An Internship Report on

Electronically Assisted Clutch

Submitted to

Vishwakarma Institute of Technology, Pune (An

Autonomous Institute Affiliated to Savitribai Phule Pune
University)

in partial fulfilment of the requirements for

B.Tech.
in
Production Engineering
by
Mayank.S.Jain
(GR No:-162155)

Under the guidance of

Prof. Sunil Kuber

Department of Industrial & Production

Engineering Vishwakarma Institute of
Technology, Pune-411037 Academic Year 2018-19

1
 Bansilal Ramnath Agarwal Charitable Trust’s
Vishwakarma Institute of Technology, Pune-37
(An Autonomous Institute Affiliated to Savitribai Phule Pune
University)

Certificate
This is to certify that the project titled, Electronically Assisted Clutch
submitted by Mayank S Jain (GR.No:- 162155) is a record of bonafide work
carried out by them under my guidance in partial fulfilment of the requirement
for Bachelor of Technology in Production Engineering.

Prof. (Dr .) Girish .

Prof. Sunil Kuber
Kotwal
Project Guide
Dept. of Production Head of Department
Engg Dept. of Industrial
Engg
VIT, Pune
VIT, Pune

Date:
Place: Pune

2
 Examiner Certificate

This is to certify that the project titled, Electronically Assisted Clutch

submitted by Mayank S Jain (GR.No:- 162155) is approved for the award of
the Degree of Bachelor of Technology in Production Engineering of
Vishwakarma Institute of Technology, Pune

Signature:

Examiner : Prof. Sunil Kuber

Examiner :

Date:
Place: Pune

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 Acknowledgement

I am very fortunate to be a part of Internship program initiated by the

Department of Production Engineering, VIT. I would like to express my
gratitude for shaping this initiative into a successful model. The internship
program bridges the gap between an industry and academics. I would like to
thank Prof. (Dr.) Girish Kotwal, Head, Industrial & Production Dept;
Internship Guide, Prof, Sunil Kuber Production department for their immense
support and guidance and for holding the academic side of the semester
together, throughout the internship period.
The internship opportunity I had with TATA Motors, Pune was a great
chance for learning and professional development. Therefore, I consider myself
as a very lucky individual as I was provided with an opportunity to be a part of
it. I am also grateful for having a chance to meet so many wonderful people and
professionals who led me though this internship period.
I express my deepest thanks to Mr. Makarand Takale( AGM Utility
vehicles TATA Motors Pune) for helping me on every step of my internship &
giving necessary advice and guidance. I would also like to thank Mr. Ajay
Singh, Senior Manager; for helping me throughout the internship and for
arranging all facilities to make my internship work smoother. I choose this
moment to acknowledge their contribution gratefully.
I perceive as this opportunity as a big milestone in my career
development. I will strive to use gained skills and knowledge in the best
possible way, and I will continue to work on their improvement, to attain
desired career objectives. I sincerely hope to continue cooperation with all of
you in the future.

Mayank Jain

Place: Pune
Date:

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Contents

Table of Contents
Chapter 1: Basic Introduction of TATA Motors Ltd...................................................................................................7
Commercial vehicle..........................................................................................................................................7
Military vehicles...............................................................................................................................................8
Chapter 2: Objectives of the project........................................................................................................................9
Chapter 3: Components of Chassis........................................................................................................................10
Chapter 4: Introduction to Clutch..........................................................................................................................17
Chapter 5: Electronically Assisted Clutch...............................................................................................................21
Chapter 6: Conclusion............................................................................................................................................25

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 Abstract

In my current (B-Tech, 7th semester) of engineering, I was offered an internship at TATA

