DESIGN AND OPTIMIZATION OF GEOMETRIC PARAMETERS OF GEARS FOR AN ELECTRIC VEHICLE TRANSMISSION

This study focuses on the design and optimization of the geometric parameters of gears in electric vehicle (EV) transmissions to enhance performance, efficiency, and noise reduction. The optimization process was conducted using KISSsoft, considering constraints such as input speed and torque, transmission system volume, and gear ratios for each driving mode. A novel aspect of this research is the integration of transmission efficiency analysis with a variable efficiency coefficient into the optimization workflow, which has been demonstrated to significantly influence the optimal design of multi-speed EV transmissions. Throughout the optimization, key factors such as tooth bending stress, contact stress, contact ratio, and specific sliding were analyzed. Additionally, the impact of module variations on gear profile geometry, overlap ratio, tooth count, and gear pair mass was investigated. Strength calculations for the optimized gear pairs, determined for all geometric parameters using KISSsoft, were performed in accordance with the mathematical model outlined in ISO 6336, and the results were subsequently compared. The findings emphasize the critical role of profile modifications and precise gear design in optimizing gear performance, ultimately contributing to improved efficiency, reliability, and service life. Keywords: gear design optimization, electric vehicle transmission, KISSsoft, gear profile modification, ISO 6336.