Automated Design and Optimization  of Transmissions for Electric Vehicles

Kieninger, Daniel; Hemsen, Jonas; Köller, Sven; Uerlich, Roland

doi:10.1007/s38313-019-0126-9

Cited by 8 publications

(7 citation statements)

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“…The thermal analysis can be combined with the gearbox topology design module of the ika design methodology. The topology is optimised with a genetic algorithm based on set weight factors for different characteristics [12]. The combination allows optimising a gearbox topology for the best possible thermal performance.…”

Section: Discussionmentioning

confidence: 99%

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Method for thermal evaluation of automotive gearbox packages taking into account load point-dependent oil distribution

Uerlich

Koch

Theising

et al. 2022

Automot. Engine Technol.

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The spread of all-electric drives is steadily increasing in all sectors of road transport. Due to the constantly increasing demands on efficiency and performance by legislation and customers, it is necessary to continuously push the system limits of the powertrains. This paper presents an approach that performs an initial thermal system analysis based on a first gearbox configuration and efficiency calculation. Here, the componentwise loss calculation is used to identify thermal hotspots within the gearbox stage. The basis of this analysis is the thermal network method. For the approach, the gearbox elements gear, bearing, shaft, seal and housing are broken down into standard thermal elements to be created automatically for any subsequent gearbox configuration. The linking of these elements to each other is also standardised and automated comparably. An extensive simulation study is carried out using the smoothed particle hydrodynamics method to consider the load point-dependent oil distribution, which enables an initial estimate of the oil distribution. The thermal network filled in this way is then solved on a time-step basis, allowing dynamic load cases to be considered. The quality of the method is validated within the paper using the VW ID 3 gearbox as an example. Due to the use of a series gearbox, the validation was carried out on the basis of the accessible housing temperatures. These already show good convergence of the method compared to other existing approaches, which reinforces the necessity of conducting further experimental studies.

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Section: Discussionmentioning

confidence: 99%

“…At this point, results of an advanced efficiency calculation of the system are used for the component power losses to be considered. The approach used has already been presented by Kieninger et al and Uerlich et al [12,24].…”

Section: Methodological Approach To Thermal Modellingmentioning

confidence: 99%

Method for thermal evaluation of automotive gearbox packages taking into account load point-dependent oil distribution

Uerlich

Koch

Theising

et al. 2022

Automot. Engine Technol.

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“…The simulations and responses involved are, however, often relatively complex and computationally non-trivial, such that the selection and tuning of effective optimization algorithms is difficult. Optimization and automated design approaches and workflows have been developed and investigated for applications as: topology optimization and generative design of structures [89,90], circuit design [91,92], Elevator Systems [93] bioelectrochemical systems [94], automotive control actuators [95] and electric vehicle transmissions [96]. These examples demonstrate the use and potential of automated Modeling Simulation and Optimization (MSO) workflows for specific applications of industrial relevance.…”

Section: Computational Physics and Uncertainty Quantificationmentioning

confidence: 99%

Computational Rational Engineering and Development: Synergies and Opportunities

Sala

2021

Lecture Notes in Networks and Systems

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Research and development in computer technology and computational methods have resulted in a wide variety of valuable tools for Computer-Aided Engineering (CAE) and Industrial Engineering. However, despite the exponential increase in computational capabilities and Artificial Intelligence (AI) methods, many of the visionary perspectives on cybernetic automation of design, engineering, and development have not been successfully pursued or realized yet. While contemporary research trends and movements such as Industry 4.0 primarily target progress by connected automation in manufacturing and production, the objective of this paper is to survey progress and formulate perspectives targeted on the automation and autonomization of engineering development processes. Based on an interdisciplinary mini-review, this work identifies open challenges, synergies, and research opportunities towards the realization of resource-efficient cooperative engineering and development systems. In order to go beyond conventional human-centered, tool-based CAE approaches and realize Computational Intelligence Driven Engineering and Development processes, it is suggested to extend the framework of Computational Rationality to challenges in design, engineering and development.

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“…This choice provides a compact unit with the best balance of length (L), width (W) and height (H) (Figure 19). In parallel to the engineering of the drive module, a design process is being developed which aims to identify the best combination of components for the demonstrator vehicle [18]. "Best", herein, means the ideal compromise between costs, efficiency, performance, weight, volume and complexity.…”

Section: Module Assembly and Final Specificationsmentioning

confidence: 99%

“…This is because properties of fully electric drive modules result from multi-physical interaction of the powertrain components (electrical, mechanical and thermal). A design of the components with regard to the performance on vehicle level is necessary in order to find a global optimum for a specified vehicle and fixed driving requirements [17,18]. Furthermore, the control system design for the drive module is important to consider because it can increase the interaction between different subsystems but also be a remedy for unwanted interaction.…”

Section: Module Assembly and Final Specificationsmentioning

confidence: 99%

Innovative and Highly Integrated Modular Electric Drivetrain

Hemsen

Kieninger

Eckstein

et al. 2019

WEVJ

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A highly integrated electric drivetrain module with 157 kW peak power is presented, which incorporates novel technologies in the field of electric machines, power electronics and transmissions: 1. High-speed electric machine with six phases and injection mould polymer-bonded magnets; 2. High-ratio dual-speed transmission with double planetary gear set (Ravigneaux gear set); 3. Gallium nitride (GaN) power electronics with winding reconfiguration feature.The combination of these components in one single housing makes the drive module flexible to integrate and to combine with conventional or alternative propulsion technologies, thus allowing various hybrid and electric drivetrain topologies. All technologies are selected in accordance with mass production potential and can therefore have a high impact on the automotive market in the future. Currently, the drive module is under development; the first models will be assembled in winter 2019. The integration into a demonstrator vehicle in 2020 will prove the potential of many new technologies and the suitability for the automotive market.

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Automated Design and Optimization of Transmissions for Electric Vehicles

Cited by 8 publications

References 0 publications

Method for thermal evaluation of automotive gearbox packages taking into account load point-dependent oil distribution

Method for thermal evaluation of automotive gearbox packages taking into account load point-dependent oil distribution

Computational Rational Engineering and Development: Synergies and Opportunities

Innovative and Highly Integrated Modular Electric Drivetrain

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