Motors Ltd. This internship proved to be a fulfilling experience providing me with vast
industrial exposure and a huge amount of practical knowledge.
During my internship at TATA Motors, I was involved in different activities in the company. I
started my internship by gaining some basic knowledge about the working and components
of an automobile and what are the different automobiles that are being are manufactured at
the PUNE plant. I was also introduced with different departments in the company and was
explained about their individual roles in carrying out any project. I was stationed at the TATA
Motors most prestigious department “ENGINEERING RESEARCH CENTRE”, under the
department “CHASSIS ANALYSIS AND SIMULATION” A.K.A. CAS as a Project Manager
Intern. My deliverables were pretty simple. I had to keep a track of upcoming projects under
New Technology Development A.K.A NTD. CAS team basically helps the design team to
validate any component designed by them. Various simulation softwares (for eg: creo ,
hypermesh , amesim ,etc) are used by the CAS team engineers for simulating the designed
components. Various parameters were used to draw inferences. These analysis were then
passed on to the design team for necessary changes. I had the opportunity to learn various
advance components, the communication process, and how a corporate office works in a
nutshell.
New Technology Development i.e. NTD is a joint collaboration with marketing and product
line to anticipate the need of markets and customers for passenger vehicles. Its objective is to
perform technology planning and development in alignment with passenger vehicles strategy
ensuring robustness and affordability. Basically the projects in NTD arrives from:
1) It can be initiated from customer problem or by customer feedback
2) Technology available globally and its adaption for Indian market
3) Innovative features of a vehicle by benchmarking a particular vehicle or vehicles.

In order to approve any project in NTD it had to go through the following process which
includes; To consolidate and analyse required inputs from all internal and external
stakeholder like marketing, sales, warranty services, and legal; Idea generation that is
achieved through formal review; Engineering review which includes to verify and ensure that
whether this project is feasible for the market or not. Later I was shifted to brakes and
control team which had a project named Electronically Assisted Clutch which is also a project
under New technology development.

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Chapter 1: Basic Introduction of TATA Motors Ltd.

Part of the USD100 billion Tata group founded by Jamsetji Tata in 1868, Tata Motors is
among the world’s leading manufacturers of automobiles. Tata Motors
Limited (formerly TELCO, short for Tata Engineering and Locomotive Company)
headquartered in Mumbai, is an Indian multinational automotive manufacturing company and
a member of the Tata Group. Its products include passenger cars, trucks, vans, coaches,
buses, sports cars, construction equipment and military vehicles. Tata Motors has auto
manufacturing and assembly plants in Jamshedpur, Pantnagar, Lucknow, Sanand, Dharwad,
and Pune in India, as well as in Argentina, South Africa, Great Britain and Thailand. It has
research and development centres in Pune, Jamshedpur, Lucknow, and Dharwad, India and in
South Korea, Great Britain and Spain. Tata Motors' principal subsidiaries purchased the
English premium car maker Jaguar Land Rover (the maker of Jaguar and Land Rover cars)
and the South Korean commercial vehicle manufacturer Tata Daewoo. Tata Motors has a bus-
manufacturing joint venture with Marcopolo S.A. (Tata Marcopolo), a construction-
equipment manufacturing joint venture with Hitachi (Tata Hitachi Construction Machinery),
and a joint venture with Fiat Chrysler which manufactures automotive components and Fiat
Chrysler and Tata branded vehicles.

TATA Motors Products:

Commercial vehicle

 Tata Ace
 Tata Ace Zip
 Tata Super Ace
 Tata TL/Telcoline/207 pick-up truck
 Tata 407 Ex and Ex2
 Tata 709 Ex
 Tata 807 (Steel cabin chassis, cowl chassis, medium bus chassis, steel cabin + steel
body chassis)
 Tata 809 Ex and Ex2
 Tata 909 Ex and Ex2
 Tata 1210 SE and SFC (Semi Forward)
 Tata 1210 LP (Long Plate)
 Tata 1109 (Intermediate truck/ LCV bus)
 Tata 1512c (medium bus chassis)
 Tata 1515c/1615 (medium bus chassis)
 Tata 1612c/1616c/1618c (heavy bus chassis)
 Tata 1618c (semilow-floor bus chassis)
 Tata 1623 (rear-engined low-floor bus chassis)
 Tata 1518C (Medium truck) 10 ton
 Tata 1613/1615c (medium truck)
 Tata 1616/1618c (heavy duty truck)
 Tata 2515c/2516c,2518c (heavy duty 10 wheeler truck)
 Tata Starbus (branded buses for city, intercity, school bus, and standard passenger
transportation)
 Tata Divo (Hispano Divo)
 Tata CityRide (12- to 20-seater buses for intracity use)
 Tata 3015 (heavy truck)
 Tata 3118 (heavy truck) (8×2)
 Tata 3516 (heavy truck)

