Abstract
In the design process of electric powertrains, consisting of electric machine, gearbox and power electronics, the requirements regarding performance, package and costs are typically set on system level. This imposes that deduction of component requirements is not unique and component properties interfere with each other. As a component of the powertrain system, the gearbox represents a linking element between the electric machine and drive shafts to the wheels. Through this the available installation space of the gearbox shows manifold characteristics due to multiple possible motor- and power electronics variants as also versatile system installation positions and angles. This space can be utilized by different gearbox variants, which are characterized by gearbox-internal design parameters. They affect gear ratio, configuration of gear wheels, outer shape of the gearbox and therefore the package as well as efficiency and production costs. The high variability of gearbox design parameters and packaging-related aspects lead to a complex problem in the design process.In this context, the present contribution introduces a gearbox design optimization process to support decision-making in the early development phase. For given load-, lifetime- and package-requirements, the introduced differential-evolution-based process delivers design parameters for shafts, gears, bearings and their arrangement to handle efficiency, package and costs in a multi-objective manner. The results are represented by a Pareto front of gearbox designs variants, from which decision makers are able to choose the best and most suitable trade-off. The new approach is exemplarily demonstrated on a single-speed, two-stage helical gearbox with an integrated differential drive, which represents a common gearbox topology for xEV-axle drives.
Highlights
Zusammenfassung Bei der Auslegung elektrischer Antriebsstränge, bestehend aus Elektromotor, Getriebe und Leistungselektronik, werden Anforderungen bezüglich Leistung, Bauraum und Kosten üblicherweise auf Systemebene gestellt
An electric powertrain— known as eDrive—consists of the electric machine, the gearbox and the power electronics (Fig. 1a). It can be applied in fully electric vehicles or in axle-split hybrid electric vehicles [1]
The high variability of gearbox design parameters, conflicting design objectives and packaging-related aspects lead to a complex problem in the design process
Summary
Zusammenfassung Bei der Auslegung elektrischer Antriebsstränge, bestehend aus Elektromotor, Getriebe und Leistungselektronik, werden Anforderungen bezüglich Leistung, Bauraum und Kosten üblicherweise auf Systemebene gestellt. Diese ist sowohl abhängig von den verwendeten Motor- und Leistungselektronikvarianten als auch von den Freiheitsgraden, die bei der Systemanordnung bestehen. An electric powertrain— known as eDrive—consists of the electric machine, the gearbox and the power electronics (Fig. 1a). In the gearbox design process of a new eDrive (Fig. 2), several input parameters have to be considered [2], e. Various gearbox variants are eligible to fulfill these requirements; each being characterized by gearbox-internal design parameters They affect the main components (Fig. 1b) found in a gearbox, which are: a. Each of these components influences the outer shape of the gearbox and the package as well as the efficiency and production costs; favorable noise, vibration and harshness (NVH) behavior is a key design goal ( not yet covered by the presented approach). The high variability of gearbox design parameters, conflicting design objectives and packaging-related aspects lead to a complex problem in the design process
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