電動車動力系統傳動箱體結構之優化設計

Abstract

本研究以華創車電/華擎機械開發之電動車動力系統為研究對象，針對其傳動箱體結構進行優化設計。電動車重要的問題之一在於續航力不足，輕量化是提升續航力的有效方法，但輕量化後容易使結構剛性降低而產生共振，導致傳動效率降低、元件壽命減少及乘客舒適性下降…等問題，因此輕量化導致的共振問題不容小覷。本論文針對電動車動力系統之傳動箱體結構進行優化設計，使用有限元素軟體Abaqus建立動力系統模型，並透過模態敲擊試驗驗證模型的準確性。藉由文獻回顧探討結構輕量化設計與可能發生的共振問題，建立一套完整之設計流程。本流程整合結構設計之拓樸(Topology)最佳化方法，使結構同時滿足強度、剛性及振頻的目標需求，以改善結構因輕量化引起的振動問題。

Weight reduction of gearbox is an effective approach for electrical vehicles to extend their driving range. Nevertheless, lightening will result in reduction of the stiffness of structure, which makes resonance excited that drops off the efficiency of driveline, life time of parts, and passengers comfort. Therefore, this thesis brings up a brand new method, which optimize the structure of gearbox in electric vehicles. By using Abaqus(FEA software) to build the EV car driveline model. The accuracy of the driveline model is verified by the experimental modal analysis. This design strategy also includes the Topology optimization, and it can achieve the design goals in strength, stiffness, and natural frequency simultaneously so that we can avoid resonance to improve the driveline efficiency.