Drive shaft

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Drive shaft with universal joints at each end and a spline in the centre Cardan Shaft.jpg
Drive shaft with universal joints at each end and a spline in the centre
3D animation of a Cardan shaft in a z-arrangement Cardan-joint DIN808 type-D z-arrangement topview animated.gif
3D animation of a Cardan shaft in a z-arrangement
Skoda 422 rear axle, suspension and drive shaft on display at the Skoda Museum 13-04-05-Skoda Museum Mlada Boleslav by RalfR-009.jpg
Škoda 422 rear axle, suspension and drive shaft on display at the Škoda Museum

A drive shaft, driveshaft, driving shaft, tailshaft (Australian English), propeller shaft (prop shaft), or Cardan shaft (after Girolamo Cardano) is a component for transmitting mechanical power, torque, and rotation, usually used to connect other components of a drivetrain that cannot be connected directly because of distance or the need to allow for relative movement between them.

Contents

As torque carriers, drive shafts are subject to torsion and shear stress, equivalent to the difference between the input torque and the load. They must therefore be strong enough to bear the stress, while avoiding too much additional weight as that would in turn increase their inertia.

To allow for variations in the alignment and distance between the driving and driven components, drive shafts frequently incorporate one or more universal joints, jaw couplings, or rag joints, and sometimes a splined joint or prismatic joint.

History

The term driveshaft first appeared during the mid-19th century. In Stover's 1861 patent reissue for a planing and matching machine, the term is used to refer to the belt-driven shaft by which the machine is driven. [1] The term is not used in his original patent. [2] Another early use of the term occurs in the 1861 patent reissue for the Watkins and Bryson horse-drawn mowing machine. [3] Here, the term refers to the shaft transmitting power from the machine's wheels to the gear train that works the cutting mechanism.

In the 1890s, the term began to be used in a manner closer to the modern sense. In 1891, for example, Battles referred to the shaft between the transmission and driving trucks of his Climax locomotive as the drive shaft, [4] and Stillman referred to the shaft linking the crankshaft to the rear axle of his shaft-driven bicycle as a drive shaft. [5] In 1899, Bukey used the term to describe the shaft transmitting power from the wheel to the driven machinery by a universal joint in his Horse-Power. [6] In the same year, Clark described his Marine Velocipede using the term to refer to the gear-driven shaft transmitting power through a universal joint to the propeller shaft. [7] Crompton used the term to refer to the shaft between the transmission of his steam-powered Motor Vehicle of 1903 and the driven axle. [8]

The pioneering automobile industry company, Autocar, was the first to use a drive shaft in a gasoline-powered car. [9] Built in 1901, today this vehicle is in the collection of the Smithsonian Institution. [10]

Automotive drive shaft

Vehicles

An automobile may use a longitudinal shaft to deliver power from an engine/transmission to the other end of the vehicle before it goes to the wheels. A pair of short drive shafts is commonly used to send power from a central differential, transmission, or transaxle to the wheels.

A truck two section propeller shaft Universal joints shaft.jpg
A truck two section propeller shaft

Front-engine, rear-wheel drive

In front-engined, rear-wheel drive vehicles, a longer drive shaft is also required to send power the length of the vehicle. Two forms dominate: The torque tube with a single universal joint and the more common Hotchkiss drive with two or more joints. This system became known as Système Panhard after the automobile company Panhard et Levassor which patented it.

