Design and Analysis of Electric Vehicle Gearbox and Differential

Electric vehicles (EVs) use simpler drivetrain because of the characteristics of the torque speed curve of an electric motor. The Electric Vehicle market is rapidly growing and the transmission unit of an EV is not the same as a Combustion Vehicle. Every EV’s torque requirement to obtain the desirable performance is different. This paper focuses on the part development and analysis of a single speed two stage reduction compound gearbox for electric vehicle to obtain all the desirable characteristics. Furthermore, the design factors including material selection for gears and shafts, gear ratio selection on the basis of torque requirement, number of teeth in a helical gear and bearing selection is considered. All the hand calculations were carried out in MS Excel to make it simpler and less time consuming. The gearbox was designed as per the parameters obtained by the Excel calculations on Autodesk Inventor. Then the design was optimized for weight reduction by carrying out the structural analysis of gears and shaft.