Multi-objective gearbox design optimization for xEV-axle drives under consideration of package restrictions

Martin Hofstetter; Dominik Lechleitner; Mario Hirz; Martin Gintzel; Andreas Schmidhofer

doi:10.1007/s10010-018-0278-9

Multi-objective gearbox design optimization for xEV-axle drives under consideration of package restrictions

Titel in Übersetzung: Multi-kriterielle Optimierung eines xEV-Getriebes unter Berücksichtigung von Bauraumeinschränkungen

Martin Hofstetter, Dominik Lechleitner, Mario Hirz, Martin Gintzel, Andreas Schmidhofer

Institut für Fahrzeugtechnik (3310)

Publikation: Beitrag in einer Fachzeitschrift › Artikel › Begutachtung

Abstract

Bei der Auslegung elektrischer Antriebsstränge, bestehend aus Elektromotor, Getriebe und Leistungselektronik, werden
Anforderungen bezüglich Leistung, Bauraum und Kosten üblicherweise auf Systemebene gestellt. Dadurch ist die Ableitung
der Komponentenanforderungen nicht eindeutig und Komponenteneigenschaften interferieren. Der verfügbare Bauraum für
das Getriebe, welches das Verbindungselement zwischen Elektromotor und Antriebswellen der Räder darstellt, kann somit
vielfältige Gestalt annehmen. Diese ist sowohl abhängig von den verwendeten Motor- und Leistungselektronikvarianten als
auch von den Freiheitsgraden, die bei der Systemanordnung bestehen. Dieser Bauraum kann durch verschiedene Getriebevarianten
genutzt werden, die durch getriebespezifische Gestaltungsparameter beschrieben werden. Diese beeinflussen
beispielsweise Übersetzungsverhältnis, Verzahnungsparameter und äußere Gestalt bzw. Bauraumbedarf, sowie Effizienz
und Herstellungskosten. Somit führen die hohe Gestaltungsvielfalt und bauraumbezogene Aspekte zu einem komplexen
Problem im Entwurfsprozess.
In diesem Zusammenhang wird ein auf Differential-Evolution basierender, multi-kriterieller Getriebeoptimierungsprozess
vorgestellt, um die Entscheidungsfindung in der frühen Entwicklungsphase zu unterstützen. Für gegebene Last-, Lebensdauer-
und Bauraumanforderungen werden Auslegungsparameter für Wellen, Verzahnung, Lager und deren Anordnung
generiert, um Effizienz, Bauraum und Kosten zu optimieren. Als Ergebnis liegt eine Pareto-Front von Getriebevarianten
vor, aus denen Entscheidungsträger die bestgeeigneten Kompromisslösungen auswählen können.
Der neuartige Ansatz wird beispielhaft anhand eines zweistufigen Ein-Gang-Stirnradgetriebes mit integriertem Differentialgetriebe
vorgestellt, das eine verbreitete Getriebetopologie für elektrische Antriebsachsen darstellt.

Titel in Übersetzung	Multi-kriterielle Optimierung eines xEV-Getriebes unter Berücksichtigung von Bauraumeinschränkungen
Originalsprache	englisch
Fachzeitschrift	Forschung im Ingenieurwesen
DOIs	https://doi.org/10.1007/s10010-018-0278-9
Publikationsstatus	Elektronische Veröffentlichung vor Drucklegung. - 6 Sept. 2018

ASJC Scopus subject areas

Fahrzeugbau

Fields of Expertise

Mobility & Production

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10.1007/s10010-018-0278-9

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title = "Multi-objective gearbox design optimization for xEV-axle drives under consideration of package restrictions",

abstract = "In the design process of electric powertrains, consisting of electric machine, gearbox and power electronics, the requirementsregarding performance, package and costs are typically set on system level. This imposes that deduction of componentrequirements 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 theavailable installation space of the gearbox shows manifold characteristics due to multiple possible motor- and powerelectronics variants as also versatile system installation positions and angles. This space can be utilized by differentgearbox variants, which are characterized by gearbox-internal design parameters. They affect gear ratio, configuration ofgear wheels, outer shape of the gearbox and therefore the package as well as efficiency and production costs. The highvariability 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 theearly development phase. For given load-, lifetime- and package-requirements, the introduced differential-evolution-basedprocess delivers design parameters for shafts, gears, bearings and their arrangement to handle efficiency, package andcosts in a multi-objective manner. The results are represented by a Pareto front of gearbox designs variants, from whichdecision makers are able to choose the best and most suitable trade-off. The new approach is exemplarily demonstratedon a single-speed, two-stage helical gearbox with an integrated differential drive, which represents a common gearboxtopology for xEV-axle drives.",

author = "Martin Hofstetter and Dominik Lechleitner and Mario Hirz and Martin Gintzel and Andreas Schmidhofer",

note = "Journal-publication based on previous conference contribution at VDI Dritev, Bonn, June 2018",

year = "2018",

month = sep,

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doi = "10.1007/s10010-018-0278-9",

language = "English",

journal = "Forschung im Ingenieurwesen",

publisher = "Springer Verlag",

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AU - Hofstetter, Martin

AU - Lechleitner, Dominik

AU - Hirz, Mario

AU - Gintzel, Martin

AU - Schmidhofer, Andreas

N1 - Journal-publication based on previous conference contribution at VDI Dritev, Bonn, June 2018

PY - 2018/9/6

Y1 - 2018/9/6

N2 - In the design process of electric powertrains, consisting of electric machine, gearbox and power electronics, the requirementsregarding performance, package and costs are typically set on system level. This imposes that deduction of componentrequirements 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 theavailable installation space of the gearbox shows manifold characteristics due to multiple possible motor- and powerelectronics variants as also versatile system installation positions and angles. This space can be utilized by differentgearbox variants, which are characterized by gearbox-internal design parameters. They affect gear ratio, configuration ofgear wheels, outer shape of the gearbox and therefore the package as well as efficiency and production costs. The highvariability 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 theearly development phase. For given load-, lifetime- and package-requirements, the introduced differential-evolution-basedprocess delivers design parameters for shafts, gears, bearings and their arrangement to handle efficiency, package andcosts in a multi-objective manner. The results are represented by a Pareto front of gearbox designs variants, from whichdecision makers are able to choose the best and most suitable trade-off. The new approach is exemplarily demonstratedon a single-speed, two-stage helical gearbox with an integrated differential drive, which represents a common gearboxtopology for xEV-axle drives.

AB - In the design process of electric powertrains, consisting of electric machine, gearbox and power electronics, the requirementsregarding performance, package and costs are typically set on system level. This imposes that deduction of componentrequirements 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 theavailable installation space of the gearbox shows manifold characteristics due to multiple possible motor- and powerelectronics variants as also versatile system installation positions and angles. This space can be utilized by differentgearbox variants, which are characterized by gearbox-internal design parameters. They affect gear ratio, configuration ofgear wheels, outer shape of the gearbox and therefore the package as well as efficiency and production costs. The highvariability 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 theearly development phase. For given load-, lifetime- and package-requirements, the introduced differential-evolution-basedprocess delivers design parameters for shafts, gears, bearings and their arrangement to handle efficiency, package andcosts in a multi-objective manner. The results are represented by a Pareto front of gearbox designs variants, from whichdecision makers are able to choose the best and most suitable trade-off. The new approach is exemplarily demonstratedon a single-speed, two-stage helical gearbox with an integrated differential drive, which represents a common gearboxtopology for xEV-axle drives.

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Multi-objective gearbox design optimization for xEV-axle drives under consideration of package restrictions

Abstract

ASJC Scopus subject areas

Fields of Expertise

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