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 Tata 4018 (heavy truck)
 Tata 4923 (ultraheavy truck) (6×4)
 Tata Novus (heavy truck designed by Tata Daewoo)
 Tata Prima (Tata Daewoo)
 Tata Ultra (ICV Segment)
 Tata Winger - Maxivan

Military vehicles

 Tata LSV (Light Specialist Vehicle)

 Tata Mine Protected Vehicle (4×4)
 Tata 2 Stretcher Ambulance
 Tata 407 Troop Carrier
 Tata LPTA 713 TC (4x4)
 Tata LPT 709 E
 Tata SD 1015 TC (4x4)
 Tata LPTA 1615 TC (4x4)
 Tata LPTA 1621 TC (6x6)
 Tata LPTA 1615 TC (4x2)
 Tata LPTA 5252 TC (12x12)
 Tata Sumo 4x4
 Tata Xenon
 Tata 207

TATA Motors Cars:

 Tata Indica
 Tata Safari
 Tata Safari Storme
 Tata Winger
 Tata Nano
 Tata Telcoline/207
 Tata Xenon
 Tata Zest
 Tata Bolt
 Tata Tiago
 Tata Tigor
 Tata Hexa
 Tata Nexon
 Tata Harrier

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Chapter 2: Objectives of the project.

1) To understand the working principle of clutch and what are the basic
components of a Chassis.
2) What is Electronically Assisted Clutch?
3) To carry out a literature survey about the technology if it is already in the
market or is upcoming
4) To find a feasible supplier which is going to help in the success of the project.

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Chapter 3: Components of Chassis.

Introduction to Chassis Frame.

Chassis frame is the basic frame work of the automobile. It supports all the parts of the
automobile attached to it.It is made of drop forged steel. All the parts related to automobiles
are attached to it only. All the systems related to automobile like power plant, transmission,
steering, suspension, braking system etc. are attached to and supported by it only.

Layout of Chassis and its main components.

“Chassis” a French term which means the complete Automobiles without Body and it
includes all the systems like power plant, transmission, steering, suspension, wheels tyres,
auto electric system etc. without body. If Body is also attached to it them it is known as the
particular vehicle as per the shape and design of the body.

The Functions of the Chassis frame

1. To carryall the stationary loads attached to it and loads of passenger and cargo carried in it
2. To withstand torsional vibration caused by the movement of the vehicle
3. To withstand the centrifugal force caused by cornering of the vehicle
4. To control the vibration caused by the running of the vehicle
5. To withstand bending stresses due to rise and fall of the front and rear axles.

Types of Chassis frame

There are different types of chassis frame sections
1. Channel section
2. Box section
3. Tubular section

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The conventional frame is also known as Non-load carrying frame. In this types of frame, the
loads on the vehicle are transferred to the suspension by the frame which is the main skeleton
of the vehicle. The channel section is used in long members and box section in short
members. Tubular section is used now-a-days is three wheelers, scooters, matadors and
pickup vans. The frames should be strong enough to bear load while sudden brakes and
accidents.

Steering Systems.

Steering is the collection of components, linkages, etc. which allows any vehicle to follow the
desired course. An exception is the case of rail transport by which rail tracks combined
together with railroad switches provide the steering function.

Requirements of Vehicle Steering System

The steering system of a vehicle is having the following requirements
1. It should be able to turn the vehicle with more mechanical advantage and less efforts.
2. It should turn the wheel within shortest possible time
3. There should be self-centering action in the steering geometry
4. It should be certain degree irreversible so that the shocks of the roads surface are not
transmitted to the hands of the driver.

Types of Steering Gear boxes

1. Worm and wheel steering gear.
2. Worm and roller steering gear.
3. Worm and sector steering gear.
4. Can and lever steering gear.
5. Rack and pinion steering gear.
6. Re circulating ball steering gear.

Rack and Pinion Steering Gear.

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In this steering gear, a pinion is mounted at the end of the steering inner column. It engages
the rack which has ball joints at each end to allow the raise and fall of the wheels, the rods are
connected with ball joints to the sub axles. The rotary movement of steering wheel turn the
pinion which moves the rock sideways parallel to tie rod. Now a days all the cars use this
type of steering system.

