A friction drive [1] [2] or friction engine is a type of transmission that utilises the static friction of two smooth surfaces (instead of contact pressure of meshing teeth) to transfer torque between two rotating parts.
This type of mechanism is also called a traction drive, although this term often refers specifically to drives where a layer of traction fluid (that becomes momentarily solid under pressure) is used to increase the friction coefficient between the two parts, to 0.1 or more. [3] [4] [5]
In general, least one of the two parts is rigid, and it may be any solid of revolution, such as a disk, cylinder, or cone. While the bulk of the rigid part(s) may be constructed of any hard material, such as metal or plastic, at least one of the surfaces where they come into contact usually is coated with some high-friction material, such as hard rubber (or, in early systems, paper or leather).
The most common example of friction drive is a pulley and (smooth) belt pair. However, the name "friction drive" is more often used when both parts are rigid.
A traction drive was patented by C. W. Hunt in 1887. They were occasionally used by General Motors and NASA in the following years, but became more widely used only after better traction fluids and high-precision CNC milling machines were developed. [3]
The simplest form of friction drive is a pair of cylinders mounted on parallel axes, pressing against each others.
The mechanical advantage of this system is determined by the ratio r between the radii R1 and R2 of the two cylinders. Namely, the torques T and T on the two axles will satisfy T1/T2 = r = R1/R2, while the rotation speeds ω1 and ω2 will satisfy ω1/ω2 = 1/r = R2/R1.
This system is used, for example, to drive the spools in some tape recorders. In a typical configuration, one of the cylinders is the axle of an electric motor, say 1 mm in diameter, while the other is a disk with a hard rubber rim, say 50 mm in diameter, yielding a 1:50 mechanical advantage. A gear train with the same ratio would require either much larger gears or very fine teeth, which would be much more expensive and delicate to produce.
Another important application is motorized bicycles, where a rubber-coated roller connected to the motor drives one of the bike wheels by friction. Other examples are add-on motors to operate hand wheels. [6]
Another important type of friction drive consists of a wheel rolling over a mostly flat surface or mostly straight track. This could be seen as a limiting case of the parallel-cylinder arrangement where one of the cylinders has practically infinite radius. In this case the goal is not to transfer torque but to convert torque into linear force, and the rotary motion of the wheel to relative linear motion of the two parts.
The most common example is of course wheeled vehicles traveling on roads or railway tracks. But the same arrangement is also used in many other applications, such as conveyor belts [7] and roller coasters.
Another important type of friction drive consists of two discs with perpendicular axes, arranged so that the edge of one wheel presses against the flat face of the other. Friction between the two wheels causes torque applied to one wheel to be transferred to the other.
The mechanical advantage of the system is determined by the ratio r between the radius R1 of the first wheel and the distance R2 on the second wheel between its axis and the point of contact. If the first disk is mounted so that it can slide along its shaft, the radius R2, and therefore the ratio r, can be varied continuously even while the disks are rotating. The system is then a continuously variable transmission that requires no clutch.
One problem with this design is that the inner and outer edges of the first disk are moving at the same speed, but the speed on the surface of the second disk increases proportionally with distance from the axis. This speed mismatch causes considerable friction at the edges of the first disk, wearing it out and wasting mechanical power as heat. Since these effects are proportional to the contact pressure and to the relative speed of the rubbing surfaces, they limit the torque and rotational speed that can be transferred.
This kind of friction drive was once employed in early automobiles, but today the system is most commonly used on scooters, particularly go-peds, as a substitute for a chain and gear system. It is mechanically identical to a ball-and-disk integrator, but is designed to handle higher torque levels.
Friction drive has been most successfully used in low-power applications, such as driving phonograph turntables.
