Electric Vehicle Gearbox Design

1) Introduction

Clearly outline the technical specification of your work, together with the objectives and how you plan to achieve them.

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2) Gear macro geometry selection

Provide a summary of your gear macro-geometry, as a table with ISO terms and symbols, together with a bulleted summary justifying your choices.  You may also want to provide any additional supporting calculations or information that you have used to help justify your chosen macro geometry.

3) Gear manufacturing method, geometry tolerances (ISO1328-1) and material and heat treatment (ISO 6336-5) specification.

Briefly define your gear manufacturing method, your subsequent chosen geometrical accuracy grade chosen in accordance with ISO1328-1, and the material, heat treatment and material quality specification in accordance with ISO 6336-5. This type of data is preferred in a table format. However, also provide justification for your choices. 

4) Micro-geometry specification

Propose suitable tip relief and helix crowning modifications.  Provide any calculation procedures and justifications for these values and clearly Illustrate your micro-geometry corrections on a clear sketch.

5) ISO 6336 bending and contact stress fatigue analysis using Dontyne GPS software.

Paste a copy of the Dontyne GPS ‘Design Unit Format geometry and report’ template here, and discuss,

  • Your resulting factors of safety.
  • The values you used for misalignments due to random manufacturing errors and deflections, with supporting evidence/calculations as you see necessary.
  • Discuss as a minimum, the resulting Kv and KHβ

6) Gearbox cross section

Provide a clear cross-section drawing (sketch) of your gearbox layout, illustrating the gears, shafts and bearing arrangements, clearly showing how everything is mounted and constrained.  This does not have to be done in CAD, and you do not have to provide any bearing calculations, but you must choose suitable bearing types.

7) Discussion and Conclusions

Discuss the conclusions from your work, highlighting the advantages and weaknesses of your design, and any recommendations for further work


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