Braking system.

In Automobiles brakes play important role in slowing down and stopping of the vehicle as
and when required by the driver. Fundamentally the brakes are of two types
1. Internal expanding
2. External contracting type.

Different types of brakes are used in different vehicles as per the requirement. According
to application, the brakes are of different types-mechanical, hydraulic air, vacuum, Air
assisted Hydraulic.

Functions of Brakes
1. To slow down or to stop the vehicle as and when required.
2. To control the vehicle when the vehicle is rolling down on a slope road down ward.
3. To travel smoothly and safely even in heavy flow of traffic by controlling the movement of
the vehicle.

Requirement of Automobile Brakes

1. The brakes must stop the vehicle within shortest possible distance.
2. These must be released suddenly after releasing them.
3. Total control of the vehicle should be there.

Disc Brakes.
The disc brake consists a cast iron disc bolted to the wheel hub and a stationary housing
called calliper. The Calliper is connected to some stationary part of vehicle, like axle casing
or the stab axle and is cast in two parts, each part containing a piston. In between each piston
and the disc, there is a friction pad held in position by retaining pins, spring plates etc.

12
When the brakes are applied, hydraulically actuated piston move the friction pads into contact
with the disc, applying equal and opposite forces on the later. On releasing brakes, the rubber
sealing rings act as return springs and retract the pistons and the friction pads away from the
disc.

Drum Brakes.

In this type of brakes, a brake drum is attached concentric to the axle hub whereas on the axle
casing is mounted a back plate. In case of front axle, the brake plates are bolted to the
steering knuckle. The back plate is made of pressed steel and is ribbed to increase rigidity and
to provide support for the expanding brake shoes. These brakes are also known as internal
expanding brakes.

Suspension System.

Suspension is the system of tires, tire air, springs, shock absorbers and linkages that connects
a vehicle to its wheels and allows relative motion between the two. Suspension systems must
support both road holding/handling and ride quality, which are at odds with each other.

Leaf Springs.
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The leaf springs are of different types namely-full elliptic three quarter elliptic, semi elliptic,
quarter elliptic transverse. In almost all automobiles which are having conventional
suspension system the semi elliptic leaf springs are most commonly used. The leaf springs
are made of long flat strip steel. Several strips are placed one on the other and held together
by means of centre bolt and champs. Each strip is called is leaf. There is one main leaf which
is extended to full length. Each succeeding leaf is shorter than the preceeding one. The main
leaf contains eyes are both ends for making connections with the frame. The entire set is
fitted from the chassis frame by hanging with a shackle at one side and the other side is fixed
to frame. During jerks, the leaf spring bounces and each strip flexes and rebounces again and
again.

Macpherson strut.

