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PRESENTATION TO

PRESENTATION TO. CONTENTS. SETCO’s Global Business Structure. Setco Automotive Corporate. SAL OES OEM India. SAL I.B India. SAUL R&D UK. SANAI USA. Global Presence.

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PRESENTATION TO

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  1. PRESENTATION TO

  2. CONTENTS

  3. SETCO’s Global Business Structure Setco Automotive Corporate SAL OES OEM India SAL I.B India SAUL R&D UK SANAI USA

  4. Global Presence Lipe Clutch is part of Setco Automotive with clutch manufacturing facilities in three locations around the world UK North America India

  5. Global Presence • Setco Automotive North America Incest. 1932 • Lipe Clutch sales to North America & manufacturing of pressure converters for CAT. • Manufactures air compressors and hydraulic systems • Clutch manufacturing began in 1932 • Setco Automotive U.K. Ltdest. 1973 • Lipe Clutch has a design and manufacturing base servicing UK, Europe and China with Lipe Clutch products. • Setco Automotive Ltd (India)est. 1982 • Manufacture Lipe Clutches for Tata, Ashock Leyland, AMW & Eicher, totalling over 50,000 units per month. In the last year Bharat Daimler have approved Setco to supply 395 product for the new range of vehicles to be built in India. 430 product is currently on test.

  6. UK operation Setco Automotive (UK) Ltd York Avenue, Haslingden, Rossendale, Lancashire, BB4 4HU, U.K. Tel: +44 (0)1706 228321 Fax: +44 (0)1706 229585 Toll Free: +44 (0)808 1789001 Fax No: +44 (0)808 8736000 E-mail salesuk@setcoclutch.com

  7. UK operation • Lipe have been manufacturing heavy duty commercial vehicle clutches at Haslingden, Lancashire England since 1973. • Lipe traded under Lipe-Rollway, Lipe Limited, Lipe Clutch Division and has been part of large groups Echlin then Dana and now Setco Automotive. • Lipe continue to produce the high standard of hand built new clutches on the same site.

  8. UK operation • Setco Automotive uses ISO/TS 16949 to control quality of product and processes. • Manufacturing plants in UK and India are certified to this standard.

  9. Customers OE CLUTCH SUPPLIER TO OES CLUTCH SUPPLIER TO

  10. Customers AFTERMARKET FITMENT TO MOST MAJOR COMERICAL VEHICLE ON THE ROAD…

  11. European Product Range • Clutch types: • Push or Pull • Ceramic or Organic • With or Without Pre-Damper • Size ranges include: • 362 mm • 395 mm • 400 mm twin plate • 430 mm

  12. Ceramic Type PUSH TYPE CLUTCH THE DRIVEN PLATE IS RELEASED WHEN THE RELEASE LEVERS ARE PUSHED TOWARDS THE FLYWHEEL. RELEASE LOADS ARE DEPENDENT ON THE DESIGNED RATIO OF THE RELEASE LEVERS.

  13. Ceramic Type PULL TYPE CLUTCH THE DRIVEN PLATE IS RELEASED WHEN THE RELEASE LEVERS ARE PULLED BACK TOWARDS THE TRANSMISSION. THE RELEASE LEVER RATIOS ARE HIGHER ON THIS TYPE OF CLUTCH RESULTING IN LIGHTER RELEASE LOADS. CLUTCH ADJUSTMENTS FOR DISC WEAR ARE CARRIED OUT ON THE RELEASE BEARING ASSEMBLY.

  14. Organic Type with Pre-Damper DIAPHRAGM DIAPHRAGM SPRING PUSH AND PULL TYPE CLUTCHES HAVE LESS COMPONENTS THAN COIL SPRING UNITS, BUT HAVE HIGHER RELEASE BEARING LOADS THAN COIL SPRING CLUTCHES. BOTH THE DESIGNS HOWEVER ARE NON-ADJUSTABLE. THE MAIN PRESSINGS AND CASTINGS ARE PRODUCED IN OUR OWN PLANTS IN INDIA, ALL OTHER COMPONENTS ARE EUROPEAN.

