R D, Engineering And Quality Manager - apra- · PDF fileR&D, Engineering And Quality Manager 862 employees 998 employees 862 employees ... -Deco plingDecoupling the alternator from

APRA - EUROPE 2010

High Technology in Overrunning PulleysHigh Technology in Overrunning Pulleys

Dipl Ing. Marcelo GomezR&D, Engineering And Quality Manager

862 employees862 employees



35.000 m35.000 m2 2 -- built area built area

136 employees136 employees136 employees136 employees

Transform Metals in Reliable Products Transform Metals in Reliable Products

Triplicate the Sales 20092015Triplicate the Sales 20092015

1960 – Foundation1960 Foundation

1996 – ISO 9001

1999 – QS 9000

2002 – ISO/TS 16949

2006 – Technical-Commercial offices China, USA

2008 – Technical-Commercial office in Europe

2009 – ISO 14001

2010 BOSCH FFGA “P” D hi d2010 – BOSCH FFGA “P” Degree achieved

2010 – ZEN accomplish 50 years

Starter Drives68,04%

Motorcycle Parts0,15%

Overruning Pulleys6,13%

Cold Forged Parts 9,07%

Zen Aluminium12,97%

Planetary Assy0,35%

Tensioners1,05%

Other2,24%





Zen Aluminium12,97%

Planetary Assy0,35%

Tensioners1,05%

Other2,24%





Zen Aluminium12,97%

Planetary Assy0,35%

Tensioners1,05%

Other2,24%





Zen Aluminium12,97%

Planetary Assy0,35%

Tensioners1,05%

Other2,24%





Zen Aluminium12,97%

Planetary Assy0,35%

Tensioners1,05%

Other2,24%





Zen Aluminium12,97%

Planetary Assy0,35%

Tensioners1,05%

Other2,24%

N. America

S. America6,5%

Europe16,5%

18,2%

Brasil52 0%

IAM

C.America/Mex

Asia2,9%

,52,0%53%

OEM47%

Oceania0,1%

Africa0,5%

M. East0,7%

x2,3%

47%

300

200

250

100

150

0

50

0

Starter Drives Cold Formed Parts Aluminum Parts Overruning Pulleys Planetary Assy Motorcycle Parts Belt Tensioners

Damper Belt TensionerCombined Damper + Overrunning

Pulley

Planetary Assembly

Engines, Bench Tests and Prototype ResearchesEngines, Bench Tests and Prototype Researches

B lt T i Idl P ll & D T iBelt Tensioner, Idle Pulley & Damper Tensioner

Complete Development Facilities

Overrunning Pulley & Damper Pulley

ANVIDES – PLM tool for Product Development and Process ManagementHexagon – ZAR 5 Planetary Gear Calculation1 FEMAP/Nastran (Finite Element Analysis)

Simufact Forming (3D deformation).Hexagon – ZAR 1 Gear Calculation

AMESIM – Dynamic Simulationy15 SolidEdge Workstations

MATRIA (fit for Rings)

R&D Laboratory:- 11 Combustion Engines to develop automotive parts;

- Supervisor Software for engines management;- Complete structure for Starter Drive development;

Cooperation with Research Institutes:UFSC – Federal University of Santa CatarinaIEL – Innovation InstituteSenai – Foment Institute of TechnologyComplete structure for Starter Drive development;

- Test bench for overrunning pulley and belt tensioner;- HBM Acquisition System.

Senai – Foment Institute of TechnologySOCIESC – Foment Institute of TechnologyMETALAB – Analysis Lab

Total 19 employees- Failure Analysis & Vibration

- Finite Element & Fatigue

Total 20 employees- Plastic Injection - Heat Treatment- Cold Forming - Sheet Stamping

-1-D Dynamic Simulation-Lean Development

2 Msc Engineer2 Pos grad ated

1 Msc Engineer1 P g d t d

g p g- Machining - Assembling

2 Pos-graduated

2 Engineers on Msc Programs6 engineers

1 Pos-graduated

2 Engineers on Msc Programs2 engineers 3 Technologist

5 Technicians & 2 Trainees 11 Technicians

High Technology in Overrunning Pulley


SUMMARY

Overrunning Pulley Function Design features Benchmarking Product Performance OEM Validation Tests OEM Validation Tests Applications


Overrunning Pulley Function

Overruning Pulley Function

Why use a FWP?Deco pling the alternator from high ac clism generated b

y- Decoupling the alternator from high acyclism generated bythe combustion engines;

- Improve the behavior of the FEAD, since the alternator hasthe higher moment of inertia in the system

- Longer life of the belt;

- Allow the engine to run in very low idle speed and bringthe strategy to reduce fuel consumption and emissions

- Protect the regulator from overcharges;


ZEN’s One-Way Clutch Technology Function principle is the one way roller-clutch system

ZEN h b d i i thi t f t i it i th

y gy

ZEN has broad experience in this type of system, since it is the sameused in starter drives which are produced since 1960


Compact, Reliablep

C t d i ith f t Compact design with few components;

Ball Bearings and springs purchased from quality-d ISO TS liassured ISO-TS suppliers.


