FORM 2
THE PATENT ACT 1970 (as amended)
[39 OF 1970]
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
[See Section 10 and Rule 13]
TITLE: "A SYSTEM FOR TESTING DURABILITY OF A CLUTCH AND METHOD THEREOF"
Name and address of the Applicant:
TATA MOTORS LIMITED, an Indian company having its registered office at Bombay
House, 24 Homi Mody Street, Hutatma Chowk, Mumbai 400 001, Maharashtra, INDIA.
Nationality: INDIAN
The following specification particularly describes the nature of the invention and the manner in which it is to be performed.

TECHNICAL FIELD:
Embodiments of the disclosure relates to a system for testing clutch. More particularly, embodiments relate to the system for testing durability of the clutch.
BACKGROUND OF THE DISCLOSURE:
A clutch is a mechanical device which provides for the transmission of power from one member to another i.e. from driving member to the driven member. In vehicles the clutch is used to transfer the motion from engine to the transmission mechanism.
The clutch in the vehicle undergoes different loading conditions depending upon the loading conditions of the vehicle, road conditions and gear usage pattern on the vehicle. Depending upon above conditions, different level of energy is dissipated in the clutch leading to wear of the friction lining of the clutch disc. Hence, the durability of the clutch is to be tested before assembling the clutch in the automobile.
Conventionally the clutches are tested on the rig in which certain test inertia is simulated with inertia plates. The test conditions, inertia and test speed, are maintained constant through out the test. The inertia is selected based on the test requirements for the specific application. In these conventional test setups, only clutch assembly is tested. Further, it is not possible to test clutch for the dynamic conditions in the vehicle. Inertia loading is in steps and sudden running inertia change is not accurate and not possible. In addition, the accuracy in engine ramp up control, dynamic vehicle load condition simulation are all not possible with the conventional test setup.
Further, in the conventional system the clutch cannot be tested with its actuation system.
In light of foregoing discussion, it is necessary to provide a system for testing the clutch which would test the clutch for the specific vehicle application along with its actuation system, and is capable of simulating the different dynamic loading conditions for the clutch based on the power train configuration of the vehicle application.

STATEMENT OF THE DISCLOSURE:
Accordingly, the present disclosure provides a system for testing durability of a clutch, said system comprising, a test bench configured to form a base of the system, atleast one motor mounted on one end of the test bench configured to simulate an engine condition, atleast one motor mounted on other end of the test bench configured to simulate a vehicle condition; a mounting fixture provided in between the motors for mounting a clutch assembly; atleast one propeller shaft connected from each of the motors to the clutch assembly for transmitting the torque from motors to the clutch assembly; a control unit for regulating speed and torque of said motors to conduct durability test, and also relates to a method of conducting a durability test on a clutch, said method comprising acts of simulating an engine condition using a motor and simulating a vehicle condition using a motor; transmitting a torque from motors to a clutch assembly using atleast one propeller shaft connected from each of the motors to the clutch assembly; and operating a clutch pedal to engage and disengage the clutch for conducting durability test.
SUMMARY OF THE DISCLOSURE:
The shortcomings of the prior art are overcome and additional advantages are provided through the provision of system and method as claimed in the present disclosure.
Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
The present disclosure relates to a system for testing durability of a clutch. The system comprises, a test bench configured to form a base of the system, a pair of motors mounted on either ends of the test bench configured to simulate an engine condition and vehicle condition. A mounting fixture is provided in between the motors for mounting a clutch assembly and atleast one propeller shaft connected from each of the motors to the clutch assembly for transmitting the torque from motors to the clutch assembly. The system further comprises a control unit for regulating speed of said motors to conduct durability test.

