Advanced transmission optimization for new design challenges using RIKOR

Abstract In many cases, gear and transmission design relies on application of standard calculations combined with comprehensive methods for loaded tooth contact analysis (LTCA). Results like local flank load distribution, transmission error and local mesh efficiency evaluation have been KPIs for detail design. Mostly, the optimization cycle to find an advantageous gear main geometry and the consecutive optimization of microgeometry are separated due to different applied theory and cost of time. The new challenges arising from areas of electromobility, wind energy but also aerospace require much higher power density than in the past and a closer integration of the whole drivetrain. Tighter timelines in development lead to the necessity to handle increasing complexity in theoretical background. New possibilities in computer performance allow for application of advanced gear and transmission analysis tools. Altogether these trends culminate in a new generation of gear design software algorithms which are connecting known system approaches with advanced conclusions to achieve top quality in the desired drivetrain properties. This work outlines the scope and applied algorithms for an advanced gearbox design method within the software suite RIKOR. The method combines a full system approach including gears, shafts and bearing analysis which does not stop at resulting deformations and loads but proceeds beyond to allow capacity ratings, NVH evaluations and efficiency information. Comparative calculations in this work demonstrate the functional scope and applicability of the implemented and documented algorithms. New optimization goals may be tackled with this integrative approach.