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1、IEEE Vehicle Power and Propulsion Conference (VPPC), September 3-5, 2008, Harbin, China 978-1-4244-1849-7/08/$25.00C2008 IEEE Design and Development of Few-Tooth-Deference Planetary Gear Powertrain Coupling System with Biased Bent Shaft in Electric and HEV for All-Terrain Vehicles Wang Yong-bin Zhan
2、g Zeng-nian Chen Wen-xin Yang Ya-ping Liang Feng Tu Xiao-feng Shi Yi-ping Zhang Xin Li Chang-gang Zhejiang Wanli University / School of Electronic and Information Engineering, Ningbo City, P.R.China. Email: AbstractThe article has analyzed the domestic and international present research status and
3、development trend of the electric and hybrid electric vehicles (HEV). Considering actual scientific research, according to the characteristic and environment requirement of all-terrain vehicle（ATV）, the principle of elected and designed component parts for Powertrain Coupling system of ATV, and the
4、demands of performance parameter of power, torque and speed of moving ATV, this article studies on the performance parameter and control strategy of powertrain coupling system of engine, electric motor and the storage battery. The optimization matching, the modeling simulation and the experiment hav
5、e been carried out. The article proposes a new multipurpose design and development plan on the powertrain coupling system in electric and HEV for ATVs. It introduces a new transmission system based on few- tooth - deference planetary gear powertrain coupling system with biased bent shaft （FPS）, whic
6、h have been applied in powertrain coupling system of the multipurpose light electric and HEV for ATV. The research results show that the proposed FPS meets the performance requirement for entire vehicle （ATV）, especially in regard infinitely variable speed. The method and the obtained result provide
7、 the basis design theory for the low-speed vehicles (that is, agricultural vehicles) and multipurpose light electric and HEVs. The technology has been applied to ATVs in Ningbo Saiting Electric Bicycle Science & Technology CO., LTD, and is applying for nation invention patent. Keywordshybrid electri
8、c vehicle; powertrain coupling system; few- tooth - deference planetary gear transmission; optimize matching I. INTRODUCTION UP to the present, the low-speed vehicles and ATV yet not used the technology of the electric and HEV. According to low-speed vehicles and ATV of HEV in road, environment, spe
9、ed and load situations, through the engine, the rechargeable battery and the electric motor/generator optimal fit, it studies one kind design and development plan of the new powertrain coupling system in electric and HEV for ATV. It focal introduces the new transmission set based on the FPS, which h
10、ave applied in powertrain coupling system of the multipurpose light electric and HEV for ATV, it emphasis introduces its application. Because the FPS have merits of the structure compact, the velocity ratio big, the efficiency high, the revolution steady, bearing capacity strong, the processing simp
11、le, the cost low status. It may apply in the ATV, the national defense, the metallurgy, the mine; lifts heavy objects professions and so on transportation, measuring appliance manufacture, etc1. The FPS may enhance the engine working efficiency, save the energy, discharge cleanly, and reduce the env
12、ironmental pollution and so on. This kind of vehicle besides the engine can charge to the battery, the power can be regenerated to battery when vehicle is in deceleration, the brake can transform mechanical energy to electrical energy avoiding the energy waste. With the HEV, the fuel efficiency of v
13、ehicle may enhance one time compared to the ordinary vehicle, simultaneously changes CO2 withdrawal to one half, which lead the earth to warm. It is innovative that the ATV uses the HEV technology, and the breakthrough point of infinitely variable speed is appropriate. Having the broad market applic
14、ation prospect, this technology also may be used in the ATV, and it will have huge development potential and favorable market prospect. The designing and developing light electric and hybrid electric vehicles E & HEVs for ATV are very significant contemporary activity referring to ecological require
