APRA - EUROPE 2010

High Technology in Overrunning Pulleys

Dipl Ing. Marcelo Gomez
R&D, Engineering And Quality Manager

862 employees

998 employees

35.000 m2 - built area

136 employees
 Transform Metals in Reliable Products

Triplicate the Sales 20092015

1960 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
Degree achieved
hi d
2010 ZEN accomplish 50 years
 Starter Drives
68,04%

Zen Aluminium
12,97% Cold Forged Overruning Pulleys
Parts 9,07% 6,13% Motorcycle Parts
0,15%
Planetary Assy
0,35%
Other Tensioners
2,24% 1,05%
 Starter Drives
68,04%

Zen Aluminium
12,97% Cold Forged Overruning Pulleys
Parts 9,07% 6,13% Motorcycle Parts
0,15%
Planetary Assy
0,35%
Other Tensioners
2,24% 1,05%
 Starter Drives
68,04%

Zen Aluminium
12,97% Cold Forged Overruning Pulleys
Parts 9,07% 6,13% Motorcycle Parts
0,15%
Planetary Assy
0,35%
Other Tensioners
2,24% 1,05%
 Starter Drives
68,04%

Zen Aluminium
12,97% Cold Forged Overruning Pulleys
Parts 9,07% 6,13% Motorcycle Parts
0,15%
Planetary Assy
0,35%
Other Tensioners
2,24% 1,05%
 Starter Drives
68,04%

Zen Aluminium
12,97% Cold Forged Overruning Pulleys
Parts 9,07% 6,13% Motorcycle Parts
0,15%
Planetary Assy
0,35%
Other Tensioners
2,24% 1,05%
 Starter Drives
68,04%

Zen Aluminium
12,97% Cold Forged Overruning Pulleys
Parts 9,07% 6,13% Motorcycle Parts
0,15%
Planetary Assy
0,35%
Other Tensioners
2,24% 1,05%
 N. America
18,2%
Europe
16,5%
S. America
IAM 6,5%
, Brasil
53% 52,0%
52 0%
Asia
2,9%
OEM C.America/Me
47% x
2,3%
M. East
0,7% Africa Oceania
0,5% 0,1%

300

250

200

150

100

50

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

Combined Damper + Overrunning

Damper Belt Tensioner
Pulley

Planetary Assembly
 Engines, Bench Tests and Prototype Researches

B lt T
Belt Tensioner,
i Idl
Idle P
Pulley
ll & D
Damper T
Tensioner
i
Complete Development Facilities

Overrunning Pulley & Damper Pulley

ANVIDES PLM tool for Product Development and Process Management

Hexagon ZAR 5 Planetary Gear Calculation
1 FEMAP/Nastran (Finite Element Analysis)
Simufact Forming (3D deformation).
Hexagon ZAR 1 Gear Calculation
y
AMESIM Dynamic Simulation
15 SolidEdge Workstations
MATRIA (fit for Rings)

R&D Laboratory: Cooperation with Research Institutes:

- 11 Combustion Engines to develop automotive parts;
- Supervisor Software for engines management;
- Complete structure for Starter Drive development;
- Test bench for overrunning pulley and belt tensioner;
- HBM Acquisition System.
UFSC Federal University of Santa Catarina
IEL Innovation Institute
Senai Foment Institute of Technology
SOCIESC Foment Institute of Technology
METALAB Analysis Lab

Total 19 employees Total 20 employees

- Failure Analysis & Vibration - Plastic Injection - Heat Treatment
- Finite Element & Fatigue - Cold Forming g - Sheet Stamping
p g
-1-D Dynamic Simulation - Machining - Assembling
-Lean Development
2 Msc Engineer 1 Msc Engineer
Pos grad ated
2 Pos-graduated P g d t d
1 Pos-graduated

2 Engineers on Msc Programs 2 Engineers on Msc Programs

6 engineers 2 engineers 3 Technologist

5 Technicians & 2 Trainees 11 Technicians

High Technology in Overrunning Pulley

High Technology in Overrunning Pulley

SUMMARY
Overrunning Pulley Function
Design features

Benchmarking

Product Performance

OEM Validation Tests

Applications
 High Technology in Overrunning Pulley

Overrunning Pulley
Function

Overruning Pulley Function

Why
y use a FWP?
-Decoupling
Deco pling the alternator from high acyclism
ac clism generated by
b
the combustion engines;
- Improve the behavior of the FEAD, since the alternator has
the higher moment of inertia in the system
- Longer life of the belt;
- Allow the engine to run in very low idle speed and bring
the strategy to reduce fuel consumption and emissions
- Protect the regulator from overcharges;
 High Technology in Overrunning Pulley

