Multi-kriterielle Optimierung eines xEV-Getriebes unter Berücksichtigung von Bauraumeinschränkungen

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

Publikation: Beitrag in einer FachzeitschriftArtikelForschungBegutachtung

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 ÜbersetzungMulti-kriterielle Optimierung eines xEV-Getriebes unter Berücksichtigung von Bauraumeinschränkungen
Originalspracheenglisch
FachzeitschriftForschung im Ingenieurwesen
DOIs
PublikationsstatusElektronische Veröffentlichung vor Drucklegung. - 6 Sep 2018

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Drive axles
Electric machinery
Powertrains
Gears
Wheels
Bearings (structural)
Shafts (machine components)
Electric drives
Power electronics
Design optimization
Costs
Packaging
Decision making

ASJC Scopus subject areas

  • Fahrzeugbau

Fields of Expertise

  • Mobility & Production

Dies zitieren

Multi-objective gearbox design optimization for xEV-axle drives under consideration of package restrictions. / Hofstetter, Martin; Lechleitner, Dominik; Hirz, Mario; Gintzel, Martin; Schmidhofer, Andreas.

in: Forschung im Ingenieurwesen, 06.09.2018.

Publikation: Beitrag in einer FachzeitschriftArtikelForschungBegutachtung

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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",
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