An efficient analytical approach to assess root cause of nonlinear electric vehicle gear whine

Abstract

Noise, vibration, and harshness (NVH) issues pose considerable challenges for electric vehicle powertrain engineers. Gear vibrations generate an intrusive gear whine noise, with significant impact on the sound quality of electric powertrains. Dynamic transmission error (DTE) is the most quantitative indicator for gear NVH. Backlash, time variable meshing stiffness and damping contribute to DTE. Hence, a better understanding of these excitation sources is essential. A gear tribodynamics model is developed using potential energy method to estimate time variable meshing stiffness (TVMS). A fully analytical time-efficient model is proposed for lubricated contact stiffness based on transitions in the regimes of lubrication. The model accounts for the combined effects of surface elasticity and lubricant stiffness. Film thickness and damping coefficients are transiently updated at each instant during meshing cycle. The predictions from this model are compared with measured results from the literature and predicted results from Hertz contact model. The lubricated contact model successfully shows the contribution of the lubricant stiffness to TVMS and its variations with elasticity and viscosity parameters during meshing cycle. Gear harmonic and super-harmonic resonances are accurately estimated in terms of amplitude, frequencies and stiffness softening nonlinearities. Time history responses and phase-displacement diagrams show good agreement with the gear dynamics response at the main harmonic and second super-harmonic frequencies. The proposed model has a reasonable accuracy, significantly better than those from Hertzian contact models, and is considerably time efficient in comparison to numerical EHL solvers.