Automobiles using this drive system included the Anglo-Dane, the Arista, the Armadale, the Astra, the Allvelo, the Bukh & Gry, the Cartercar, the Crown 12HP Model Two (1905-1906), the Davis Totem, the G.W.K., the Kelsey, the Lambert, the LuLu, the Metz, the Ner-a Car, the Richardson, and the Turicum. The Turicum's friction drive consisted of a flat steel disk coupled directly to the engine. This primary disk subsequently drove a smaller leather covered wheel oriented normal to its surface. Assuming a constant rotational velocity on the primary wheel, the angular velocity on the disk's surface will increase proportionally to the distance from the center of rotation. Therefore, positioning the smaller wheel at different points along the larger wheel's surface varies the gear ratio. Furthermore, since there are no limitations beyond the minimum and maximum positions, the gear ratios are infinitely adjustable. The Lambert's friction drive (illustrated) was similar but used an aluminium-faced driving disk and a fiber-faced driven wheel.
Plymouth Locomotive Works's first three models, the AL, BL and CL were equipped with a friction drive. [8] [9]
Early models of the permanent way maintenance ganger's Wickham trolley used a vee-twin JAP engine. This drove through a large flat flywheel and a friction drive. [10]
While mechanically simple, friction drives have a number of limitations. The first is that the amount of torque that can be transferred is a function of the area of the contact patch between the two members and the pressure applied to it by the two parts. Increasing either parameter increases the maximum transmitted torque, but also increases losses due to friction and local deformation of the material at the contact.
Friction drives also suffer from splippage when overloaded, as the static friction limit is reached. They also accumulate small amounts of slippage in normal operation because local deformation of the surface changes the effective radius of the part. Thus they cannot be used for precise rotational positioning, unless the motor uses some feedback scheme to compensate for those errors.
On the other hand, there are applications where slippage is desired, as it prevents damage to the mechanism in case of overload.
A gear or gearwheel is a rotating machine part typically used to transmit rotational motion and/or torque by means of a series of teeth that engage with compatible teeth of another gear or other part. The teeth can be integral saliences or cavities machined on the part, or separate pegs inserted into it. In the latter case, the gear is usually called a cogwheel. A cog may be one of those pegs or the whole gear. Two or more meshing gears are called a gear train.
A differential is a gear train with three drive shafts that has the property that the rotational speed of one shaft is the average of the speeds of the others. A common use of differentials is in motor vehicles, to allow the wheels at each end of a drive axle to rotate at different speeds while cornering. Other uses include clocks and analogue computers. Differentials can also provide a gear ratio between the input and output shafts. For example, many differentials in motor vehicles provide a gearing reduction by having fewer teeth on the pinion than the ring gear.
In railway engineering, the term tractive effort describes the pulling or pushing capability of a locomotive. The published tractive force value for any vehicle may be theoretical—that is, calculated from known or implied mechanical properties—or obtained via testing under controlled conditions. The discussion herein covers the term's usage in mechanical applications in which the final stage of the power transmission system is one or more wheels in frictional contact with a railroad track.
A continuously variable transmission (CVT) is an automated transmission that can change through a continuous range of gear ratios. This contrasts with other transmissions that provide a limited number of gear ratios in fixed steps. The flexibility of a CVT with suitable control may allow the engine to operate at a constant angular velocity while the vehicle moves at varying speeds.
A limited-slip differential (LSD) is a type of differential gear train that allows its two output shafts to rotate at different speeds but limits the maximum difference between the two shafts. Limited-slip differentials are often known by the generic trademark Positraction, a brand name owned by General Motors and originally used for its Chevrolet branded vehicles.
A locking differential is a mechanical component, commonly used in vehicles, designed to overcome the chief limitation of a standard open differential by essentially "locking" both wheels on an axle together as if on a common shaft. This forces both wheels to turn in unison, regardless of the traction available to either wheel individually.
Rolling is a type of motion that combines rotation and translation of that object with respect to a surface, such that, if ideal conditions exist, the two are in contact with each other without sliding.
Torsional vibration is the angular vibration of an object - commonly a shaft - along its axis of rotation. Torsional vibration is often a concern in power transmission systems using rotating shafts or couplings, where it can cause failures if not controlled. A second effect of torsional vibrations applies to passenger cars. Torsional vibrations can lead to seat vibrations or noise at certain speeds. Both reduce the comfort.