Most of these vehicles have a clutch and gearbox (or transmission) mounted directly on the engine, with a drive shaft leading to a final drive in the rear axle. When the vehicle is stationary, the drive shaft does not rotate. Some vehicles (generally sports cars, such as the Chevrolet Corvette C5/C6/C7, Alfa Romeo Alfetta and Porsche 924/944/928), seeking improved weight balance between front and rear, use a rear-mounted transaxle. In some non-Porsche models, this places the clutch and transmission at the rear of the car and the drive shaft between them and the engine. In this case the drive shaft rotates continuously with the engine, even when the car is stationary and out of gear. However, the Porsche 924/944/928 models have the clutch mounted to the back of the engine in a bell housing and the drive shaft from the clutch output, located inside of a hollow protective torque tube, transfers power to the rear mounted transaxle (transmission + differential).Thus the Porsche driveshaft only rotates when the rear wheels are turning as the engine-mounted clutch can decouple engine crankshaft rotation from the driveshaft. So for Porsche, when the driver is using the clutch while briskly shifting up or down (manual transmission), the engine can rev freely with the driver's accelerator pedal input, since with the clutch disengaged, the engine and flywheel inertia is relatively low and is not burdened with the added rotational inertia of the driveshaft. The Porsche torque tube is solidly fastened to both the engine's bell housing and to the transaxle case, fixing the length and alignment between the bell housing and the transaxle and greatly minimizing rear wheel drive reaction torque from twisting the transaxle in any plane.

A drive shaft connecting a rear differential to a rear wheel may be called a half-shaft. The name derives from the fact that two such shafts are required to form one rear axle.

Early automobiles often used chain drive or belt drive mechanisms rather than a drive shaft. Some used electrical generators and motors to transmit power to the wheels.

Front-wheel drive

In British English, the term drive shaft is restricted to a transverse shaft that transmits power to the wheels, especially the front wheels. The shaft connecting the gearbox to a rear differential is called a "propeller shaft", or "prop-shaft". A prop-shaft assembly consists of a propeller shaft, a slip joint and one or more universal joints. Where the engine and axles are separated from each other, as on four-wheel drive and rear-wheel drive vehicles, it is the propeller shaft that serves to transmit the drive force generated by the engine to the axles.

Several different types of drive shaft are used in the automotive industry:

  • One-piece drive shaft
  • Two-piece drive shaft
  • Slip-in-tube drive shaft

The slip-in-tube drive shaft is a new type that improves crash safety. It can be compressed to absorb energy in the event of a crash, so is also known as a "collapsible drive shaft".

Four wheel and all-wheel drive

These evolved from the front-engine rear-wheel drive layout. A new form of transmission called the transfer case was placed between transmission and final drives in both axles. This split the drive to the two axles and may also have included reduction gears, a dog clutch or differential. At least two drive shafts were used, one from the transfer case to each axle. In some larger vehicles, the transfer box was centrally mounted and was itself driven by a short drive shaft. In vehicles the size of a Land Rover, the drive shaft to the front axle is noticeably shorter and more steeply articulated than the rear shaft, making it a more difficult engineering problem to build a reliable drive shaft, and which may involve a more sophisticated form of universal joint.

Modern light cars with all-wheel drive (notably Audi or the Fiat Panda) may use a system that more closely resembles a front-wheel drive layout. The transmission and final drive for the front axle are combined into one housing alongside the engine, and a single drive shaft runs the length of the car to the rear axle. This is a favoured design where the torque is biased to the front wheels to give car-like handling, or where the maker wishes to produce both four-wheel drive and front-wheel drive cars with many shared components.

Research and development

The automotive industry also uses drive shafts at testing plants.

At an engine test stand, a drive shaft is used to transfer a certain speed or torque from the internal combustion engine to a dynamometer.

A "shaft guard" is used at a shaft connection to protect against contact with the drive shaft and for detection of a shaft failure.

At a transmission test stand a drive shaft connects the prime mover with the transmission.

Symptoms of a bad drive shaft

An automotive drive shaft can typically last about 120,000 kilometres. However, if the vehicle experiencing any of the signs below, drivers should get it checked as soon as possible. [11]

Cardan shaft park brakes

A cardan shaft park brake works on the drive shaft rather than the wheels. [12] These brakes are commonly used on small trucks. This type of brake is prone to failure and has led to incidents where the truck has run away on a slope, leading to safety alerts being issued. [13] Heavy vehicles that have this type of park brake usually have a ratchet handle similar to a car's hand brake or parking brake, as opposed to an air brake button or lever.

Risk factors for drivers include parking on a steep slope when heavily loaded, not applying the brake with enough force, changing the load or load balance while parked on a slope, or parking where one side of the vehicle is able to slip. Using chocks on the wheels is one way of preventing the vehicle from moving on a slope.

