Manufacturers of EV drive systems are leaving no stone unturned in their quest for quiet-running, dependable transmission gears and shafts. Where once chamfering and deburring operations were almost an afterthought, they’re now considered a primary soft machining process, with widespread recognition that anything less than a flawless tooth flank can result in premature transmission failure, less-than-optimal efficiency, and unacceptable noise.

Congratulations Gear Technology on your 40th Anniversary! This magazine has been publishing emerging technology in gearing before we used the term, “emerging.” I constantly search past issues to get information on topics we are discussing in committees. From skiving to electric drive development, and lubrication to the beginnings of strain wave gear technology, I have found great information for the work that we are doing today. Thank you!

You've been asking for a course that focuses on electric vehicles (EVs) and we're happy to oblige! Introducing the all-new EV Automotive Transmission System Design class. Due to demand, seats for this course are projected to fill quickly, so register ASAP to ensure you get a spot!

AGMA hosted an EV Town Hall last month during their Motion + Power Technology Expo (MPT Expo). This event was planned to explicitly ask the question, “Is industry ready to roll up its sleeves and start the process of sharing common outcomes that will serve as the building blocks for standards for electric vehicle technology?” Spoiler Alert: The answer was a resounding, yes. And the discussion uncovered some key issues, and perhaps a surprise or two, that will help AGMA leverage its 107 years of experience in this space to start to frame future discussions for electric vehicle standards development.

For 107 years, AGMA has been the go-to place for gear standards. We have been bringing together engineers and leaders from across our industry to keep our standards updated and in line with new technologies. We started with noise issues on electric street cars in the early 1900s, and today we lead the global ISO TC 60 committee on standards including wind-turbine gear-box development. As new technologies and gear applications emerged, AGMA has gathered experts to discuss, brainstorm, share, and collaborate on the topics of the day such as plastic gears, epicyclic gears, marine gears, wind turbine gearboxes, and, of course, gear sets for internal combustion vehicles. We have also kept updated standards on gear accuracy, materials, and lubrication. This work has led to standards that reduce costs, improve quality, and make safer products for manufacturers and consumers worldwide.

A significant amount of work is being done to advance the technology of gears specifically for use in electric vehicles. No longer hidden by the noise of the internal combustion engine, the transmission has taken center stage as the noisiest component in most electric-driven cars.

The performance of an Electric Vehicle Power Unit is directly connected with critical tolerances. Tolerances drive opportunities for performance enhancement with cost reduction. The tests normally used to determine and validate tolerances are both expensive and time consuming with prototype parts. By replacing the initial tests with Digital Twin simulations, results can be obtained quickly, and at a much lower cost. This article discusses one of these tests and the results. 

Manufacturers must produce lighter and more compact EV transmissions from tough materials such as low-alloy steels—and those that rely on traditional manufacturing processes risk falling behind. Mats Wennmo, Global Automotive Transmission Manager at the metal cutting specialist Sandvik Coromant, explains why gear skiving is crucial for competitive manufacturing.
 

Electric vehicles or EVs are increasingly popular options for people who want to save money on gas and decrease their reliance on fossil fuels.

System-supplier Klingelnberg will be back at AMB (Booth C41, Hall 5), where it will be highlighting solutions for smooth-running gearboxes. The exhibit will feature the Höfler Cylindrical Gear Grinding Machine Speed Viper, the Klingelnberg Precision Measuring Center P 40 and the newly developed Höfler Cylindrical Gear Roll Testing Machine R 300.