To meet the development of new energy vehicles, the performance requirements for gears are becoming increasingly stringent.
▶ Lightweighting: With the development of new energy vehicles towards lightweight, gears and transmission systems are also optimized towards smaller volume and lighter mass; structural innovation, small center distance gears and planetary gear reducer configurations have become the industry development trend.
▶ High-efficiency transmission: To improve the range and overall energy efficiency of new energy vehicles, high-efficiency gears and transmission systems are continuously optimized in terms of conversion efficiency, transmission ratio, and torque density. High-speed and high-ratio gears are becoming the trend.
▶ High NVH performance requirements: Noise control is critical to the ride comfort of new energy vehicles. High NVH performance gears have become a key control indicator in the development of new energy vehicle gears. The design dimension is controlled in advance, involving multi-dimensional design control such as gear structure, machining, assembly, housing support stiffness, bearing stiffness, shaft-to-tooth modal, housing modal, electric drive modal, motor modal, order avoidance, transmission path, and acoustic radiation.
▶ Materials and Manufacturing: High-performance materials including high-strength steels, advanced alloys, non-metallics, and composites are being progressively adopted. The precision requirements for gears are increasingly stringent, with national standards mandating Grade 5 or higher precision, and some parameters reaching Grade 4 or higher. A comprehensive control system integrates human, machine, material, method, and environmental factors in gear manufacturing. Strict coordination across all machining processes ensures full sequence precision. The implementation of new technologies such as honing, ultra-finishing grinding, and precision gear manufacturing enhances accuracy while maintaining consistency.
▶ Because of the tooth tolerance, gear machining error, assembly error, etc., the gear has other order besides the characteristic order, so the control of gear precision is very important.
