Electric Vehicle Drivetrain Final Design Review June 2, 2017 Sponsor: Zachary Sharpell, CEO of Sharpell Technologies [email protected] (760) 213-0900 Team: E-Drive Jimmy King [email protected] Kevin Moore [email protected] Charissa Seid [email protected] Statement of Disclaimer Since this project is a result of a class assignment, it has been graded and accepted as fulfillment of the course requirements. Acceptance does not imply technical accuracy or reliability. Any use of information in this report is done at the risk of the user. These risks may include catastrophic failure of the device or infringement of patent or copyright laws. California Polytechnic State University at San Luis Obispo and its staff cannot be held liable for any use or misuse of the project. Table of Contents Executive Summary ...................................................................................................................1 1.0 Introduction ..........................................................................................................................2 1.1 Original Problem Statement ...........................................................................................2 2.0 Background ..........................................................................................................................2 2.1 Drivetrain Layout ...........................................................................................................2 2.2 Gear Types .....................................................................................................................4 2.3 Differentials ...................................................................................................................5 2.4 Effects of Loads on Bearings .........................................................................................9 2.5 Housing and Sealant Options .......................................................................................10 2.6 Customer Market .........................................................................................................13 2.7 Motor-Drivetrain Interface ...........................................................................................13 3.0 Requirements ....................................................................................................................14 3.1 QFD Discussion ...........................................................................................................14 4.0 Design Development ..........................................................................................................16 4.1 Concept Generation .....................................................................................................16 4.2 Idea Selection ...............................................................................................................18 4.3 Design Process .............................................................................................................19 4.4 Construction of Drivetrain ...........................................................................................20 4.5 Dynamometer Background ..........................................................................................20 4.6 Test Plan.......................................................................................................................22 4.7 Design Safety Hazard Checklist ..................................................................................23 4.8 Cost Estimation ............................................................................................................24 5.0 Management Plan ..............................................................................................................26 6.0 Adjusting to New ST5 Design ...........................................................................................27 6.1 Changes to Design Specifications ................................................................................27 6.2 Updated Specification Table ........................................................................................31 7.0 Justification of Final Design ..............................................................................................31 7.1 Component Selection ...................................................................................................33 7.1.1 Gear Selection .....................................................................................................33 7.1.2 Right Hand versus Left Hand Gear Cut ..............................................................35 7.1.3 Gears Material Selection Justification ................................................................36 7.1.4 Gear Processing ..................................................................................................37 7.1.5 Shaft Design ........................................................................................................38 7.1.6 Bearing Selection ................................................................................................40 7.1.7 Bearing Housing .................................................................................................42 7.1.8 Differential ..........................................................................................................43 7.1.9 Housing ...............................................................................................................44 7.1.10 Motor Coupler ...................................................................................................48 7.2 Design for Safety .........................................................................................................48 7.3 Budget ..........................................................................................................................48 8.0 Manufacturing Plan ............................................................................................................49 8.1 Assembly Plan .............................................................................................................50 8.2 Maintenance and Repair ..............................................................................................50 9.0 Design Verification Plan ....................................................................................................51 9.1 Housing Leakage Test..................................................................................................51 9.2 Gear Reduction Confirmation Test ..............................................................................51 9.3 Dynamometer Testing ..................................................................................................52 9.4 BMW 330Ci Implementation .....................................................................................52 9.5 Alternate Plan...............................................................................................................53 9.6 Drivetrain Specification Checklist ...............................................................................53 10.0 Manufacturing ..................................................................................................................54 10.1 Housing Blocks ..........................................................................................................54 10.2 Bearing Mounts ..........................................................................................................56 10.3 Input and Intermediate Shaft ......................................................................................56 10.4 Keys ...........................................................................................................................58 10.5 Housing Plates ...........................................................................................................59 10.6 Ring Gear Bolt Pattern ..............................................................................................59 10.7 Differential .................................................................................................................61 11.0 Assembly..........................................................................................................................62 12.0 Testing..............................................................................................................................68 12.1 Speed Reduction Test ................................................................................................68 12.2 Original Torque Increase Test ...................................................................................69 12.3 Oil Leak Test..............................................................................................................73 13.0 Conclusions ......................................................................................................................75 13.1 Design Concept vs Final Prototype............................................................................75 13.2 Prototyping Cost .......................................................................................................75 13.3 Future Manufacturing Recommendations ..................................................................76 13.4 Safe Operation of Drivetrain ......................................................................................76 14.0 References ........................................................................................................................77