電動車用傳動箱體結構之最佳化設計方法

Abstract

車輛產業正逐漸邁向電動車的新時代。電動車最重要的問題在於其續航力不足，輕量化是提升效率的最佳途徑。但輕量化的結果，會使得齒輪箱易產生共振，將導致齒輪箱噪音過大及效率下降。輕量化導致的共振問題不容忽視。因此本研究針對電動車用的傳動齒輪箱之結構設計方法進行研究與探討，針對輕量化與可能發生的共振問題，建構了一套完整之設計流程。本設計流程整合拓墣(Topology)結構最佳化方法以及形貌(Topography)結構最佳化方法，可同時達到其強度、剛性、與振頻的目標需求，以降低因輕量化引起的振動，進而避免其效率下降的問題。本研究產出之設計流程，並實務應用於Formosun先進動力研究中心所開發之鋰電池純電動車─Green Jumper之傳動齒輪箱設計上，進而驗證本流程之可行性與實用性。

The vehicle industry is developing to a new generation of the electric vehicle. The main problem of the EV is the short driving range. Although reducing the weight is the best way to prolong the driving range, light-weight will cause the resonance between the gearbox and the gear, and it may lead to more noises and less efficiency. Therefore, this research brings up a new design method to solve the resonance problem caused by reducing weight. This design method includes the Topology optimization and the Topography optimization, and it can reach the design target of strength, stiffness, and natural frequency simultaneously. So the vibration can be reduced to prevent the problem of efficiency decrease. The new design process provided from this research is applied to the transmission gearbox of the EV, named Green Jumper, which is made by FAPRC (Formosun Advance Power Research Center), to verify the practicability and the feasibility of this design method of EV’s transmission gearbox structure.