Design of 4x4's

Hummer · #1 01-24-2006, 11:39 PM

When powering two wheels simultaneously, something must be done to allow the wheels to rotate at different speeds as the vehicle goes around curves. When driving all four wheels, the problem is much worse. A design that fails to account for this will cause the vehicle to handle poorly on turns, fighting the driver as the tires slip and skid from the mismatched speeds.

A differential allows one input shaft to drive two output shafts with different speeds. The differential distributes torque (angular force) evenly, while distributing angular velocity (turning speed) such that the average for the two output shafts is equal to that of the input shaft. Each powered axle requies a differential to distribute power between the left and right sides. If all four wheels are to be driven, a third differential can be used to distribute power between the front and rear axles.

Such a design would handle very well. It distributes power evenly and smoothly, making it unlikely to start slipping. Once it does slip though, recovery will be difficult. Suppose that the left front wheel (of a design that drives all four wheels) slips. Because of the way a differential works, the slipping wheel will spin twice as fast as desired while the wheel on the other side stops moving. (the average speed remains unchanged, and neither wheel gets any torque) Since this example is a vehicle that drives all four wheels, a similar problem occurs between the front and rear axles via the center differential.

The average speed between front and rear will not change, torque will be matched, torque goes to zero, speed at the rear goes to zero, and the speed at the front goes to double what it should be... making the left front wheel actually turn four times as fast as it should be turning. This problem can happen in both 2WD and 4WD vehicles, whenever a driven wheel is placed on a patch of slick ice or raised off the ground. The simplistic design works acceptably well for a 2WD vehicle. Since a 4WD is twice as likely to have a driven wheel on an icy patch, the simplistic design is usually considered unacceptable.

Traction control was invented to solve this problem for 2WD vehicles. When one wheel spins out of control, the brake can be automatically applied to that wheel. The torque will then be matched, causing power to be divided between the pavement (for the non-slipping wheel) and the brake. This is effective, though it does cause brake wear and a sudden jolt that can make handling less predictable. By extending traction control to act on all four wheels, the simple 4WD vehicle design based on three differentials can now recover from wheel spin. One nice feature of this design, is that it is traction control, and thus will not work against traction control. This design is commonly seen on luxury crossover SUVs.

Another way to solve the problem is to temporarily lock together the differential's output shafts, usually just for the center differential that distributes power between front and rear. Recall that a drivetrain without differentials will fight the driver, causing tire wear and handling problems. This is of little concern when the wheels are already slipping. One very common design joins the output shafts together via a multi-plate clutch under computer control. This design causes a small jolt when it activates, which can disturb the driver or cause more wheels to lose traction.

Another common design uses a viscous coupling unit. A dilatant fluid inside the viscous coupling unit acts like a solid when under shear stress caused by high shaft speed differences, causing the two shafts to become connected. This design suffers from fluid degradation with age and exponential locking (joining) behavior. It can also waste fuel, because it requires that there be a slight shaft speed difference under normal driving conditions (via gearing) to prepare to fluid for operation. Older designs used manually operated locking devices.

Yet another way to solve the problem is via a Torsen differential. When a normal differential is replaced with a Torsen differential, it is possible to drive the output shafts with different amounts of torque. While this is useless in a zero-torque situation, it will help greatly when the slippage is not so extreme. As the slipping side begins to spin out of control, more power is delivered to the other side. A typical Torsen differential can deliver up to twice as much power to the non-slipping side as it delivers to the slipping side. Most Audi Quattro cars, notably excluding the A3 and TT, use a center Torsen differential. For a time, the Volkswagen Passat 4motion shared this design. The HMMWV uses front and rear Torsen differentials, but only has a normal differential in the center. Torsen differentials generally work very well, though they are expensive and heavy.

Many lower-cost vehicles entirely eliminate the center differential. These vehicles behave as 2WD vehicles under normal conditions. When the drive wheels begin to slip, one of the locking mechanisms discussed above will join the front and real axles. Such systems distribute power unevenly under normal conditions, and thus do not help prevent loss of traction; they only enable recovery once traction has been lost.

Most minivan 4WD/AWD systems are of this type, usually with the front wheels powered during normal driving conditions and the rear wheels served via a viscous coupling unit. Such systems may be described as having a 95%/5% or 90%/10% power split. Light trucks and SUVs tend to use multi-plate clutches under computer control, often with 100% of the power going to the rear axle under normal conditions. Sports cars using this type of system always drive only the rear under normal conditions. For example, Lamborghini uses a viscous coupling unit to drive the front, and the Nissan Skyline GT-R uses a clutch. The Audi TT normally powers the front, and has a multi-plate clutch to power the rear.

Thread Tools
Show Printable Version Email this Page
Display Modes
Linear Mode Switch to Hybrid Mode Switch to Threaded Mode