Motorcycle drive shafts

The exposed drive shaft on BMW's first motorcycle, the R32 BMW R32 hr TCE.jpg
The exposed drive shaft on BMW's first motorcycle, the R32

Drive shafts have been used on motorcycles since before WW1, such as the Belgian FN motorcycle from 1903 and the Stuart Turner Stellar motorcycle of 1912. As an alternative to chain and belt drives, drive shafts offer long-lived, clean, and relatively maintenance-free operation. A disadvantage of shaft drive on a motorcycle is that helical gearing, spiral bevel gearing or similar is needed to turn the power 90° from the shaft to the rear wheel, losing some power in the process.

BMW has produced shaft drive motorcycles since 1923; and Moto Guzzi have built shaft-drive V-twins since the 1960s. The British company, Triumph and the major Japanese brands, Honda, Suzuki, Kawasaki and Yamaha, have produced shaft drive motorcycles.

Lambretta motorscooters type A up to type LD are shaft-driven [14] the NSU Prima scooter is also shaft-driven [15]

Motorcycle engines positioned such that the crankshaft is longitudinal and parallel to the frame are often used for shaft-driven motorcycles. This requires only one 90° turn in power transmission, rather than two. Bikes from Moto Guzzi and BMW, plus the Triumph Rocket III and Honda ST series all use this engine layout.

Motorcycles with shaft drive are subject to shaft effect, where the chassis climbs when power is applied. This effect, which is the opposite of that exhibited by chain-drive motorcycles, is counteracted with systems such as BMW's Paralever, Moto Guzzi's CARC and Kawasaki's Tetra Lever.

Marine drive shafts

On a power-driven ship, the drive shaft, or propeller shaft, usually connects the propeller outside the vessel to the driving machinery inside, passing through at least one shaft seal or stuffing box where it intersects the hull. The thrust, the axial force generated by the propeller, is transmitted to the vessel by the thrust block or thrust bearing, which, in all but the smallest of boats, is incorporated in the main engine or gearbox. Shafts can be made of stainless steel [16] or composite [17] materials depending on what type of ship will install them.

The portion of the drive train which connects directly to the propeller is known as the tail shaft. [18]

Locomotive drive shafts

The rear drive shaft, crankshaft and front drive shaft of a Shay locomotive Forks, Washington Shay Locomotive 1.JPG
The rear drive shaft, crankshaft and front drive shaft of a Shay locomotive

The Shay, Climax and Heisler locomotives, all introduced in the late 19th century, used quill drives to couple power from a centrally mounted multi-cylinder engine to each of the trucks supporting the engine. On each of these geared steam locomotives, one end of each drive shaft was coupled to the driven truck through a universal joint while the other end was powered by the crankshaft, transmission or another truck through a second universal joint. A quill drive also has the ability to slide lengthways, effectively varying its length. This is required to allow the bogies to rotate when passing a curve.

Cardan shafts are used in some diesel locomotives (mainly diesel-hydraulics, such as British Rail Class 52) and some electric locomotives (e.g. British Rail Class 91). They are also widely used in diesel multiple units.

Drive shafts in bicycles

A shaft-driven bicycle Dsb-1.jpg
A shaft-driven bicycle

The drive shaft has served as an alternative to a chain-drive in bicycles for the past century, never becoming very popular. A shaft-driven bicycle (or "Acatène", from an early maker) has several advantages and disadvantages:

Advantages

Disadvantages

PTO drive shafts

Drive shafts are one method of transferring power from an engine and PTO to vehicle-mounted accessory equipment, such as an air compressor. Drive shafts are used when there is not enough space beside the engine for the additional accessory; the shaft bridges the gap between the engine PTO and the accessory, allowing the accessory to be mounted elsewhere on the vehicle. [19]

Drive shaft production

Nowadays new possibilities exist for the production process of drive shafts. The filament winding production process is gaining popularity for the creation of composite drive shafts. Several companies in the automotive industry are looking to adopt this knowledge for their high volume production process.[ citation needed ]

