AUTOMATIC DIFFERENTIAL UNIT

LOCKING SYSTEM
GUIDED
by

P. KALIDAS B.E.,
LECTURER
DONE
by
A.MUTHUKRISHANAN (10212499)
M.MANIVANNAN (10212493)
S. KISHOREKUMAR (10212485)
P. MANIKANDAN (10212491)
C. MUTHUKRISHNAN (10212498)
P. NILAGANDAN (28223426)

INTRODUCTION
A differential is a device which is used in vehicles
over a few decades and when a vehicle is
negotiating a turn, the outside wheel travels a
greater distance and turns faster than the inside
wheel.
The differential is the device transmitting the
power to each wheel, allows one wheel to turn
faster than the other.
It splits the engine torque two ways, allowing
each output to spin at a different speed.
The differential is found on all modern cars and
trucks, and also in many all-wheel-drive (full-time
four-wheel-drive) vehicles.

 These all-wheel-drive vehicles need a differential

between each set of drive wheels, and they need
one between the front and the back wheels as
well, because the front wheels travel a different
distance through a turn than the rear wheels.
Part-time four-wheel-drive systems don't have a
differential between the front and rear wheels;
instead, they are locked together so that the front
and rear wheels have to turn at the same average
speed.
The is why these vehicles are hard to turn on
concrete when the four-wheel-drive system is
engaged.
There are some drawbacks in the existing
mechanism and we overcome it in the proposed
project.


Then when a heavy truck is struck in a pit or mud
it is very difficult to recover the truck as the
differential unit cuts the power which is to be
transmitted to the wheel struck.
So in this project the unit is disengaged and
power is directly given to the axle and so the
recovery is made easier.
This is even made use in the vehicle to be driven
in the dense forests and even in dessert.

OBJECTIVE
The Manual force is required to locking the
differential unit
This pneumatic system is also working with
the help of air tank
Time Less consumption is less and noise are
less
More efficient system and simple in
construction

ABSTRACT
The proposed mechanism is to lock the
differential.
By locking the differential the differential is
disengaged from the axle.
Thus the power is directly transmitted to
the axle and hence to the wheels.
This will considerably reduce the power
loss in some occasions when unwanted
loss is happening due to the transmission
if power from the shaft to the differential

 So in mechanism the unwanted power loss in the

due course of transmission through the
differential is reduced.
There are some drawbacks in the existing
mechanism and we overcome it in the proposed
project.
The first is while climbing in steep hills the
differential is not really needed as the speed of
the vehicle is low.
And also there are some transmission loses in the
differential. So at this time the unit is locked and
the loss is overcome.

DEFINITION OF PROBLEM

There are some drawbacks in the existing mechanism

and we overcome it in the proposed project.
The first is while climbing in steep hills the differential
is not really needed as the speed of the vehicle is low.
And also there are some transmission loses in the
differential. So at this time the unit is locked and the
loss is overcome

SCHEMATIC DIAGRAM FOR

AUTOMATIC DIFFERENTIAL UNIT
LOCKING SYSTEM

METHODOLOGY (WORKING PRINCIPLE)

In this method , the main purpose of this project is to lock the differential
or to disengage the differential at the time when it is needed to be
so to lock the differential we needed to connects to shafts on the either
side so that the differential has no effect on the axle

Now to connect the two shaft we use two circular plates on the either
sides of the differential.

Both are in such a way that they get mated as soon as possible even in
their rotation.

 So when the pneumatic valve is actuated

then one of the plates is pushed to the
other so that the plates get mated and
hence the shafts are connected.

So thus the differential is disengaged. To

engage the differential again a spring is
used to push the plates apart.

DETAILS OF PARTS

Differential unit
Double acting cylinder.
5/2 DCV.
Solenoid valve.
Liver mechanism.
Flow control valve.
Compressor.

DIFFERENTIAL UNIT

The vehicle travels in a straight line , the two rear wheel turn
on the road exactly at the same speed
But when the vehicle takes a turn, the outer wheel travels
on a longer radius than the inner wheel
It will cause rapid tyer wear, steering difficulties and poor
road handling this can be avoided by a mechanism called
differential.

DOUBLE ACTING CYLINDER

In double acting cylinder, no return spring is used.

Air pressure is applied to each side of the piston.

 The pressure difference between the sides results in

the movement of the piston.
A pneumatic circuit for the direct control of a double
acting cylinder.
5/2 DCV;

Direction control valves are used to control the

direction of flow in a pneumatic circuit.
They are used to start, stop and regulate the direction

of air and help distribution of air in the desired line.

It has five ways and two positions.

FLOW CONTROL VALVE

It is used for control the

flow of air.
Also it allows some
amount of air to the
cylinder.

COMPRESSOR

It is used for compress the air that

enters form the atmosphere.
In our project we uses two hours
power compressor.

WORK DONE
NOV

DEC

JAN

FEB

WEEK Select the

title
1

Collection of
Material
Details

Assemble

Transport

WEEK
2

Project
Designing

Collection of
Material
Details

Assemble

Preparing
Report

WEEK
3

Project
Purchasing the
Designing
Material

Assemble

WEEK
4

Project
Purchasing the
Designing
Material

Assemble

Preparing
Report
Report
Completion

SPECIFICATION OF THE FITTING:

Body Material
Fluid Used
Max. Operating Pressure
Pneumatic cylinder
30mm
Wheel
alloy

Iron
Air
- 10 Bar
-

COST ESTIMATION

stand frame
----------- Double acting cylinder ----------- solenoid Switch, Screws ----------- VALVE CONNECTORS
----------- Differential unit
----------- Transportation Charge -----------------------9400.00
--------------

1500.00
1700.00
1300.00
300.00
3000.00
600.00