15、ments. This means this kind of multipurpose transportation of light & low speed are most important in some areas closed for conventional vehicles such as woodland general investigation, tourists resorts, parks, and also for utility transportation in case of airports, railway stations, fire engine et
16、c. Other application is they apply for a short range and limited speed city transportation. II. HYBRID POWERTRAIN DESIGN Basis on the technology of manufactured ATV in Ningbo Saiting Electric Bicycle Science & Technology CO., LTD. We will analyze on research and development situation about the elect
17、ric and HEVs in domestic and foreign. However, the new powertrain coupling system -FPS in electric and HEV will be applied to ATV. IEEE Vehicle Power and Propulsion Conference (VPPC), September 3-5, 2008, Harbin, China A. The general situation of FPS116 ? Two degrees of the freedom planetary gear po
18、wertrain coupling transmission system of FPS is a very attractive gear set for summing and differentiating three streams of power flows - especially in hybrid powertrains. ? There are at least two sources ICE or flywheel as energy source and battery feeding motors as power source. ? The FPS has a bi
19、g velocity ratio, highly efficient and relatively small size. ? There is easy cooperating with ICE、 motors/generator and battery units. Motor can operate in 4Q and in two generatoring/motoring modes respectively to present planetary gear propelling or braking shafts torques and its speeds directions
20、. B. The Principium of FPS116 Provides one kind of new planetary gear powertrain coupling system with few- tooth - deference, it is mainly compose of centering inner annular gear 1, planet carrier with biased bent shaft 2, first planetary gear 3, second planetary gear 4, movable inner annular gear 5
21、, bearing 6 and bearing 7. The motor drive centering inner annular gear 1s teeth number is 14 different from the first planetary gear 3s teeth number, and the teeth number of movable annular gear 5 which outputs the power to driving gear is 0 4 different from 5 the second planetary gear 4s teeth num
22、ber. Generally, the velocity ratio is above 20100, and the efficiency is 0.80.9. T EG /MC UB atC BEBE1234567Few - tooth - deference planetary gear pow er-train coupling system w ith Biased B ent ShaftT WT WC lassicalW heelBrakeD GD ifferentialM echanismabG BC lassicalW heelBrake a,b - Helical gear;
23、1 - Centering inner annular gear; 2 - Planet carrier with biased bent shaft; 3 - First planetary gear; 4 - Second planetary gear; 5 - Movable inner annular gear; 6,7 Bearing; TE -Thermal (Internal Combustion) Engine; M/G - Motor/Generator; Bat Battery; CBE Clutches-Brakes System with Electromagnetic
24、 Controlled; BE - Brakes System with Electromagnetic Controlled; DG - Main Differential Gear; TW - Traction Wheels; CU - Control Unit; GB - Main Gear (Optional: additional 2 speeds gearbox) III. OPTIMIZING MODEL OF THE FPS1722 A. Brief introduction for the structure of FPS Fig. 2 is a schematic draw
25、ing of the FPS for ATV. It is belongs to the “NN” structure. The power of engine and electrical motor through the high speed level input which is composed by pair of helical gear a and b, and the low speed level is composed by the FPS, 1 is input annular gear connect to electrical motor; 2 is a plan
26、et carrier with biased bent shaft connect to the engine; 3 and 4 are the planetary gears; 5 is output annular gear. Supposes the rotational speed of engine is ne, the output rotational speed of the annular gear is n5, and the self- rotational speed of the planetary gear is n4, the driving crank rota
27、tional speed is n3 = n4. According to the relative motion principle, the planet gear is in plane motion, when the electrical motor does not work, the BE brake, and the engine power is input, then the structure total ratio iE5 is 41535335415511ZZZZZZZZZZnniEE= (1) There are two get the teeth differen
28、ce values practicality. A: Z5 - Z4 = Z1-Z3; B: Z5 - Z4 Z1-Z3. The subject of the issues discussed by A. If difference in teeth numeral K = Z5 - Z4 = Z1-Z3; staggered teeth numeral J = Z3 - Z4. Then: Z5= Z4 + K; Z3 = Z4 + J; Z1 = Z3 + K (2) The formula (2) into the formula (1), then: iE5 = Z3 Z5/（Z3
29、Z5 - Z1 Z4）= Z3 Z5/( Z5 Z4 ) Z3 - ( Z1 - Z3 ) Z4=( Z4 + K) ( Z4 + J )/KJ (3) If K and J = constant, then, Z42 + ( K + J ) Z4 + KJ (1 iE5 ) = 0 Then, the negative root was thrown away, Z4 is: ()()()+=5241421EiKJJKJKZ(4) As long as the pre-selected K、J values, K、J and the given transmission ratio iE5