See also

Related Research Articles

<span class="mw-page-title-main">Axle</span> Central shaft for a rotating wheel or gear

An axle or axletree is a central shaft for a rotating wheel or gear. On wheeled vehicles, the axle may be fixed to the wheels, rotating with them, or fixed to the vehicle, with the wheels rotating around the axle. In the former case, bearings or bushings are provided at the mounting points where the axle is supported. In the latter case, a bearing or bushing sits inside a central hole in the wheel to allow the wheel or gear to rotate around the axle. Sometimes, especially on bicycles, the latter type of axle is referred to as a spindle.

<span class="mw-page-title-main">Differential (mechanical device)</span> Type of simple planetary 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 analog computers.

<span class="mw-page-title-main">Four-wheel drive</span> Type of drivetrain with four driven wheels

A four-wheel drive, also called 4×4 or 4WD, is a two-axled vehicle drivetrain capable of providing torque to all of its wheels simultaneously. It may be full-time or on-demand, and is typically linked via a transfer case providing an additional output drive shaft and, in many instances, additional gear ranges.

<span class="mw-page-title-main">Overdrive (mechanics)</span> Gearing that lowers engine revolutions

Overdrive is the operation of an automobile cruising at sustained speed with reduced engine speed (rpm), leading to better fuel consumption, lower noise, and lower wear. The term is ambiguous. The most fundamental meaning is that of an overall gear ratio between engine and wheels, such that the car is over-geared, and cannot reach its potential top speed, i.e. the car could travel faster if it were in a lower gear, with the engine turning at higher RPM.

<span class="mw-page-title-main">Freewheel</span> Mechanism which disconnects a driveshaft from a faster-rotating driven shaft

In mechanical or automotive engineering, a freewheel or overrunning clutch is a device in a transmission that disengages the driveshaft from the driven shaft when the driven shaft rotates faster than the driveshaft. An overdrive is sometimes mistakenly called a freewheel, but is otherwise unrelated.

<span class="mw-page-title-main">Limited-slip differential</span> Differential gearbox that limits the rotational speed difference of output shafts

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.

<span class="mw-page-title-main">Quattro (four-wheel-drive system)</span> Sub-brand by Audi that designed for its all-wheel-drive cars

Quattro is the trademark used by the automotive brand Audi to indicate that all-wheel drive (AWD) technologies or systems are used on specific models of its automobiles.

<span class="mw-page-title-main">Front-engine, front-wheel-drive layout</span> Term used in automotive technology

In automotive design, a front-engine, front-wheel-drive (FWD) layout, or FF layout, places both the internal combustion engine and driven roadwheels at the front of the vehicle.

<span class="mw-page-title-main">Transfer case</span> Drivetrain used in four-wheel drive vehicles

A transfer case is a part of the drivetrain of four-wheel-drive, all-wheel-drive, and other multiple powered axle vehicles. The transfer case transfers power from the transmission to the front and rear axles by means of drive shafts. It also synchronizes the difference between the rotation of the front and rear wheels, and may contain one or more sets of low range gears for off-road use.

<span class="mw-page-title-main">Sprocket</span> Toothed wheel or cog

A sprocket, sprocket-wheel or chainwheel is a profiled wheel with teeth that mesh with a chain, track or other perforated or indented material. The name 'sprocket' applies generally to any wheel upon which radial projections engage a chain passing over it. It is distinguished from a gear in that sprockets are never meshed together directly, and differs from a pulley in that sprockets have teeth and pulleys are smooth except for timing pulleys used with toothed belts.

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.

<span class="mw-page-title-main">Hotchkiss drive</span> Shaft drive form of power transmission

The Hotchkiss drive is a shaft drive form of power transmission. It was the dominant means for front-engine, rear-wheel drive layout cars in the 20th century. The name comes from the French automobile manufacturer Hotchkiss, although other makers, such as Peerless, used similar systems before Hotchkiss.

