Design of a Gearbox for Optimal Weight and Performance in Baja SAE

Baja SAE India is a collegiate competition where teams design, build, and race off-road vehicles. Given the increasing difficulty of the competition and the engine power limitations, optimizing the powertrain components for both weight and performance is crucial. The design process starts with simulating the vehicle in MATLAB, factoring in engine performance, CVT shifting, and forces such as rolling resistance, air drag, and tractive force to determine the optimal gearbox ratio. Following this, the gearbox shaft diameters are calculated, and the module, width, and diameter of the gears, as well as the bearings, are specified using ASME standards. The gears are then modeled in design software and analyzed for fatigue to ensure an adequate factor of safety. Finally, the gearbox is integrated into the overall vehicle design. The results were verified using Simulink Baja module and Optimum lap. The newly formulated gearbox is 32% lighter and gives an acceleration of 7.99 m/s2.