Automatic Differential Locking

System
PRESENTED BY

UNDER GUIDANCE OF
WHAT IS DIFFERENTIAL ?

Fig. 1 Component OF Differential

1. I/P Shaft 2. Pinion

3. Crown wheel 4. Planet gear
5. Sun gear 6. Cage
7. RH O/P Shaft 8. LH O/P Shaft
 PURPOSE OF DIFFERENTIAL ?
The differential is designed to drive a pair of wheels while
allowing them to rotate at different speeds.

When the vehicle is traveling in a straight

line, there will be no differential
action.

While the vehicle Rear Wheel at Turning

condition :-
 PROBLEM DEFINITION
(NEED FOR PROJECT)
When one wheel is in slippery road or in mud ,or in snow then that wheel is
rapidly rotates and other wheel is remain stationary and wheel are not moves
forward.

At this condition differential action is occurring there and whole power is

goes to wheel in mud, The differential works like turning moment of vehicle.

Avoiding this problem differential locking is very important when vehicle

one wheel is stationary and other is rotating.
 SOLUTIONS

TYPES OF LOCKING
1 LSD (LIMITED-SLIP DIFFERNTIAL) LOCKING
2 EPICYCLIC DIFFERNETIAL LOCKING
3 SPUR GEAR DIFFERENTIAL
4 AUTOMATIC DIFFERENTIAL LOCKING
 Locking mechanism
Before Engagement

Locking mechanism
Before Engagement
ACTUAL LAYOUT
 Fig. ACTUAL MODEL
1.AC Power supply (230v) 2.Relay circuit
3.Transformer with rectifier (100 VA, 12v DC)
4.Direction control valve 5.DC motor
6.Shifter mechanism 7.Locking mechanism
8.Proximity sensor 9.Single phase AC motor
10.O/P shaft.
 DESIGN METHODOLOGY

DESIGN OF DIFFERENTIAL LOCKING SYSTEM

STANDARD PARTS TO BE PURCHASE

PARTS TO BE DESIGN
 MOTOR SPECIFICATIONS

Single phase AC motor

Commutator motor
Power = 1/15hp=50 watt
Speed= 1440 rpm
 PARTS TO BE DESIGN

BELT
PULLY
SPIKE SHAFT
DOG RING
OUTPUT SHAFTS (LH & RH)
 BELT SELECTION
Selection an open belt drive using V-belt ;
Reduction ratio = 4
Planning an 1 stage reduction ;
A) Motor pulley ( D1) =25mm
B) Main shaft pulley ( D2) =100mm
Selection of belt FZ 6 x 600 from std manufacturers
catalogue
1. BELT SELECTED FZ 6 x 600

2. Tight side Tension T1 =124.24 N

3. Slack side Tension T2 = 16 N

4. Motor pulley did.( D1) D1 =25 MM

5. Pulley (a) diameter (D2) D2 =100MM

 SPIKE SHAFT

MATERIAL SELECTION : - Ref :- PSG (1.10 & 1.12) + (1.17)

DESIGNATION ULTIMATE TENSILE YEILD STRENGTH

STRENGTH N/mm2 N/mm2

EN 24 800 680

NEW DIAMENSIONS- 16 * 101 MM

 OUTPUT SHAFTS (LH & RH)
MATERIAL SELECTION : - Ref :- PSG (1.10 & 1.12) + (1.17)

DESIGNATION ULTIMATE TENSILE YEILD

STRENGTHN/mm2
STRENGTH N/mm2

EN 24 800 680

DIAMENSIONS- 16 * 225
 DOG RING

MATERIAL SELECTION :-Ref :- (PSG 1.10, 1.12 & 1.17)

DESIGNATION TEXTILE YEILD
STRENGTH STRENGTH
N/mm2 N/mm2
EN 24 850 680
 GENERAL MATERIAL TO BE USED

EN24- ALLOY STEEL

EN9- PLAIN CARBON STEEL
MS-MILD STEEL
STD- STANDARD PARTS SELECTED FROM PSG DESIGN
DATA/MANUFACTURER CATALOGUE
TOTAL COSTING

Raw material cost = Rs 3100/-

Machining cost = Rs 2960/-
Miscellaneous cost = Rs 520/-
Cost of Purchased Parts = Rs 15330/-
Overhead cost = Rs 400/-

Total cost of Project = Rs 22310/-

 ADVANTAGES

PROVIDES BETTER TRACTION

COMPACT DESIGN
SIMPLE OPERATION
BEST OPTION FOR 4-WHEEL DRIVE
LOW COST
 APPLICATIONS

IN ALL AUTOMOBILE HAVING DIFFERNTIAL..

IN TRANSPORT VEHICLE
IN MILLITARY VEHICLE
 REFERENCES
Automobile Engineering Vol-1, Kirpal Singh; Standard Publishers; 12th Edition 2011.
Machine Design, R.S.Khurmi, J.K.Gupta; S.Chand & Company Ltd.
Advances in Automobile Engineering,Kanwar Bharaat Singh; Proceeding of the World
Congress on Engineering 2008 Vol-2 WCE 2008, July 2-4,2008, London, U.K.
PSG Design Data Book .
Proximity Sensors By Carlo Gavazzi.
Differential disassembly / assembly instructions, Auburn Gear; Inc. 400 East Auburn Drvie
Auburn, IN 46706-3499.
Epicyclic differential transmission, sedwick, geof-frey, International publish report no.
WO2005/120877 A1, 22.12.2005, London.
Spur gear differential lockable to a limited extent, Mr. Helmet Wiese,Meinsenweg,Fed; Patent
no. 5,09,353, Mar24 1992, Germany.
The active differential for future drive trains, Dr. Tomas Smetana; Schaeffl er SYMPOSIUM
2010.
THANKING YOU