The MacPherson strut is a type of automotive suspension system that uses the top of a
telescopic damper as the upper steering pivot. It is widely used in the front suspension of modern
vehicles and is named for American automotive engineer Earle S. MacPherson, who originally
invented and developed the design.
A MacPherson strut uses a wishbone, or a substantial compression link stabilized by a
secondary link, which provides a mounting point for the hub carrier or axle of the wheel. This
lower arm system provides both lateral and longitudinal location of the wheel. The upper part
of the hub carrier is rigidly fixed to the bottom of the outer part of the strut proper; this slides
up and down the inner part of it, which extends upwards directly to a mounting in the body
shell of the vehicle. The line from the strut's top mount to the bottom ball joint on the control
arm gives the steering axis inclination. The strut's axis may be angled inwards from the
steering axis at the bottom, to clear the tire; this makes the bottom follow an arc when
steering. To be really successful, the MacPherson strut required the introduction
of unitary construction, because it needs a substantial vertical space and a strong top mount,
which unibodies can provide, while benefiting them by distributing stresses. The strut will
usually carry both the coil spring on which the body is suspended and the shock absorber,
which is usually in the form of a cartridge mounted within the strut. The strut can also have
the steering arm built into the lower outer portion. The whole assembly is very simple and
can be preassembled into a unit; also by eliminating the upper control arm, it allows for more
width in the engine compartment, which is useful for smaller cars, particularly
with transverse-mounted engines such as most front wheel drive vehicles have. It can be
further simplified, if needed, by substituting an anti-roll bar (torsion bar) for the radius arm.
For those reasons, it has become almost ubiquitous with low cost manufacturers.
Furthermore, it offers an easy method to set suspension geometry
Many modern implementations replace the lower control arm by a wishbone. An anti-roll
bar is optional and if present is attached by a ball-jointed rod to the spring-damper or by a
ball or elastomeric ally jointed rod to the wishbone.
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Need of Shock Absorber.
Shock absorber compresses with the road shock and rebalances while travelling on uneven
roads due to usage of this, the effect of road shock in required by the shock absorber suddenly
and releases slowly whole travelling on uneven roads.
Hydraulic Shock Absorber.
The shock absorber develop resistance to the spring by forcing a fluid through check valves
and small holes. ‘Double” acting shock absorber offer resistance both during compression
and rebound of the spring. The ‘Double acting Hydraulic telescopic shock absorber ‘are the
commonly used shock absorber. Its upper eye is connected to the axle and the lower eye to
the chassis frame. A two way valve ‘A’ is attached to as rod ‘G’ . Another two way valve B is
attached to the lower and of the cylinder C. The fluid is in the space above and below the
cylinder C and tube D, which is connected to the space below the valve B. The J has glad H.
Any fluid scrapped off the rod G is brought down into the annular space through the inclined
passage. When the vehicle comes across a bump the lower eye E moves up. Therefore the
fluid passes from the lower side of the vehicle A to its type’s side .But since the volume of the
space above valve A is less than the volume B. This pressure of the fluid through the valve
opening provides the damping force. Similarly when the lower eye E moves down. The fluid
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passes from the upper side of the valve A to the lower side and also from the lower of the
valve B to the upper side

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Chapter 4: Introduction to Clutch.

Clutch Introduction
A Clutch is a machine member used to connect the driving shaft to a driven shaft, so that the
driven shaft may be started or stopped at will, without stopping the driving shaft. A clutch
thus provides an interruptible connection between two rotating shafts Clutches allow a high
inertia load to be stated with a small power. A popularly known application of clutch is in
automotive vehicles where it is used to connect the engine and the gear box. Here the clutch
enables to crank and start the engine disengaging the transmission Disengage the
transmission and change the gear to alter the torque on the wheels. Clutches are also used
extensively in production machinery of all types.

Two inertia’s I and I and traveling at the respective angular velocities ω 1 and ω2, and one of
which may be zero, are to be brought to the same speed by engaging. Slippage occurs
because the two elements are running at different speeds and energy is dissipated during
actuation, resulting in temperature rise.

Friction Clutches.
As in brakes a wide range of clutches are in use wherein they vary in there are in use their
working principle as well the method of actuation and application of normal forces. The
discussion here will be limited to mechanical type friction clutches or more specifically to the
plate or disc clutches also known as axial clutches.

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Frictional Contact axial or Disc Clutches.
An axial clutch is one in which the mating frictional members are moved in a direction
parallel to the shaft. A typical clutch is illustrated in the figure below. It consist of a driving
disc connected to the drive shaft and a driven disc co9nnected to the driven shaft. A friction
plate is attached to one of the members. Actuating spring keeps both the members in contact
and power/motion is transmitted from one member to the other. When the power of motion is
to be interrupted the driven disc is moved axially creating a gap between the members.

Single plate dry clutch- Automative application.

The clutch used in automotive applications is generally a single plate dry clutch. In this type
the clutch plate is interposed between the flywheel surface of the engine and pressure plate.

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Single Clutch and Multiple Disk Clutch.
Basically, the clutch needs three parts. These are the engine flywheel, a friction disc called
the clutch plate and a pressure plate. When the engine is running and the flywheel is rotating,
the pressure plate also rotates as the pressure plate is attached to the flywheel. The friction
disc is located between the two. When the driver has pushed down the clutch pedal the clutch
is released. This action forces the pressure plate to move away from the friction disc. There
are now air gaps between the flywheel and the friction disc, and between the friction disc and
the pressure plate. No power can be transmitted through the clutch.
Operation of Clutch.
When the driver releases the clutch pedal, power can flow through the clutch. Springs in the
clutch force the pressure plate against the friction disc. This action clamps the friction disk
tightly between the flywheel and the pressure plate. Now, the pressure plate and friction disc
rotate with the flywheel. As both side surfaces of the clutch plate is used for transmitting the
torque, a term ‘N’ is added to include the number of surfaces used for transmitting the torque
By rearranging the terms the equations can be modified and a more general form of the
equation can be written as
T= N.f.Fa.R.m
T is the torque (Nm).
N is the number of frictional discs in contact.
f is the coefficient of friction.
Fa is the actuating force (N).
Rm is the mean or equivalent radius (m).
Note that N = n1 + n2 -1 Where n1= number of driving discs n2 = number of driven discs.