Robust Pulley

Cold formed pulley with inner cam profile

High quality steel;g q y ;

Internal ZEN heat treatment qualified by CQI-9 Standard.Q

Manufacturing process with high capability and dimensional stability y


Simulation - FEA The Pulley’s design was targeted to offer superior robustnesse ulley s des g was ta geted to o e supe o obust ess

Several analysis were performed to validate the concept

A d i i t d d t id li i d A new cam design was introduced to avoid slippage even in speedshigher than 18.000 RPM


1-D Dynamic SimulationA Dynamic Model was developed to simulate critical variablesA Dynamic Model was developed to simulate critical variablesof the system and define improvements for pulley design

Free Wheel Pulley DynamicsFree Wheel Pulley Dynamics

Dynamic ModelDynamic Model

Before OptimizationBefore Optimization After OptimizationAfter Optimization

Deleterious dynamic condition was eliminated


Tuned springs

Springs are tuned to have low overrunning torque and to avoid slippage in high angular speeds


Rollers

The rollers are produced at ZEN using bearing steel;

The heat treatment process is certified by CQI-9 standards;

Competitor A ZEN

The heat treatment process is certified by CQI 9 standards;

Several rollers with a fragile design 5 or 6 rollers with a robust design


Lockup Torque Capacity

h i bili d i h The torque transmittance capability was assured with a test performed in a special bench

h l b i h hi b l i l The result can be seen in the graphic below. For comparative resulta competitor product was tested in the same bench

Lock Torque TestLock Torque Test

60

70

40

50

(kgf

.m)

20

30

Tor

que ZEN

Competitor

0

10

0 8 16 23 29 34 40 46

Displacement (º)


Competitor A ZENBearing Design

Competitor A ZEN

Single sealing each side

No sealing between bearings and

Dual sealing each side

Sealing between bearings and No sealing between bearings and rollers.

Sealing between bearings and rollers to avoid contaminations;


Bearing sealing design

Radial clearance specification to reach the expected pulley life

The ball bearing supplier develop a special sealing for ZEN Pulleyg pp p p g y


C i i l f i f O Cl h

High-Performance Grease

Critical component to proper function of an One-Way Clutch system

ZEN has worked together with leading grease manufacturer to specify h b l ithe best solution

The result is a introduction of a high performance grease to work in d f l dextreme conditions for long periods

OEM Validation TestsTest Bench Configuration

ll i d b h O Fully monitored bench to run OEM tests

Experimental validation of the design iimprovements

The monitoring system gives real time information of variables such as:

Test Bench Belt Tension

Ambient Temperature

Test Bench

Ambient Temperature

Outside Pulley Rotation

Sh f l Shaft Alternator Rotation

Alternator OutputM it i tMonitoring system

OEM Validation Tests

High Speed Test

ZEN performs high speed test according to cycle described below:

OEM Validation TestsHigh Speed Test

Several test with different pulleys were carried out with no failures- Several test with different pulleys were carried out with no failures

- Transmission in high speed was excellent in all the product life as show bellow:bellow:

OEM Validation TestsHigh Speed Test

Results after 100.000 cycles

Normal function of the overrunning system

Results after 100.000 cycles

No abnormal wear in the contact parts

Normal grease conditiong

A li TOEM Validation Tests

d hi h li l f d f ll

Acyclism Test

Tests under high acyclism are also performed as follows:

OEM Validation TestsMud and Brine Test

Performed to confirm sealing effectiveness

The water solution have 5% of clay and 0,3 % of NaCl

Cycle TestCycle TestTest Bench

M d d B i T tOEM Validation Tests

Mud and Brine TestResults after 500 cycles (85 hr)

Noise level was acceptable

y ( )

Noise level was acceptable

The overrunning system was working normally

The bearings had no contamination

Field Tests

- Field tests were performed in Field tests were performed in extreme off-road conditions in Brazil.

- After 95.000 km the pulley was analyzed and show perfect conditions.

External OverviewExternal Overview Perfect SealingPerfect Sealing –– no internal contaminationno internal contaminationunlocked part (95.000 km)unlocked part (95.000 km)

Perfect Sealing Perfect Sealing no internal contamination no internal contamination and no grease leakeageand no grease leakeage


FINAL COMMENTSFINAL COMMENTS

Zen overrunning pulley design bring to FEAD very goodZen overrunning pulley design bring to FEAD very gooddynamic behavior;

Th ll b t i i d t The pulley robustness is superior compared tocompetitors and assure a reliable solution for theaftermarket and OE;aftermarket and OE;

ZEN Pulley exceed the OEM specifications of the mainautomotive manufacturers.

Documents

R D, Engineering And Quality Manager - apra- · PDF fileR&D, Engineering And Quality Manager 862 employees 998 employees 862 employees ... -Deco plingDecoupling the alternator from