The scarcity of fossil fuels and increasing oil prices are among the factors that have led to a rising ownership of electric cars [1]. Noise reduction also plays a major role primarily in the drive train of motor vehicles. Noise and vibration excitation differ between a combustion engine and an electric motor. While the disturbing noises of auxiliaries, e.g. gear noise, have been largely masked by combustion engines, theses noises are no longer masked due to the use of electric motors [2]. Therefore, gear noise is perceived more pronounced. Considering the subjective perception and the excitation by rotational frequencies, that fall into the sensitive hearing range of high-speed gearboxes, the focus must be increasingly placed on manufacturing and assembly related long-wave deviations, such as wobble, pitch errors and eccentricities.This report investigates the effects of long-wave deviations of gears in gearboxes on the excitation and noise behavior. Quasi-static investigations were carried out to verify the influences of long-wave deviations on the long-wave excitation behavior. Therefore, the transmission error was measured, which describes the rotational fluctuation between input and output and represents the excitation.This investigation verifies according to the simulativ investigation by Brecher et al. that there is no transmission error dependency on the load [3]. In addition, this investigation proves the macro geometry-independent long-wave excitation in case of eccentricity. The reason for the invariant excitation behavior lies in the effective deviation in the gear mesh which in this case is independent of the mentioned parameters.In addition to the quasi-static tests, investigations of the structure-borne noise were carried out at higher speeds (input rotational speed up to nIn = 11,500 rpm). For these investigations, a two-stage gearbox with a test gear set was used and two different eccentricities and wobbles were manufactured. The analysis of these investigations confirm an increased excitation as a result of the deviations. Especially in natural frequency ranges, the excitation in the first rotational order is amplified by the considered long-wave deviations.The experimental results prove the importance of a function-oriented tolerance system for long-wave deviations, which lead to corresponding long-wave excitations. Furthermore, the findings constitute the first basis for the derivation of these tolerance limits.
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