Computational Fluid Dynamics Analysis of Gearbox Churning Loss and Oil Splash Characteristics in Electric Vehicle Drive Units

2025-01-8182

04/01/2025

Features
Event
WCX SAE World Congress Experience
Authors Abstract
Content
The efficient operation of electric vehicles (EVs) heavily relies on the proper lubrication of the E-drive unit components, particularly the transmission gears and bearings. Improper oil supply can lead to mechanical failures, while excessive oil can increase power loss due to churning. This study focuses on utilizing Computational Fluid Dynamics (CFD) simulations to analyze the impact of drive speed, oil level, and temperature on gear churning loss in E-drive units. The research also investigates the influence of a baffle plate on power loss and oil splash characteristics. The simulations, conducted using the volume of fluid (VOF) method in Simerics-MP+, consistently illustrate a reduction in power loss with rising oil temperature and reveal decreased gear churning loss with a baffle plate, especially under high-speed conditions, highlighting its potential for enhancing energy efficiency in EVs. Additionally, post-processing analysis of oil splash patterns sheds light on the lubrication process of the gears, offering valuable insight into optimizing E-drive unit design for enhanced energy efficiency and performance.
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DOI
https://doi.org/10.4271/2025-01-8182
Pages
9
Citation
Kumar, P., Motin, A., Pandey, A., Ganamet, A. et al., "Computational Fluid Dynamics Analysis of Gearbox Churning Loss and Oil Splash Characteristics in Electric Vehicle Drive Units," SAE Technical Paper 2025-01-8182, 2025, https://doi.org/10.4271/2025-01-8182.
Additional Details
Publisher
Published
Apr 01
Product Code
2025-01-8182
Content Type
Technical Paper
Language
English