Differential
The use of differential allows the car to corner significantly better. During a turn, the differential allows one wheel to turn slower than the other. This allows the outside wheel to maintain contact with the ground without slipping. The differential case housed the sun gears, bevel gears, and star shaft. Those were encased with the differential gear and the differential joints fit through the sides of the case. The differential case was 3D printed numerous times due to redesign and maximizing its functionality. The rest of the parts in theis assembly were purchased.
Figure 3: Rear Differential
Figure 5: Sun Gear
Figure 9: Differential Joint
Figure 4: Rear Differential Case
Figure 6: Star Shaft
Figure 8: Rear Differential Gear
Figure 7: Differential Bevel Gear
Gear-Train
Figure 10: Gear-Train
Figure 11: Housing
Figure 12: Shafts
Figure 13: 40t Spur Gear
Figure 14: 16t Spur Gear
The gear-train reduces the rotational speed from the motor before it gets to the wheels. This was done through a series of small and large gears. The gears were fastened to the shafts with set screws. The shafts were press-fitted into ball bearings. The housing was manufactured with a CNC machine. The rest of the parts were purchased and assembled. The shafts had flat spots ground into them for the gear set screws.
Figure 15: Bearing
Wheel Carriers
Figure 16: Front Wheel Carrier Assembly
Figure 17: Rear Wheel Carrier
Design Changes
Originally, the car was built to be four-wheel-drive. The belt that connected the two differentials were causing unforeseen problems with the car. This belt tension made the chasis of the car bend upward. It also made the gears in the gear-train bind up from being too close. We reduced the car to two-wheel drive. This made the front housing and second differential useless with the new system; along with the gears and driveshafts affiliated with the front differential.
Figure 18: Front Housing
Figure 19: Front Differential
