and working state switching tests on the assembled hydraulic clutches to ensure that there is no leakage of hydraulic medium, smooth switching between the three states of closure, disengagement, and semi-clutching, and that the output torque and speed meet the design requirements. Unqualified products are reworked or scrapped. The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A hydraulic clutch, characterized in that: The clutch includes a bottom housing (1) that carries the entire clutch, a middle housing (2) that encloses the gears, and an upper housing (3) through which the high-pressure valve (13) for separation and the output shaft (23) protrudes. The clutch also includes a drive gear (4) and a driven gear (5, 6), a hydraulic oil pipe (12) and a high-pressure ball valve (13), and a pressure ring fork (10) for controlling the opening of the high-pressure valve. The opening of the high-pressure valve (13) is controlled by external force pushing the pressure ring fork (10), which controls the flow of hydraulic oil and thus controls the rotational resistance of the gears (4, 5, 6). When the high-pressure valve (13) is closed, the circuit between the high-pressure chamber and the low-pressure chamber formed by the driving gear (4) and the driven gear (5, 6) is closed, the hydraulic oil cannot flow, the driving gear (4) and the driven gear (5, 6) are locked at the same time, the output shaft (23) rotates with the housing, and the clutch is in the closed state; when the high-pressure valve (13) is open, the hydraulic medium pumped out by the driving gear (4) and the driven gear (5, 6) flows back to the low-pressure chamber (22) through the oil pipe (12) of the high-pressure chamber (21) to form a circuit, the output shaft (23) does not rotate with the housing, and the clutch is in the disengaged state; when the high-pressure valve (13) is half open, the hydraulic medium pumped out by the driving gear (4) and the driven gear (5, 6) from the high-pressure chamber (21) flows back to the low-pressure chamber (22) with resistance, the speed of the output shaft (23) is lower than the speed of the housing, and the clutch is in the semi-engaged state. The larger the opening of the high-pressure valve (13), the greater the flow of the hydraulic medium, and the lower the speed of the output shaft (23).

2. A hydraulic clutch as described in claim 1, characterized in that, All of the drive gear (4), driven gears (5, 6), bottom shell (1), middle shell (2) and top shell (3) are micro-clear clearance fits.

3. A hydraulic clutch as described in claim 1, characterized in that, Sliding bearings are provided between the driving gear (4), the driven gear (5, 6) and the bottom shell (1) and the upper shell (3).

4. A hydraulic clutch as described in claim 1, characterized in that, The working state of the clutch is controlled by controlling the opening and closing state of the high-pressure valve (13).

5. A hydraulic clutch as described in claim 1, characterized in that, Sealing rings are provided between the bottom shell (1) and the middle shell (2), between the middle shell (2) and the upper shell (3), and between the upper shell (3) and the end cap (9).

6. A hydraulic clutch as described in claim 1, characterized in that, A return spring (11) is provided between the pressure ring fork (10) and the end cover (9).

7. A method for manufacturing a hydraulic clutch, characterized in that, Including the following: A1: Calculate the theoretical torque and speed that the hydraulic clutch needs to transmit based on the requirements. Calculate the output shaft diameter and the theoretical torque that the spline hole on the output shaft can withstand, taking into account the output shaft material. Calculate the peak flow velocity of the hydraulic medium based on the pressure it can withstand and the clutch speed. Calculate the micro-clearances between gears and between the gears and the housing based on the material of the hydraulic medium. Calculate the gear module based on the flow velocity of the hydraulic medium and the maximum speed of the gears. A2: Preliminary determination of the structural parameters of the hydraulic clutch, including: the module, diameter and thickness of the gears, the diameter of the output shaft, the diameter of the high-pressure oil pipe, and the effective inner diameter of the high-pressure valve. A3: Based on the safety factor rules of materials mechanics, fluid mechanics, and mechanical mechanisms, calculate the accurate physical structure data.

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