In one embodiment of the present disclosure, a clutch pedal is mounted on the mounting fixture for engaging and disengaging clutch.
In one embodiment of the present disclosure, a pedal actuation mechanism is mounted proximal to the clutch pedal for actuating said clutch pedal.
In one embodiment of the present disclosure, the pedal actuation mechanism is interfaced with the control unit for receiving the signal to actuate the clutch pedal.
In one embodiment of the present disclosure, a frequency drive is connected to the motors for regulating the speed of the said motors.
In one embodiment of the present disclosure, the frequency drive is interfaced with the control unit for receiving the signal to regulate speed of the motors.
Another embodiment of the present disclosure relates to a method of conducting a durability test on a clutch. The method follows acts of simulating an engine condition using a motor and simulating a vehicle condition using a motor. Then transmitting a torque from motors to a clutch assembly using atleast one propeller shaft connected from each of the motors to the clutch assembly, and operating a clutch pedal to engage and disengage the clutch for conducting durability test.
In one embodiment of the present disclosure, regulating the speed and torque of the motors using the control unit.
In one embodiment of the present disclosure, operating a clutch pedal using a pedal actuation mechanism which is mounted proximal to a clutch pedal.
In one embodiment of the present disclosure, actuating the pedal actuation mechanism using the control unit.
In one embodiment of the present disclosure, simulating various vehicle parameters and loads (vehicle inertia, road gradient etc) by regulating the motors through a control unit.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
OBJECTIVES OF THE DISCLOSURE
One object of the present disclosure is to provide a system for testing a clutch which simulate working condition of clutch and perform durability test.
One object of the present invention is to provide a system for testing a clutch along with its actuation system for specific vehicle application based on the road mix, road loading conditions, different clutch engagement patterns and speeds, gear shift patterns etc.
One object of the present disclosure is to provide a system for testing a clutch which monitors operating parameters like energy dissipated per cycle/cumulative, pedal effort, temperatures inside clutch housing, pedal travel, CRB travel, torque, speed etc.
BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES
The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:
FIG. 1 illustrates a schematic of clutch test setup of the present disclosure.
The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION
The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
To overcome the drawbacks mentioned in the background a system for conducting durability test on clutch is disclosed. The system simulates the actual working condition of the clutch, hence better results of durability is obtained from the system.
As an exemplary embodiment of the present disclosure, FIG. 1 illustrates a schematic of system (100) for conducting durability test on the clutch. The system (100) comprises following components but not limited to a test bench (101) configured to form a base of the system (100), a pair of motors (102a and 102b) mounted on either ends of the test bench (101), one motor (102a) for simulating the engine condition and other motor (102b) simulating the vehicle condition. A mounting fixture (103) is provided in between the motors (102a and 102b) for mounting the clutch assembly (105) to be tested. The test setup (100) further comprises, a pair of propeller shafts (104) connecting the motors (102a and 102b) to the clutch assembly (105) for transmitting the torque from the motors (102a and 102b) to the clutch assembly (105), and a control unit (106) for controlling the parameters of the test. In addition to above a pedal actuation

(107) mechanism is provided in the system (100) for actuating the clutch pedal (105c) based on the signals received from the control unit (106).
The motors (102a and 102b) mounted on either ends of the test setup (100) are electric AC motors, and said motors (102a and 102b) acts as engine and vehicle respectively. The input to the motors (102a and 102b) is given by the control unit (106) which includes the control program of test rig comprising vehicle specifications of the vehicle under consideration. The vehicle specification includes but not limited to Gross Vehicle Weight (GVW) of the vehicle, gear ratios of the transmission, rear axle ratio, engine power and torque, dynamic tire radius, engine inertia rolling resistance etc for the vehicle application. The control unit (106) is interfaced with motors (102a and 102b) to regulate the speed and torque of the motors (102a and 102b). In one aspect of the present disclosure, a frequency drive is interfaced with the control unit (106) and the motors (102a and 102b) for regulating the speed of the motors (102a and 102b). The frequency drive (109) receives the signals from the control unit (106) and varies the frequency of alternate current to regulate the speed of the motors (102a and 102b) based on the signal from the control unit (106).
The clutch assembly (105) to be tested and clutch housing are mounted on the mounting fixture
(103) of the system (100). The mounting fixture (103) is designed such that the care is taken to
maintain the critical reference dimensions of flywheel and the clutch assembly (105) from engine
block face. The mounting fixture (103) is provided with mounting holes and dowel pins for
clutch housing as on engine block. In one aspect of the present disclosure, the clutch assembly
(105) comprises a clutch pedal (105c) mounted on the mounting fixture (103) and a clutch slave
cylinder (105d) and master cylinder (105e) mounted on the clutch and a clutch pedal (105c)
respectively to engage and disengage the clutch. The hydraulic line (105f) is fitted between
master cylinder (105d) and slave cylinder (105e) to operate the clutch.
The clutch assembly (105) comprises clutch input shaft connected to the motor (102a) simulating the engine condition through a propeller shaft (104) for transmitting the torque from motor (102a) to the clutch input shaft (105a). The clutch assembly (105) also comprises clutch output shaft connected to the motor (102b) simulating the vehicle condition through a propeller shaft
(104) for transmitting the torque from motor (102b) to the clutch output shaft (105b).