ZENs One-Way
y Clutch Technology
gy
Function principle is the one way roller-clutch system
ZEN has
h broad
b d experience
i i this
in thi type
t off system,
t since
i it is
i the
th same
used in starter drives which are produced since 1960

High Technology in Overrunning Pulley

Compact,
p Reliable

Compact
C t design
d i with
ith ffew components;
t
Ball Bearings and springs purchased from quality-
assuredd ISO-TS
ISO TS suppliers.
li
 High Technology in Overrunning Pulley

Robust Pulley

Cold formed pulley with inner cam profile

High
g quality
q y steel;;
Internal ZEN heat treatment qualified by
Q Standard.
CQI-9
Manufacturing process with high capability
and dimensional stabilityy

High Technology in Overrunning Pulley

Simulation - FEA
The
e Pulleys
ulley s des
design
g was ta
targeted
geted to o
offer
e supe
superior
o robustness
obust ess
Several analysis were performed to validate the concept
A new cam design
d i was introduced
i t d d to
t avoid
id slippage
li even in
i speeds
d
higher than 18.000 RPM
 High Technology in Overrunning Pulley
1-D Dynamic Simulation
A Dynamic Model was developed to simulate critical variables
of the system and define improvements for pulley design
Free Wheel Pulley Dynamics
Dynamic Model

Before Optimization After Optimization

Deleterious dynamic
condition was eliminated

High Technology in Overrunning Pulley

Tuned springs
Springs are tuned to have low overrunning torque and to avoid
slippage in high angular speeds
 High Technology in Overrunning Pulley

Rollers
The rollers are produced at ZEN using bearing steel;
The heat treatment process is certified by CQI
CQI-9
9 standards;

Competitor A ZEN

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

High Technology in Overrunning Pulley

Lockup Torque Capacity

The
h torque transmittance
i capability
bili was assured
d with
i h a test
performed in a special bench
The
h result
l can be
b seen in
i the
h graphic
hi below.
b l For comparative
i result
l
a competitor product was tested in the same bench
Lock Torque Test
70

60

50
Torque (kgf.m)

40

ZEN
30
Competitor
20

10

0
0 8 16 23 29 34 40 46
Displacement ()
 High Technology in Overrunning Pulley
Bearing Design
Competitor A ZEN

Single sealing each side Dual sealing each side

No sealing between bearings and Sealing between bearings and
rollers. rollers to avoid contaminations;

High Technology in Overrunning Pulley

Bearing sealing design

Radial clearance specification to reach the expected pulley life
The ball bearing
g supplier
pp develop
p a special
p sealing
g for ZEN Pulleyy
 High Technology in Overrunning Pulley
High-Performance Grease
Critical
C i i l component to proper ffunction
i off an O
One-Way Clutch
Cl h system
ZEN has worked together with leading grease manufacturer to specify
the
h bbest solution
l i
The result is a introduction of a high performance grease to work in
extreme conditions
d ffor llong periods
d

OEM Validation Tests

Test Bench Configuration
Fully
ll monitored
i dbbench
h to run O
OEM tests
Experimental validation of the design
improvements

The monitoring system gives real time

information of variables such as:
Test Bench
Belt Tension
Ambient Temperature
Outside Pulley Rotation
Shaft
Sh f Alternator
l Rotation
Alternator Output
M it i system
Monitoring t
 OEM Validation Tests
High Speed Test

ZEN performs high speed test according to cycle described below:

OEM Validation Tests

High Speed Test
- 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:
 OEM Validation Tests
High Speed Test
Results after 100.000 cycles
Normal function of the overrunning system
No abnormal wear in the contact parts
Normal g
grease condition

OEM Validation Tests

A
Acyclism
li T
Test
Tests under
d hihigh
h acyclism
li are also
l performed
f d as ffollows:
ll
 OEM Validation Tests
Mud and Brine Test

Performed to confirm sealing effectiveness

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

Cycle Test
Test Bench

OEM Validation Tests

M d and
Mud d Brine
B i T Testt
Results after 500 cycles
y ((85 hr))

Noise level was acceptable

The overrunning system was working normally
The bearings had no contamination
 Field Tests

- Field tests were performed in

extreme off-road conditions in Brazil.

- After 95.000 km the pulley was

analyzed and show perfect conditions.

External Overview Perfect Sealing no internal contamination

unlocked part (95.000 km) and no grease leakeage

High Technology in Overrunning Pulley

FINAL COMMENTS
Zen overrunning pulley design bring to FEAD very good
dynamic behavior;
The pulley
Th ll robustness
b t i superior
is i compared
d to
t
competitors and assure a reliable solution for the
aftermarket and OE;
ZEN Pulley exceed the OEM specifications of the main
automotive manufacturers.