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Construction of Clutch.

Two basic types of clutch are the coil-spring clutch and the diaphragm-spring clutch. The
difference between them is in the type of spring used. The coil spring clutch shown in uses
coil springs as pressure springs (only two pressure spring is shown). The coil-spring clutch
has a series of coil springs set in a circle. At high rotational speeds, problems can arise with
multi coil spring clutches owing to the effects of centrifugal forces both on the spring
themselves and the lever of the release mechanism. These problems are obviated when
diaphragm type springs are used, and a number of other advantages are also experienced.

20
Chapter 5: Electronically Assisted Clutch.

Problem statement.

In most conventional cars cable type clutch is used because it is very simple to design, lower
cost and is most reliable. But its application life is limited due to:

1. System efficiency ,pedal box design complexity,

2. Packaging constraint for clutch with high RBL

3. Increment in pedal effort (>12 kg) after 20000 kms

4. Customer replaces the clutch assembly & cables before its end

5. Of life due to deterioration of comfort.

Scope of the project:

As it can be seen from the above graph that the cable type actuation clutch deteriorates over a
period of time i.e. the pedal effort required to get the effect increases in KG over certain
kilometers which makes the pressing of clutch hard and requires more effort from driver to
get the required action of clutch. The aim of this project is to achieve constant pedal effort
throughout its life with respect to running kilometers of a vehicle.

21
Why Electronically assisted clutch?

22
 Detail Description.

12

10
6 8
5
7

4
2

9 10
11
1

Schematic representation of invention.

Clutch pedal 1 along with a potentiometer 2 are assembled in the pedal box 16. The full pedal
box assy is mounted on the fire wall inside of the passenger compartment with nuts 10. The
potentiometer 2 is connected to battery 3 which provides the power source. Battery 3 in turn
connected altogether to solenoid unit 5, coil winding 6 & plunger 11. Solenoid unit 5 is
assembly of coil winding 6, fork 9 & 10, plunger 11.

One end of clutch cable 4 is connected to clutch pedal 1 and other end is connected to fork 9
of solenoid unit 5. One Clutch cable transaxle end 7 is connected to fork 10 and other end to
release lever 8.

When the driver press the clutch pedal output signals from potentiometer are passes to the
solenoid. The solenoid unit (consist of coil winding 6, plunger 11, fork 9 & 10) actuates by
electrical current. Current generates electromagnetic field in the coil winding and due to
electromagnetic field, plunger located inside winding gets to & fro motion with required
force. The movement of plunger 11 in the solenoid unit 5 is restricted by release lever travel.

The plunger is connected to fork 9 at one end and fork 10 at the other end. As the plunger
gets actuates and transfer the motion to fork 9, 10 consecutive to clutch cable 4 and 7. Once
the required amount of electromagnetic field is generated to overcome the clutch system
resistance (friction, Release bearing load etc.) along with the load transferred by cable,
plunger move inward which in turn pulls the cable results in to rotate the Clutch release lever.

Thus, while depressing clutch pedal, assistance received from solenoid which make
comfortable pedal operation for driver. Driver needs to apply hardly 7 to 8 kg of force. Once
the driver release the clutch pedal modulation of assistance force from the solenoids unit
23
 2

9 10 17 7
17
4
8

Vehicle layout of invention

happens in reverse manner as explained above due to change in potentiometer output. When
the operator takes the foot off the pedal 1, it returns to original position due to pedal return
spring at clutch pressure plate.

24
Chapter 6: Conclusion.
We developed a concept design such that it would helped the customer to apply minimal
pedal effort. To bring this idea into application my job was to find out the best supplier which
would give us the required products for our application.

25