Differentials Fig. 4. Differential or. Cuno. Introduction This lesson explains why differentials are used in the power train, identifies the components of a differential and describes the operation of a differential. Objectives 1. Understand the importance of differentials. 2. Know the components of a standard differential. 3. Understand the operation of a standard differential. Differ osag Fig. 4.2 Power To The Differentials Power to the Wheels ‘The power from the transmission is transmitted to the differential and bevel gear before it goes to the wheels, Figure 4.2 illustrates a machine with two differentials. Wheel loaders and smaller models of articulated trucks have differentials at the front and rear wheels. Larger models of articulated trucks have a third differential at the center axle. Some machines, such as off-highway trucks, only have a rear differential. Fig. 43 Machines All of the machines shown in Figure 4.3 contain differentials. wheel loaders and backhoe loaders have a differential inthe front and rear axle,x Fig. 44 Bevel Gear and Pinion Power to the Wheels Figure 4.4 shows a bevel gear and pinion set. This changes the power output by 90 degrees. With the bevel gear and pinion set, power from the transmission drives the pinion gear. The pinion gear drives the bevel gear. The axle shafts for the wheels turn with the bevel gear. ‘An arrangement such as this is used on some of the older motor graders. In some motor grader applications, a short turning radius is not important, turns are not made frequently. The effects on the machine may not be excessive. In other machines, such as off- highway trucks, a solution was needed to deal with the effects of tums. In all machines, a differential will decrease the amount of drive train stress.Fig. 4.8 Turning Radius ‘Turns ® In Figure 4.5, the rear differential is shown making a U-turn. The front wheels are steering the machine, The front wheels are not shown . In this particular situation, the inside wheel travels a half circle with a 10 foot (3.05 m) radius and the outside wheel travels a half circle with a 20 foot (6.1 m) radius. Fig. 4.6 Distance Traveled In A Turn Figure 4.6 shows the additional distance that the outside wheel has to travel in order to make this turn. The distance traveled by the inside wheel is 31.5 feet (9.6 m) and the distance traveled by the outside wheel is 63 feet (19.2 m). With a solid axle, one tire cannot travel a greater distance than the other without some tire slippage.Fig. 4.7 Solid Axle If the rear axle was a bevel gear and pinion set, the axle between the two wheels would be one piece. The rear wheels would always be driven at the same speed, try to go in the same direction and try to travel the same distance. ‘When the front wheels force the machine around the turn, the rear wheels would resist. The front wheels would have to force the rear wheels to follow the turn. As a result, the front tires and the rear tires will begin to wear excessively. Many of the other stresses and strains will not be evident until a part, such as an axle, fails. Fig. 48 Separate Axle Separate Axles To improve operations in a turn, the rear axle is cut in half. If that is all that is done, the machine is driven with one wheel and other wheel nuns free. While this will make it easier to round a turn, all the stress has been placed on one axle. The driving tire will wear rapidly and the machine will pull to one side in straight ahead operation.Fig. 4.9 Differential Housing and Side Gears Differential Housing and Side Gears © Anhousing is placed around the two separate axles. The housing provides some support for the axle shafts. The housing also acts as a container for all of the differential components. ‘The differential housing rotates with the bevel gear. Then a gear is added to the end of each axle. These gears are generally called side gears or output gears. The side gears rotate with the axles. The side gears are not connected to the differential housing. Cree SF alaeG 0" Gove 2 Fig. 4.10 Side Gears Side Gears In Figure 4.10, the side gears are splined to the end of each axle. The bevel gear and the pinion can be seen. Notice that the side gears are not splined to the differential housing. The side gears turn independent of the differential housing. appiass OU Ure de ogFig. 4.1 Spider and Differential Pinion Gears Spider and Differential Pinion Gears The side gears are not connected directly to the bevel gear or to the differential housing. ‘The spider has four ends that are at right angles to one another. These ends fit through holes in the differential housing. It does not touch the side gears, but turns with the differential housing. Four gears are mounted on the four ends of the spider. The ends of the spider go through the center axis of the gears. These gears are called differential pinion gears, bevel gears or spider gears. ‘The differential pinion gears are at a right angle to the side gears. The differential pinion gear teeth mesh with the side gears. When the differential pinion gears rotate with the spider, the side gears move with them, ? 9° e4 Fig. 4.12 Spider and Differential Pinion Gears Jeon Spider and Differential Figure 4.12, shows the spider and the differential pinion gears. The smaller part of the spider fits in holes in the differential housing,Fig. 4.13 Spider Spider ry In Figure 4.13, the spider has been placed in the differential housing. If the differential pinion gears are not installed, the bevel gear will rotate the differential housing and spider without turning the side gears. Fig. 4.14 Differential Pinion Gears Figure 4.14, shows the differential pinion gears placed on the ends of the spider. The differential pinion gear teeth mesh with the side gear teeth, If there is no resistance from the axles, the differential pinion gears will not rotate on their axes. The torque on both of the side gears will be equal. The differential pinion gears will be held between them. In this situation, the differential housing, the spider and the differential pinion gears rotate as a solid mass and drive the side gears. When the machine is being driven straight ahead with equal traction under each wheel, it is as if the axle shafts are solid. There is no relative motion inside the differential housing.Fig. 4.15 Differential Pinon Gears Turn During a turn, the inside wheel is more resistant to the turn than the outside wheel, This resistance causes different torques on the two side gears, When one of the axles slows down, the differential pinion gears will walk around the slower side gear. The movement of the differential pinion gears causes the other side gear to speed up. The two axles tum at different speeds. When one wheel has more traction than the other wheel, the differential operates in the same manner as if the machine is turning. The same amount of torque is sent to both wheels. This torque is only equal to the amount that is necessary to turn the wheel with the least resistance.