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Design of a Compound Planetary Gearset

Dandanell Litzén, Johan LU (2024) MMEM01 20241
Machine Elements
Abstract
The ever evolving automotive industry is pushing for further electrification of the vehicle fleet and the need for new electric drivetrains is therefore in high demand. The Formula Student competitions have also shifted their focus towards electric vehicles where innovative and efficient drivetrains are premiered in the design events. This master thesis work aimed to continue the development of Lund Formula Students future AWD system by developing the planetary gearbox that connects the electric motors to the wheels.

System requirements were derived from previously recorded data and performance targets set by Lund Formula Student. Target gearbox mass, size, gear ratio and life expectancy were determined. A suitable gearbox layout was... (More)
The ever evolving automotive industry is pushing for further electrification of the vehicle fleet and the need for new electric drivetrains is therefore in high demand. The Formula Student competitions have also shifted their focus towards electric vehicles where innovative and efficient drivetrains are premiered in the design events. This master thesis work aimed to continue the development of Lund Formula Students future AWD system by developing the planetary gearbox that connects the electric motors to the wheels.

System requirements were derived from previously recorded data and performance targets set by Lund Formula Student. Target gearbox mass, size, gear ratio and life expectancy were determined. A suitable gearbox layout was found and different design parameters were investigated to find how they could be utilized in the design process. An iterative process was used where gear teeth number, macro geometry and tooth flank modifications were simulated to find the best design. Design and simulations of the gearbox were conducted in the driveline simulation software MASTA. Design of surrounding components such as planet carrier, bearings and seals was also done.

The resulting design satisfied all the initial requirements of the gearbox. The gearset had sufficient safety factors in terms of bending and contact stress as well as scuffing. Transmission error was reduced by altering tooth flank modifications in order to limit the vibrations within the gearbox. A suitable gearbox oil was selected based on viscosity and anti-scuffing properties. Mass was reduced in the components through structural analysis in ANSYS and component stiffness confirmed using MASTA simulations. (Less)
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author
Dandanell Litzén, Johan LU
supervisor
organization
course
MMEM01 20241
year
type
H2 - Master's Degree (Two Years)
subject
keywords
Planetary gearbox, gears, Formula Student
other publication id
LUTMDN/TMME—5013—SE
language
English
id
9152714
date added to LUP
2024-05-22 09:28:47
date last changed
2024-05-22 09:28:47
@misc{9152714,
  abstract     = {{The ever evolving automotive industry is pushing for further electrification of the vehicle fleet and the need for new electric drivetrains is therefore in high demand. The Formula Student competitions have also shifted their focus towards electric vehicles where innovative and efficient drivetrains are premiered in the design events. This master thesis work aimed to continue the development of Lund Formula Students future AWD system by developing the planetary gearbox that connects the electric motors to the wheels. 

System requirements were derived from previously recorded data and performance targets set by Lund Formula Student. Target gearbox mass, size, gear ratio and life expectancy were determined. A suitable gearbox layout was found and different design parameters were investigated to find how they could be utilized in the design process. An iterative process was used where gear teeth number, macro geometry and tooth flank modifications were simulated to find the best design. Design and simulations of the gearbox were conducted in the driveline simulation software MASTA. Design of surrounding components such as planet carrier, bearings and seals was also done.

The resulting design satisfied all the initial requirements of the gearbox. The gearset had sufficient safety factors in terms of bending and contact stress as well as scuffing. Transmission error was reduced by altering tooth flank modifications in order to limit the vibrations within the gearbox. A suitable gearbox oil was selected based on viscosity and anti-scuffing properties. Mass was reduced in the components through structural analysis in ANSYS and component stiffness confirmed using MASTA simulations.}},
  author       = {{Dandanell Litzén, Johan}},
  language     = {{eng}},
  note         = {{Student Paper}},
  title        = {{Design of a Compound Planetary Gearset}},
  year         = {{2024}},
}