Hybrid Synergy Drive (HSD), also known as Toyota Hybrid System II, is the brand name of Toyota Motor Corporation for the hybrid car drive train technology used in vehicles with the Toyota and Lexus marques. First introduced on the Prius, the technology is an option on several other Toyota and Lexus vehicles and has been adapted for the electric drive system of the hydrogen-powered Mirai, and for a plug-in hybrid version of the Prius. Previously, Toyota also licensed its HSD technology to Nissan for use in its Nissan Altima Hybrid. Its parts supplier Aisin offers similar hybrid transmissions to other car companies.
Rolling resistance, sometimes called rolling friction or rolling drag, is the force resisting the motion when a body rolls on a surface. It is mainly caused by non-elastic effects; that is, not all the energy needed for deformation of the wheel, roadbed, etc., is recovered when the pressure is removed. Two forms of this are hysteresis losses, and permanent (plastic) deformation of the object or the surface. Note that the slippage between the wheel and the surface also results in energy dissipation. Although some researchers have included this term in rolling resistance, some suggest that this dissipation term should be treated separately from rolling resistance because it is due to the applied torque to the wheel and the resultant slip between the wheel and ground, which is called slip loss or slip resistance. In addition, only the so-called slip resistance involves friction, therefore the name "rolling friction" is to an extent a misnomer.
A gear train or gear set is a machine element of a mechanical system formed by mounting two or more gears on a frame such that the teeth of the gears engage.
A linear actuator is an actuator that creates linear motion, in contrast to the circular motion of a conventional electric motor. Linear actuators are used in machine tools and industrial machinery, in computer peripherals such as disk drives and printers, in valves and dampers, and in many other places where linear motion is required. Hydraulic or pneumatic cylinders inherently produce linear motion. Many other mechanisms are used to generate linear motion from a rotating motor.
A cycloidal drive or cycloidal speed reducer is a mechanism for reducing the speed of an input shaft by a certain ratio. Cycloidal speed reducers are capable of relatively high ratios in compact sizes with very low backlash.
Jeep uses a variety of four-wheel drive systems on their vehicles. These range from basic part-time systems that require the driver to move a control lever to send power to four wheels, to permanent four-wheel systems that monitor and sense traction needs at all four wheels automatically under all conditions.
An idler-wheel is a wheel which serves only to transmit rotation from one shaft to another, in applications where it is undesirable to connect them directly. For example, connecting a motor to the platter of a phonograph, or the crankshaft-to-camshaft gear train of an automobile.
Super Select is the brand name of a four-wheel drive system produced by Mitsubishi Motors, used worldwide except for North America, where it was initially known as Active-Trac. It was first introduced in 1991 with the then-new second generation of the Mitsubishi Pajero.
Nuvinci Cycling technology currently under development for other applications, including wind turbines, light electric vehicles, outdoor power equipment, and automotive front-end accessory drives.
The Beier variable-ratio gear or Beier variator is a mechanical drive offering a continuously variable gear ratio between input and output.
A drivetrain or transmission system, is the group of components that deliver mechanical power from the prime mover to the driven components. In automotive engineering, the drivetrain is the components of a motor vehicle that deliver power to the drive wheels. This excludes the engine or motor that generates the power. In marine applications, the drive shaft will drive a propeller, thruster, or waterjet rather than a drive axle, while the actual engine might be similar to an automotive engine. Other machinery, equipment and vehicles may also use a drivetrain to deliver power from the engine(s) to the driven components.
This glossary of automotive terms is a list of definitions of terms and concepts related to automobiles, including their parts, operation, and manufacture, as well as automotive engineering, auto repair, and the automotive industry in general. For more specific terminology regarding the design and classification of various automobile styles, see Glossary of automotive design; for terms related to transportation by road, see Glossary of road transport terms; for competitive auto racing, see Glossary of motorsport terms.