Fall Technical Meeting Papers: 2000–2019

2019 PAPERS
19FTM01. Electric Vehicle Transmission with Hypoid Gearset
Author: Hermann Stadtfeld, and Hanspeter Dinner
Compact electric vehicles require a cost effective and compact solution for the location of the electric motor and
the transmission. Yes, even small electric vehicles today require a transmission, if the maximal possible motor
efficiency has to be available in the majority of drive conditions. Most of the existing solutions for front wheel
driven electric vehicles place the eMotor and the transmission inline between the front wheels. This results in an
asymmetric weight distribution as well as motor heat radiation towards one of the two front wheels.
The paper presents a new design concept which utilizes a super reduction hypoid with a ratio between 7 and 15.
The hypoid gearset rotates the eMotor away from the limited space between the front wheels and delivers a
symmetrical weight distribution as well as a heat radiation away from the wheels. Due to the preferred one stage
reduction, the proposed eDrive transmission is very compact and provides multiple possibilities for an optimal
vehicle component packaging. The paper will discuss the variety of transmission designs, orientations and
locations. The compact design as well as the fact that a one stage transmission minimizes the number of shafts,
bearings and gears allows for a cost effective eDrive manufacture.
Design and dimensioning of the transmission and its components was done with the KISSsoft system. In order to
utilize a super reduction hypoid gearset for an automotive eDrive, not only the efficiency has to be high, but
equally important is a high back driving efficiency. A good back driving efficiency allows recuperating maximal
amounts of electrical energy for battery re-charging. To allow the optimization of the back driving efficiency the
coefficient CBD (Back Driving Coefficient) is proposed. Furthermore, fundamental changes of the SRH geometry
versus conventional hypoid gears had to be developed in order to achieve desirable values for CBD.
ISBN: 978-1-64353-040-6

19FTM02. Misalignment Compensation Spline Design

Author: Davide Marano, Mariano Lorenzini, Luca Mastrandrea, Francesco Pulvirenti, Massimiliano Turci, and
Nicolas Fillault
Shaft misalignment is a significant problem in the design of spline joint transmissions. Involute splines with flank
line crowned teeth are a solution to compensate shaft parallel misalignments avoiding interferences between shaft
and hub teeth. A precise determination of the influence of misalignment on spline load capacity can be performed
by FEM or other powerful numerical simulation.
In this study a geometrical model of crowned spline joint for misalignment compensation is proposed. Flank line
crowning is determined as a function of shaft misalignment and the minimum theoretical circumferential backlash.
The proposed approach is adopted for the design of a spline joint, part of a high-performance automotive
driveline. Finite element simulation has been performed to determine the spline loaded tooth contact pattern and
optimize the theoretical crowning value. Experimental results are in good agreement with simulations.
Keywords: Power transmission, Spline joint, Misalignment, Crowning, Pitch deviation, Analytical modelling,
Concentration factor, Strength calculations.
ISBN: 978-1-64353-041-3

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AGMA Publications Catalog 31 April 2020