The pedal actuation mechanism (107) is mounted proximal to the clutch pedal (105c) for operating the clutch pedal (105c). The pedal actuation (107) system is interfaced with the control unit (106) for receiving the signals to engage and disengage the clutch. In one aspect of the present disclosure, the pedal actuation system (107) is servo actuator that actuates the clutch pedal (105c) based on the signal from the control unit (106). In the control unit (106), the clutch pedal (105c) travel is set for its fully disengaged and engaged condition through a teaching function while operating the electric servo actuator. Once the pedal travel is defined, same is used throughout the test. The control unit (106) has in built functions for defining different clutch disengagement and engagement patterns. The time for both disengagement and engagement of the clutch can be defined. As per the pattern selected and the time defined, the servo actuator will press and release the clutch pedal (105c).
In one aspect of the present disclosure, the system (100) for testing the clutch operates in the regenerating mode. For example the system (100) is designed such that it would use only 30 % of the power as compared to other rigs. When the motor acting as engine generates the power is transmitted through the test component and is absorbed by motor/dynamo. This absorbed power is consumed again to generate electricity and is fed back to the same power line (recirculation of power is achieved).
The control unit (106) has built in programs for different tests which can be further configured for the number specific variable related to the test. In one aspect of the present disclosure, the test programs stored in the control unit (106) comprising but not limited to:
1. Endurance test.
2. Shifting simulation test.
3. Gradient restart test.
4. Inertia simulation test.
The control unit (106) controls the road loads with two different approaches, one based on the torque control (Record Level Sharing-A) and other based on speed control (Record Level Sharing -B). There is threshold defined based on the inertia when to use RLS-A and RLS-B mode. Test no. 1,2 and 3 are run through RLS mode of the control system. In the RLS mode the

reflected inertia of the virtual vehicle as per the configuration is simulated. Based on the gear shift to be simulated (as defined in the test cycle), the motor (2) simulate the reflected inertia and speed of the vehicle at clutch (w.r.t gear and final drive ratio) and motor (1) simulates the engine. The clutch is then engaged with speed differential, dissipating the energy.
1. Endurance test:
In the Endurance test configuration, the test is defined in terms of gear shift from 'x' gear to y gear at specific speed difference between engine and gear box input shaft (differential speed during clutch engagement), number of times the gear shift from V gear to y gear at specific speed difference between engine and gear box input shaft shift pattern is repeated.
In the system (100) of the present disclosure, maximum 10 shift patterns can be defined in one cycle. And in the control unit (106) total number of cycles to be repeated is defined.
2, Shirking simulation test:
The 'Shift Simulation Test' is a test that read file data recorded at real vehicle and relays the data on the rig. The test is defined in terms of gear shifting sequence and the vehicle speed at which the gear to be shifted from V gear to y gear.
In the control unit (106) the following sequence is defined for one cycle, the road gradient to be simulated and the number of time this cycle to be repeated.
3. Gradient Restart test:
The gradient test simulates a start of a vehicle on a configurable road gradient. The purpose of
the test is to generate high amount of work in less time.
In the control unit (106) the following terms are defined to carry out the test; the road gradient to be used for testing, gear to be used for the simulation and number of cycles to done.
4. Inertia Simulation Test:
In the inertia simulation test the clutch is tested against fixed test inertia (as per the test
requirement) and fixed test speed. In the control unit (106) the test inertia is specified and the

