Multi-Objective Gearbox Design Optimization for xEV-Axle Drives under Consideration of Package Restrictions

In the design process of electric powertrains, consisting of electric machine, gearbox and power electronics, the requirements regarding performance, package and costs are typically set on system level. This imposes that deduction of component requirements 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 the available installation space of the gearbox shows manifold characteristics due to multiple possible motor- and power electronics variants as also versatile system installation positions and angles. This space can be utilized by different gearbox variants, which are characterized by gearbox-internal design parameters. They affect gear ratio, configuration of gear wheels, outer shape of the gearbox and therefore the package as well as efficiency and production costs. The high variability of gearbox design parameters and packaging-related aspects lead to a complex problem in the design process.