An Investigation of Dynamic Behavior of Electric Vehicle Gear Trains

Abstract The automotive industry has been experiencing a significant transition toward electrified powertrains in recent years. A torsional model of a common type of electric vehicle (EV) drivetrains is proposed to demonstrate certain dynamic behaviors that are unique to such high-speed applications. This two-stage helical gear drive train is supported by three shafts and connects the electric motor to the vehicle axle. The gear mesh interfaces are modeled by periodically time-varying stiffnesses subjected to backlash and displacement excitations to represent gear tooth errors and modifications. In addition to these internal excitations, torque fluctuations caused by electric motor are included as the external excitations. Two different operating conditions are studied here: (i) steady-state response as the vehicle is operated under steady torque conditions and (ii) transient response during EV system transitions between the drive and regenerative (regen) braking modes of operation. The torsional model predictions are verified through comparisons to simulations from a deformable-body contact model. Parameter sensitivity studies are performed to demonstrate nonlinear behavior of a helical gear train caused by external torque fluctuations as well as the interactions between external and internal excitations. Finally, drivetrain structural modes are shown to respond to drive-regen transitions resulting in certain transient (vibro-impact) behavior with elevated dynamic mesh forces.