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Detailed Explanation of the Working Principle and Testing Methods of the Clutch Booster
The clutch booster is specifically designed for vehicles with hydraulically operated clutch systems. The clutch booster assists in the engagement and disengagement of the clutch by increasing the output force. It is installed between the clutch and the clutch master cylinder, without the need for mechanical transmission components. During the clutch's engagement and disengagement process, it plays a crucial role by providing additional force to aid operation. This booster is cleverly installed between the clutch and the clutch master cylinder, enabling its functionality without any extra mechanical transmission parts.
The clutch booster involves multiple key technical parameters during operation. The booster has a wide range of operating pressure and temperature, uses specific types of brake fluid and compressed air, and is equipped with multiple ports to ensure stable operation. Its operating pressure in a brake fluid environment is 4 MPa, and in a compressed air environment is 600 KPa. At the same time, the maximum pressure can reach 12 MPa for brake fluid and 1 MPa for compressed air, respectively. In addition, the booster has a wide operating temperature range, from -40° to 80°. Regarding the medium, it primarily uses brake fluid, specifically types 719 and 8013B synthetic brake oil, as well as compressed air. Moreover, the booster is equipped with multiple ports, including an input port (for compressed air, with specified pipeline cross-section), a control port (for brake fluid, with specified pipeline cross-section), an exhaust port (for compressed air), and a drain port (for brake fluid). These port designs enable the booster to efficiently and stably assist the operation of the clutch.When testing the clutch booster, sealing is a crucial consideration.
▲ Detection in Non-Working StateIn the non-working state, it is necessary to inspect the condition of all connections and exhaust ports under air pressure and oil pressure. This is done by brushing and checking the valve body, connections, and exhaust ports to ensure sealing. The specific detection steps include: introducing the rated working air pressure to port 1, carefully brushing and inspecting the valve body, all connections, and exhaust ports, while closely monitoring changes in gauge pressure; then disconnecting the air supply to port 1 and introducing a working oil pressure of 4 MPa to port 4 (if it is an air inlet inspection, a high air pressure of no less than 1.2 MPa should be applied), similarly brushing and inspecting the valve body, connections, and exhaust ports, while observing any changes in the gauge pressure.
▲ Power Assist Status InspectionWhen in the power assist state, that is, when the valve is in operating condition, we need to focus on the following inspection points: ensure there are no leaks during operation, monitor the gauge pressure drop, and, if necessary, perform dynamic testing to evaluate the assist effect and response speed, ensuring system flexibility and smooth exhaust. Specific steps include: carefully observing the working condition of the valve body, all connection points, and the exhaust port to ensure there are no leaks or abnormalities; monitoring changes in gauge pressure drop to determine whether the performance is stable under power assist conditions; and, if necessary, conducting dynamic tests to evaluate the assist effect and response speed.In the power assist state, we first need to ensure that the system is correctly connected and supplied with appropriate pressure. Specifically, port 1 should be connected to the rated working air pressure, while port 4 should be connected to oil pressure or high-pressure air. With the pushrod extended and maintaining the front-end load, we should carefully inspect the working condition of the valve body, all connections, and air ports, while closely monitoring changes in the gauge pressure drop. This step aims to assess the static characteristics under power assist conditions, that is, the system's performance in a stable state.
1. Power Assist Characteristics: Conduct electrical tests based on the characteristic curves of different product specifications to ensure that the power assist performance meets requirements.
2. Following Balance: When the input oil pressure changes, the system can output the corresponding force and maintain stability, reaching the preset value synchronously.In addition, attention should be paid to the dynamic characteristics of the system, that is, the system's response speed and stability under different operating conditions.
1. Repeatedly operate the 4-way switch to ensure that moving parts such as the pushrod and piston can move freely, without any sticking or jamming.
2. Check the exhaust port to ensure smooth exhaust flow without obstruction.
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