<span class="mw-page-title-main">Torque tube</span>

A torque tube system is a power transmission and braking technology that involves a stationary housing around the drive shaft, often used in automobiles with a front engine and rear drive. The torque tube consists of a large diameter stationary housing between the transmission and rear end that fully encloses a rotating tubular steel or small-diameter solid drive shaft that transmits the power of the engine to a regular or limited-slip differential. The purpose of a torque tube is to hold the rear end in place during acceleration and braking. Otherwise, the axle housing would suffer axle wrap, such that the front of the differential would lift up excessively during acceleration and sink down during braking. Its use is not as widespread in modern automobiles as is the Hotchkiss drive, which holds the rear end in place and prevents it from flipping up or down, during acceleration and braking, by anchoring the axle housings to the leaf springs using spring perches.

ATTESA is a four-wheel drive system used in some automobiles produced by the Japanese automaker Nissan, including some models under its luxury marque Infiniti.

<span class="mw-page-title-main">Chevrolet Engineering Research Vehicle</span>

The Chevrolet Engineering Research Vehicle (CERV) is a series of Chevrolet experimental cars. Chevrolet Staff engineer, designer, and race car driver Zora Arkus-Duntov started development of the CERV I in 1959, and began work on the CERV II in 1963. Chevrolet chief engineer Don Runkle and Lotus' Tony Rudd discussed creating a new show car to demonstrate their engineering expertise in 1985; It would become the CERV III. Corvette chief engineer Dave Hill unveiled the CERV IV in 1993, a test vehicle for the 1997 C5 Corvette.

The following outline is provided as an overview of and topical guide to automobiles:

Motorcycle components and systems for a motorcycle are engineered, manufactured, and assembled in order to produce motorcycle models with the desired performance, aesthetics, and cost. The key components of modern motorcycles are presented below.

<span class="mw-page-title-main">Drivetrain</span> Group of components that deliver power to the driving wheels

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.

<span class="mw-page-title-main">H-drive</span> Drivetrain for off-road vehicles

An H-drive drivetrain is a system used for heavy off-road vehicles with 6×6 or 8×8 drive to supply power to each wheel station.

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.

References

  1. Henry D. Stover, Improvement in Wood-Planing Machines, U.S. Patent Reissue 1,190, May 21, 1861.
  2. Henry D. Stover, Planing Machine, U.S. Patent 30,993, December 18, 1860, 1861.
  3. John DeLancy Watkins and Robert Bryson, Mowing Machines, U.S. Patent Reissue 1,904, July 23, 1861.
  4. Rush S. Battles, Locomotive, U.S. Patent 455,154, June 30, 1891.
  5. Walter Stillman, Bicycle, U.S. Patent 456,387, July 21, 1891.
  6. Dudley D. Bukey, Horse-Power, U.S. Patent 631,198, August 15, 1899.
  7. Charles Clark, Marine Velocipede, [U.S. Patent 637,547], November 21, 1899.
  8. Charles Crompton, Motor-Vehicle U.S. Patent 718,097, January 1903
  9. "Autocar, 1901".
  10. "Autocar automobile". National Museum of American History. November 2, 2016. Retrieved November 19, 2017.
  11. "Drive Shaft — The Definitive Guide 2021". Saiko. Malaysia. Retrieved September 10, 2021.
  12. "What is a cardan shaft brake and why do they fail". Driving Tests Resources. November 10, 2022. Retrieved November 14, 2022.
  13. "Driveshaft parking brake failures in commercial and industrial vehicles". WorkSafe. Retrieved November 14, 2022.
  14. "Lambretta Scooters Models". Cambridge Lambretta Workshop. UK. Retrieved August 26, 2016.
  15. "NSU Prima sales brochures". NSU Prima. Retrieved August 26, 2016.
  16. "BT Marine Propellers - Propeller shafts". www.btmarinepropellers.co.uk. Retrieved March 28, 2021.
  17. "Composite Shafting". www.vulkan.com. Retrieved March 28, 2021.
  18. "Wärtsilä Encyclopedia of Marine Technology".
  19. "What Is A PTO Driven Air Compressor?". VMAC. March 15, 2019. Retrieved March 25, 2019.