This content is not included in your SAE MOBILUS subscription, or you are not logged in.
An Analytical Procedure to Analyse Efficiency, Cooling and Thermal Management of a BEV Sport Car Transmission
ISSN: 0148-7191, e-ISSN: 2688-3627
Published September 27, 2020 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
The implementation of increasingly stricter regulations on CO2 emissions by the European Community is pushing the automotive industry towards a radical change. In a rush to electrify their model ranges, global carmakers are investing heavily on developing new electrified powertrains.
Within this context, this work focuses on the analysis of electric axles drives (eAxles) for a BEV (battery electric vehicle) sport car, with the aim to develop an analytical tool useful to perform predictive analysis in the concept design phase.
Through a parametric definition of the procedure, the tool is able to “adapt” to any drivetrain layout analysed. The tool actually allows to enter more than 100 input values including lubrication conditions (oil viscosity and operating temperature), gears (number, macrogeometry, mesh), bearings (number, type, geometry, mounting layout, angle mesh), shafts, oil seals, external layout and external fluid conditions.
The tool allows to calculate efficiency matrices of the drivetrain system (both total matrices and single component matrices) for any desired set of speed, torque and temperature under steady state conditions.
Moreover, the tool can be used to efficiently analyse different cooling concepts (oil bath, wet-sump, and dry-sump system) in order to define the correct choice of pump and intercooler, thus ensuring a proper lubrication and cooling of the gearbox and electric motor.
Consequently, the tool allows to determine the optimal design of the whole ePowertrain in compliance with requested key performance indicators, such as efficiency, performance, packaging and cost.
Effectiveness of the tool has been verified by applying it to an industrial application, namely a single speed and cascade of gears transmission, which had already been bench-tested.
The efficiency matrices obtained analytically with the tool perfectly matched those obtained by bench testing the transmission, with an average deviation of less than 1%.
CitationBonci, M., Begovic, A., Governatori, D., Marchini, D. et al., "An Analytical Procedure to Analyse Efficiency, Cooling and Thermal Management of a BEV Sport Car Transmission," SAE Technical Paper 2020-24-0023, 2020, https://doi.org/10.4271/2020-24-0023.
Data Sets - Support Documents
|Unnamed Dataset 1|
|Unnamed Dataset 2|
- Haycock , R.F. , Hillier , J.E. , and Caines , A.J. Automotive Lubricants Reference Book Warrendale, PA SAE International and Professional Engineering Publishing 2004 978-0-7680-1251-4
- Vickerman , R. , Streck , K. , Schiferl , E. , and Gajanayake , A. The Effect of Viscosity Index on the Efficiency of Transmission Lubricants SAE Int. J. Fuels Lubr. 2 2 20 26 2010 https://doi.org/10.4271/2009-01-2632
- Dowson , D. Elastohydrodynamics Proceedings of the Institution of Mechanical Engineers, Conference Proceedings 182 1 151 167 1967 doi.org/10.1243/PIME_CONF_1967_182_014_02
- Niemann , G. , and Winter , H. Maschinenelemente: Band 1: Konstruktion Und Berechnung Von Verbindungen, Lagern, Wellen Springer 2001 978-3-662-08520-2
- Niemann , G. , and Winter , H. Maschinenelemente Band 2: Getriebe allgemein, Zahnradgetriebe - Grundlagen, Stirnradgetriebe Springer 2003 978-3-662-11873-3
- Vullo , V. Gears Volume 2: Analysis of Load Carrying Capacity and Strength Design Springer 2020 978-3-030-38632-0
- Harris , T.A. Roller Bearings Analysis Chichester John Wiley & Sons 1984 doi.org/10.1002/jsl.3000010407
- Lima , A. , Fukumasu , N. , Profito , F. , Souza , R. et al. Effect of Helical Tooth Geometry on Gear Efficiency Using Numerical Analyses in Lubricated Contact SAE Technical Paper 2018-36-0196 2018 https://doi.org/10.4271/2018-36-0196
- Achtenova , G. , and Pakosta , J. Estimation of the Gearbox No-Load Losses SAE Technical Paper 2016-01-1092 2016 https://doi.org/10.4271/2016-01-1092
- July 2003
- July 2007
- Aug. 2007
- Jih , E. , Chen , K. , Abraham , T. , and Siddapureddy , V. Thermal Management for the HEV Liquid-Cooled Electric Machine SAE Technical Paper 2001-01-1713 2001 https://doi.org/10.4271/2001-01-1713
- Ferraris , W. , Rostagno , M. , and Bettoja , F. Thermal Management Architectures Virtual Evaluation for HEV/PHEV SAE Technical Paper 2018-37-0025 2018 https://doi.org/10.4271/2018-37-0025
- Matsumoto , T. , Kato , H. , Takizawa , K. , Yashiro , T. et al. Development of Motor Cooling Technology in Hybrid Vehicles SAE Int. J. Adv. & Curr. Prac. in Mobility 2 1 454 458 2020 https://doi.org/10.4271/2019-01-2312