  15. Material Source Typical material sources: Friction Material Organic: Valeo (France) Ceramic: Miba (Austria) Diaphragm Spring Haussermann (Germany) Cover pressing Setco (India) Disc Springs Performance springs (UK) Pressed disc components Setco (India) Machined pressure plate Setco (India) ENSURING WORLD CLASS QUALITY AT THE BEST COMPETATIVE COST

  16. Eaton Spicer Types 15.5 SOFT CENTRE

  17. Product Packaging

  18. Manufacturing Facilities • Clutch assembly facilities in India, UK and USA with full functional checking capabilities • Extensive component manufacturing facilities in India including: • Deep drawing & complex Pressings using tonnage of up to 1000 tons • Precision machined components • Heat treatment • Laser welding

  19. Manufacturing Facilities • In process functional checking capabilities include: • Cover analysis including pressure plate lift and attitude on a hydraulic clamping rig • Disc torque and flatness analysis • Full statistical process control capabilities

  20. Design and Development • Setco R&D facilities exist in the UK and India. • Global Design & Development is lead from the UK R&D centre, which has been developing commercial vehicle clutches for over 30 years. • Key R&D facilities and capabilities include: • 3D CAD Modeling and FEA analysis with PRO/Engineer • Product Life Cycle management with Siemens Team Center • Clutch endurance and analysis capabilities

  21. Clutch Design • Advanced Product Quality Planning is applied meticulously to major projects • Projects are planned and tracked against each element of APQP • Project planning and verification activities are coordinated closely with the OE where applicable

  22. Clutch Design Basic Application Calculation Outputs

  23. Testing • Products modelled with Pro/Engineering software and analysed with Pro/Mechanica • Finite Element analysis is used extensively throughout the development process, including stress and deflection analysis. • CAD data is controlled and accessed globally using Siemens Teamcenter PLM software

  24. Test Facilities Disc Endurance Cover Endurance Bearing Endurance • Used to exercise disc assemblies from 280mm to 430mm. • Splined centre rotated from 0 to +/- 15 degrees. • Speeds from 300 to 1,200 cycles per minute • Standard Setco disc endurance test requirements: 2.5 million cycles • Used to exercise cover assemblies from 300mm to 430mm. • Heated to simulate worst case truck conditions • Pressure plate lift measured in 3 places. • Speeds up to 120 cycles per minute • Loads capability > 10,000N • Test rig also used for cushion spring endurance • Standard Setco cover endurance test requirements: 3.6 million cycles • Dynamic release bearing durability testing

  25. Test Facilities Cover Clamp Load Measurement • Measures cover assembly clamp and release loads. • Accommodates cover assemblies from 300mm to 430mm. • Can simulate pressure plate lift in new and worn conditions. • Clamp load measured by 3 linked load cells (capacity 68,000 N) • Release load measured by 1 load cell (capacity 9,000 N) Disc Hysteresis Measurement • Measures torque induced by the damper springs and hysteresis in the assembly. • Disc centre rotated from 0 to +/- 15 degrees.

  26. Test Facilities Burst Testing • Burst testing carried out at an external test facility. • All Setco clutch sizes can be accommodated. • Rotational speeds up to 10,000 rpm. • Temperatures up to 200ºC. • Standard Setco burst test requirements: Disc assembly heated to 200ºC and spun at 2.5 x engine speed for 5 minutes without failure. Vehicle Testing • Setco on-highway field trials are run in partnership with haulage companies; Minimum test duration is 100,000Km, dependent of qualification requirements. • Vehicle trials have been conducted world wide for qualification in different operating environments, including India, Africa, Europe and USA. • Off road vehicle trials are also conducted when applicable, such as mining applications. • Vehicle trials for specific OE applications are typically carried out by the OEM with Setco support.

  27. Current Developments • Current focus is on delivering cushioned ceramic discs, to combine the benefits of durability of ceramic material with the engagement characteristics of a cushioned organic disc. • Dyno testing at the friction material supplier indicates significant durability advantages as well as driveability improvements. • Samples have been provided for vehicle trails in India.

  28. THANK YOU… SCL 2007

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