Differential Case
3 part differential case
Overview
The original differential case on the car was extremely difficult to install. In addition, there were large portions of empty volume in the case in between the gear network and the inner case wall where gear lubricant would accumulate off the gear teeth. This screenshot was sourced from the Electric Racing PDM vault and showcases abilities in designing with solidworks.
Problem
Redesign the diff case in order to be easier to install and to increase the exposure of the diff internals to gear lubricant.
Design Constraints
Must be 3D printed
Must fully enclose the differential with an interface to the mounting block
Must fit inside the chassis bars
Challenges
Sketching the curvature of the differential mounting block in order to ensure that the top and bottom portions of the case were flush to mount.
Results
The implementation of the diff case resulted in the original 2 part case no longer needing to be hammered into place. The 3 part design allows for an installation process that doesn't risk part damage. In addition, more conformity to the gear network ensures that more gear lubricant is in contact with the gears.