Customised clutch

Recently, a manufacturer of power transmission systems for locomotives approached Warner’s engineers with a request for a customised clutch to integrate with a new hybrid transmission; a challenge they were eager to accept.

The nature of the application meant that the clutch had to perform to a very tight set of parameters. Firstly, it must be able to cope with high speeds (up to 3,000 rpm) and high torque (up to 5,000 Nm) for an operating life of over 50,000 hours without maintenance. Because the clutch itself would be enclosed in a housing as part of the transmission, access for maintenance would be nigh on impossible. The housing also meant that the clutch would be exposed to extreme operating temperatures and was required to operate reliably in ambient temperatures ranging from -40°C to 100°C.

No stranger to heavy duty, industrial applications, Warner’s engineers were able to use the standard E220 range of robust electromagnetic clutches as a starting point. The E220 range of power-activated, zero backlash clutches is designed for embedded applications and is particularly suited to hybrid transmissions where no residual torque can be transmitted when the clutch is disengaged.

In this case, the clutch has been specifically adapted for connecting a diesel engine to an electric drive system when the battery power is low. A tolerance of +/-30% on the pilot voltage of the clutch has been included and a stabilising system has been implemented to avoid any unforeseen engagement. Sealed bearings and a specialised friction face composition have also been added for longevity without maintenance.

The E220 range is available from Warner Electric in a number of different sizes as standard, though customisation is available to suit almost any application.