Clutch Selection for American Marine Z-Drive Product

1
Clutch Selection for American MarineZ-Drive
Product

• ETM 5131 Project
• Phillip Magee
• July, 2004

2

• Problem Statement

American Marine has approved a project for a new
z-drive to replace the current Charlie and Delta
products. The new z-drive project is currently
in the conceptual phase. The purpose of this
project is to select a clutch type to be used in
a new z-drive design for American Marine.
Clutch type selection has a large impact on the
products overall design.
3

• Objectives

Information on available clutch
types Information on clutch safety Information
on clutch performance attributes and
cost Clutch type selection for the new z-drive
project
4

• Approach

5

• Alternatives Considered

Twelve clutch types were brainstormed and
considered in selection. The following clutch
types were analyzed for safety Dog Cone Wet
Disk Wet Disk Dry Disk Band The following top
4 clutch type and driveline configurations were
analyzed in a decision analysis. 1. Cone
Clutch (Bravo Style) in the upper portion of the
z-drive 2. Dog Clutch (Alpha Style) in the lower
portion of the z-drive 3. Synchronized Toothed /
Dog (w/ 2 Stage Engine Coupler) 4. Wet Disk
Master Clutch (One Engine) / Dog Selector (In
Drive)
6

• Analysis Results

Benchmarking Provided a list of current
clutches, their applications, and actuation
systems This gave the team participants
information to begin later processes ETBD Used a
Diagram to organize the energy flow in the
z-drive system and listed barriers to that
flow. Focused the team on the importance of the
clutch function for safety PHL Listed the
hazards associated with a z-drive clutch Showed
the team that a z-drive clutch fails in only 3
ways. To Forward To Neutral To Reverse
7

• Analysis Results

PHA Used FMEA to provide a Risk priority number
to each failure mode of each clutch. Showed the
team that the dog clutch only fails to neutral
(Does not transmit power when it should be
coupled). This gives the dog clutch a safety
advantage.
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• Analysis Results

Decision Analysis Used team exercises and other
data to provide brainstorm clutch and
driveline types set criteria weight
criteria rank clutch and driveline types based
on weighted criteria estimate the value of
each clutch and driveline type. This
presented the positive attributes of the dog
clutch to the team and ultimately led to the
modular z-drive configuration utilizing a dog
and wet disk clutch.
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• Conclusion

The clutch type and modular driveline selected
for development Offers flexibility to satisfy
low cost needs with a safe, reliable, and
durable dog clutch While, giving the option to
add a more expensive wet disk master clutch that
provides greatly improved shift characteristics
along with the safety, reliability, and
durability of the dog clutch for premium
products
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• Recommendations

System models should be created for the modular
driveline and shift characteristics should be
analyzed based on these models. A prototype
should be build and tested in the base product
dog configuration and in the premium product dog
selector and wet disk master clutch
configuration. A detailed cost study should be
completed along with more detailed designs. This
activity can be completed by 12/17/04 within the
current new z-drive engineering budget.
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• Use of MSETM Materials

Benchmarking The benchmarking portion of this
report used the concepts learned for process
benchmarking in a light product benchmarking
exercise System Safety The PHL and PHA
processes learned in the system safety class
were utilized in order to help direct a
significant design selection in early design
stages Failure Modes and Effects Analysis FMEA
processes presented in the FMEA course were used
to complete the PHA Problem Solving and Decision
Making Decision analysis process attributes
presented in the problem solving and decision
analysis course were utilized to evaluate the
clutch alternatives