speed of Motor (102a) is specified. The Motor (102a) runs continuously with the specified speed during the engagement and disengagement.
The system (100) for testing a clutch comprises plurality of torque transducers (108) and plurality of speed sensors mounted on outputs shafts of the motors (102a and 102b) and the clutch assembly (105) to measure the torques and the speed respectively during testing. The measured torque and speed are analyzed to measure the parameters such as work done during each engagement, cumulative work done, torque of motors, torque differential during engagement. The system (100) for testing a clutch further comprises plurality of temperature sensors mounted in the clutch assembly (105) for measuring the clutch housing temperature. And a sensor in mounted on clutch pedal (105c) to predict the force to actuate the clutch pedal (105c) at various operating parameters.
Advantages:
The present disclosure provides a system for testing a clutch which simulate working condition of clutch and perform durability test.
The present disclosure provides a system for testing a clutch, using the instant test setup the clutch can be tested with its actuation system for specific vehicle application based on the road mix, road loading conditions, different clutch engagement patterns and speeds, gear shift patterns etc.
The present disclosure provides a system for testing a clutch in which the test rig is more precisely designed to act like engine and the program is so responsive that it can behave exactly like any type of engine with the different torque, speed and power curve exactly matching it. Hence, the clutch can be tested in actual working condition.
Equivalents
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in
the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms
(e.g., the term "including" should be interpreted as "including but not limited to," the term
"having" should be interpreted as "having at Jeast," the term "includes" should be interpreted as
"includes but is not limited to," etc.). It will be further understood by those within the art that if
a specific number of an introduced claim recitation is intended, such an intent will be explicitly
recited in the claim, and in the absence of such recitation no such intent is present. For example,
as an aid to understanding, the following appended claims may contain usage of the introductory
phrases "at least one" and "one or more" to introduce claim recitations. However, the use of
such phrases should not be construed to imply that the introduction of a claim recitation by the
indefinite articles "a" or "an" limits any particular claim containing such introduced claim
recitation to inventions containing only one such recitation, even when the same claim includes
the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or
"an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or
more"); the same holds true for the use of definite articles used to introduce claim recitations. In
addition, even if a specific number of an introduced claim recitation is explicitly recited, those
skilled in the art will recognize that such recitation should typically be interpreted to mean at
least the recited number (e.g., the bare recitation of "two recitations," without other modifiers,
typically means at least two recitations, or two or more recitations). Furthermore, in those
instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general
such a construction is intended in the sense one having skill in the art would understand the
convention (e.g., "a system having at least one of A, B, and C" would include but not be limited
to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C
together, and/or A, B, and C together, etc.). In those instances where a convention analogous to
"at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense
one having skill in the art would understand the convention (e.g.. "a system having at least one of
A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A
and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be
further understood by those within the art that virtually any disjunctive word and/or phrase
presenting two or more alternative terms, whether in the description, claims, or drawings, should

be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
Referral Numerals;

Reference Number Description
100 Clutch test setup
101 Test bench
102a Motor simulating the engine
102b Motor simulating the engine
103 Mounting fixture
104 Propeller Shafts
105 Clutch assembly
105a Input shaft of the clutch
105b Output shaft of the clutch
105c Clutch pedal
105d Clutch Master cylinder
105e Clutch Slave cylinder
105f Hydraulic line
106 Control unit
107 Clutch pedal actuation system
108 Torque transducers
109 Frequency drive

We claim:
1. A system (100) for testing durability of a clutch, said system (100) comprising:
a test bench (101) configured to form a base of the system (100);
atleast one motor (102a) mounted on one end of the test bench (101) configured to simulate an engine condition;
atleast one motor (102b) mounted on other end of the test bench (101) configured to simulate a vehicle condition;
a mounting fixture (103) provided in between the motors (102a and 102b) for mounting a clutch assembly (105);
atleast one propeller shaft (104) connected from each of the motors (102a and 102b) to the clutch assembly (105) for transmitting the torque from motors (102a and 102b) to the clutch assembly (105);
a control unit (106) for regulating speed and torque of said motors (102a and 102b) to conduct durability test.
2. The system as claimed in claim 1, wherein a clutch pedal (105c) is mounted on the mounting1 fixture (103) for engaging and disengaging clutch.
3. The system as claimed in claim 2, wherein a pedal actuation mechanism (107) is mounted proximal to the clutch pedal (105c) for actuating said clutch pedal (105c).
4. The system as claimed in claim 2, wherein the pedal actuation (107) mechanism is interfaced with the control unit (106) for receiving the signal to actuate the clutch pedal (105c).
5. The system as claimed in claim 1, wherein a frequency drive (109) is connected to the motors (102a and 102b) for regulating the speed of the said motors(102a and 102b).
6. The system as claimed in claim 5, wherein the frequency drive (109) is interfaced with the control unit (106) for receiving the signal to regulate speed of the motors (102a and 102b).

7. A method of conducting a durability test on a clutch, said method comprising acts of:
simulating an engine condition using a motor (102a) and simulating a vehicle condition using a motor (102b);
transmitting torque from motors (102a and 102b) to a clutch assembly (105) using atleast one propeller shaft (104) connected from each of the motors (102a and 102b) to the clutch assembly (105); and
operating a clutch pedal (105c) to engage and disengage the clutch for conducting durability test.
8. The method as claimed in claim 7, wherein regulating the speed of the motor 102a
and torque of the motor 102b using the control unit (106).
9. The method as claimed in claim 7, wherein a clutch pedal (105c) using a pedal
actuation mechanism (107) which is mounted proximal to the clutch pedal (105c).
10. The method as claimed in claim 9, wherein actuating the pedal actuation mechanism (] 07) using the control unit (106).
11. The method as claimed in claim 7, wherein simulating various vehicle parameters and load conditions by regulating the motors (102a and 102b) through a control unit (106).
12. A system for testing durability of a clutch, a method of conducting a durability test on a clutch are substantially as herein above described and as illustrated in accompanying drawings.