With the shift from internal combustion (IC) to electric powertrains, the number of powertrain components will be significantly reduced. The remaining components in all types of vehicles will become even more critical to vehicle operation and lifespan. One such area is the gear system, essential for converting the high torque from the electric motor into RPM at the wheels.
Two factors related to vehicle operation are the efficiency, or "range capability," and gear noise in these new gear sets used in electric vehicles. To attract consumers, electric vehicles need to achieve similar mileage to internal combustion engine vehicles. Achieving this will require gears with lower surface textures, reducing surface friction and thus increasing the vehicle's overall range. Secondly, noise from the internal combustion engine (IC) typically masks noise from the powertrain. Measures to reduce cabin noise are designed into the chassis and passenger compartment. However, with the transition to electric motors, gear noise may become prominent again without changes to new manufacturing methods and processes.
Gears can be designed and manufactured in a variety of ways, leading product design engineers to evaluate different approaches to achieve stringent surface texture and waviness specifications as well as high-volume production requirements.
With the latest advancements in the manufacturing of electric vehicle gears and the implementation of more stringent standards, precision measuring instruments can play a vital role.
To ensure optimized gear surfaces, analysis, understanding, and characterization using metrology tools are essential. Because these gears are of high value, non-contact metrology solutions are preferable, as they do not damage or harm the gears after processing. As gear surfaces become smoother, the use of tactile and other analytical methods becomes more challenging.
The growth of the electric vehicle market is inevitable. It presents significant challenges for manufacturers as they grapple with the technological advancements that truly make and break down vehicle engineering. At present, the most crucial need is for advanced finishing and grinding technologies used to create extremely complex and precise surface features in gear teeth to improve efficiency and reduce noise, thereby enhancing customer satisfaction.
As often happens in advanced design and manufacturing, in the pursuit of innovative technological advancements, metrology's role shifts from a necessary evil to a supportive one. In the field of gear manufacturing for electric vehicles, the ability to accurately, quickly, and easily characterize precision surface features is crucial.
Optical metrology is a highly versatile inspection method that plays a crucial role in verifying gear quality and achieving design intent. Today, it has become the "preferred" metrology solution due to its non-contact, non-destructive, rapid, highly sensitive, and superior resolution and accuracy.
