Design and Analysis of a Lightweight HighTorque Gearbox for Electric Vehicles

Abstract

-This paper presents an optimization technique for high-torque gearbox (GB) cutting in electric cars, 
emphasizing input torque and torque fluctuations. This method facilitates vibration attenuation in Electric 
Vehicle (EV) GB. The research employs Tooth Contact Assessment (TCA) and Loaded TCA (LTCA) to examine 
the localization of meshing points, considering changes in GB tooth surfaces and distortions resulting from load. 
The research then formulates the maximum contact force equation using impact physics theory. A dynamic 
approach for the helical GB motion in the GB input phase is formulated utilizing the centralized mass approach, 
facilitating a comprehensive analysis of high-torque GB vibration features. Utilizing a genetic approach, the 
research enhances the tooth shape and parabolic modifying factors of the tooth flank, yielding excellent 
vibration-dampening surfaces to the teeth. Experimental findings across diverse input forces and torque 
indicate that the total vibration magnitude remains stable and less than traditional GB shaping techniques. 
Under varying circumstances, the root mean square of vibrational acceleration across the meshing line is 59.13 
m/s and 21.44 m/s, respectively. The vibration torque along the connecting line is 21.44 m/s and 21.13 m/s 
under different torques, with 21.44 m/s being the minimum value. The mean amplitude of the melding force of 
impact is considerably reduced to 5026.3. This high-torque GB reshaping technique improves GB dynamics and 
dependability by accounting for input torque and torque variations and significantly reduces vibrations in EV 
GB arrangements. The research offers significant insights and approaches for creating and optimizing EV shifts, 
emphasizing a thorough acceleration enhancement.