FKFS Veranstaltungen

2025 Stuttgart International Symposium
on Automotive and Engine Technology

3. - 4. Juli 2025

Session: Electric Powertrains III | | 16:30 - 17:00

Profile Modifications for Gears and their Effect on the NVH Behaviour of an Electric Vehicle Gearbox

Kai von Schulz, Furtwangen University

Improving the efficiency of vehicle powertrains remains a key focus for the automotive industry. There are several methods for achieving an optimized powertrain configuration that addresses both efficiency and customer requirements. The use of gearboxes enables the utilization of lighter electric motors with higher maximum speeds. However, both the high speeds and the lack of acoustic masking in internal combustion engines lead to an increase in the actual gear noise and its perception by the driver. In particular, the tooth mesh and its behaviour are a source of noise that must be considered during the development process. Both the macro- and micro-geometry of the teeth can be optimized to achieve improved acoustic characteristics. This article presents the results of a study examining the effect of microgeometry on both the acoustics and efficiency of gears. Virtual and physical experiments will be conducted using statistical Design of Experiments (DoE) to vary several gears’ modification parameters. The virtual tests are based on detailed gear calculations, followed by both 1D and 3D simulations to determine the effect of the vibration behaviour on a specific gearbox housing. A high-speed gear test rig is available for precise measurement of relevant variables such as speed, torque, and noise during experiments with real gears. The physical tests will be used to validate the results obtained from the simulations.