Project – Template

Differential Test Bench

While the original design for the team's differential was made in 2006, experimental testing has never been done. There has been many calculations to optimize it, but this test bench aims to validate those calculations with actual data, and more closely observe the impact of things like ramp angles, oil fullness, and allow for easier assembly.

Easy to assemble diff onto and quickly remove to mount onto car
Can collect both the torque bias ratio and the breakaway torque with the use of a torque wrench
Custom half shafts and welded locking plate
Diff tightness is specced using a torque wrench on the tightening bolts, and then torque values are collected with a torque wrench

Design

The design was made with 3 criteria in mind: ease of installing/removing the diff, stability, and ease to test. It was fairly simple to make a design which could hold the diff in a stable position, along with a mock motor shaft to be able to apply torque. The 2 main support beams are modelled to be the same as the tubing on the car which the diff is mounted to, so installation is as easy as it can be. the test bench can sit flat on a table and can be clamped down for easy testing.

Full CAD

Extrusions milled for precision

First Iteration of Tests

The bench proved to be quite unstable while testing because of the sheer amount of torque needed to "open" the differential, but this was easily solved by clamping it to the table. The only pitfall of this was that you must redo the clamps on the opposite side of the bench should you wish to test the other direction of turning.
The first couple sessions of using the test bench were used to perfect the test plan which was made prior to manufacturing. Some things that were verified or discovered experimentally:

The diff had to be spun thoroughly to distribute the oil before tests became reliable
Bolt tightness affects breakaway torque values
Wear on components has a huge impact on torque values

Spinning diff to distribute oil

Using a torque wrench to collect breakaway torque

Data Collection

Now that it had been confirmed that it is possible to tune the characteristics of the differential based on component wear and bolt tightness, data can be collected. This is in progress as of May 2026!