Development of a Shiftable High-Speed E-Drive with a Complex-Compound Planetary Gear Set

Authors

F.-T. Mitterer, R. Subramanian, MAHLE ZG Transmissions GmbH; G. Witham, J. Hemsen, ika, RWTH Aachen University

Summary

As part of the EU's Horizon 2020 research program, the ModulED project was launched with the aim of developing a highly integrated drivetrain for a BEV in the C-segment. With regard to transmission development, a topology synthesis of different wheelset arrangements was carried out based on the segment-specific requirements, from which a shiftable Ravigneaux wheelset with subsequent spur gear stage emerged as the concept to be built. In the design of the gearing macro- and micro-geometry, the focus was placed on NVH-optimised variants. A comprehensive Monte Carlo study was carried out to take into account the influence of manufacturing tolerances on gearing transmission errors and load capacity of the gearing. The concept must fulfil the requirements of a driving cycle specially designed for this project. For validation, a dynamic transmission model was built and evaluated over the frequency range. Theoretical studies on efficiency, component lifetimes and NVH-behaviour were compared with the test bench recordings.

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