30、together into the equation (4) can be obtained Z4. Then, the Z4 with K、J and together in the equation (3) calculate the actual transmission ratio. Finally, the Z4、K and J into the equation (2) was determined the value of remaining teeth Z1、Z3 and Z5. B. Design variable The design of FPS needs to det
31、ermine the parameter includes: speed ratio iab of cylindrical helical gear with Fig. 1 Appearance of all-terrain vehicles Fig.2 The schematic drawing of the FPS for ATVs IEEE Vehicle Power and Propulsion Conference (VPPC), September 3-5, 2008, Harbin, China high speed level; number of teeth za and z
32、b; module mn; graduated circle helix angle; facewidth ba and bb; speed ratio i45 of FPS with low speed level; module m; number difference of teeth zd; number of teeth z3 and z4; stand-off coefficient y3 and y4; addendum coefficient ha*; working pressure angle; facewidth b3 and b4. Among the variable
33、 up, the independent design variable have i12 、za 、mn 、b1 、m 、zd 、z3 、y3 、y4 、b3. Therefore, the design variable18,19,20 is X = iab, za , mn , b1 , m , zd , z3 , y3 , y4 , ha*, b3 T = x1 , x2 , x3 , x4 , x5 , x6 , x7 , x8 , x9 , x10 , x11 ,x12 T C. Objective function Uses the FPS in the ATV mainly a
34、re in order to obtain the small structure size. Therefore, the most research single target is optimizing by the structure volume for smallest. In order to calculate conveniently, it usually takes various gears reference volume as computation basis. Thus, first, addendum coefficient ha*, stand-off co
35、efficient y3 and y4; working pressure angle and so on parameters cannot reflect in the objective function, but these parameters have the reflection in constraint condition, such as tooth profile overlap interference, pinion transition curve interference and contact ratio. If depends on the experienc
36、e to determine them, sometimes causes not to be able to satisfy the constraint condition. Second, in order to satisfy the FPS tooth profile not to overlap the interference condition, the transmission generally uses clockwise drive and simultaneously reduces addendum coefficient ha*，but uses the cloc
37、kwise drive can cause the transmission working pressure angle to increase, and causes the crankshaft bearing radial force to increase, thus affects the bearing life and the transmission efficiency 4,5. In the FPS design, the working pressure angle is an important parameter must take a more appropria
38、te value. In order to cause the transmission device weight to be light, the volume is small, has high transmission efficiency, and has high service life, this article take the various gears volume sum is smallest and the working pressure angle is smallest as the double optimized goal4,5, namely inv=
39、 inv+2 ( y4 - y3)/zd tan （5） In the formula inv= tan-, is the pressure angle of reference circle. V = V1 + V2 + V3 + V4 =/4( da12 b1 + 2 da22 b1 + 2 df32 b3 + da42 b3)（6） In the formula, da1 、da2 、da5 respectively are the tip diameter of gear 1、2 and 5; df3 is the root diameter of gear 3.The objecti
40、ve function is f ( X) =1 (inv/ inv*) +2 ( V/ V* ) （7） In the formula, 1 、2 are the weighting factor, takes1 = 1, 2 = 2, expression the volume for main optimized goal, and the working pressure angle for secondary optimized goal; *、V * respectively is the working pressure angle and the volume empirica
41、l value. D. Constraint Condition 1) The constraint condition of movement performance a) The limiting condition of tooth profile overlap interference of internal and external gear , g1 ( X) : z5 (inva4 +2) - z3 (inva3 +1) +( z5 - z3) inv0 32 2324112cosaaarrr+= 42 2324122cosaaarrr+= In the formula, ai
42、s a center distance of the gear 3 and 5. b) The limiting condition of inner engagement contact ratio g2 ( X) : z3 (tana3 - tan) - z5 (tana4 tan) / 2 1. 05 c) The limiting condition of transition curve interference of inner and annular gear g3 ( X) : z3tana1 + ( z5 - z3) tan- ( z5 -z0) tan04- z0tana0
43、 0 In the formula, z0 is the tooth number of internal gear tooth slotting tool, a0 is the working pressure angle of tip circle of internal gear tooth slotting tool, 04is working pressure angle between internal gear tooth slotting tool and inner gear. d) The interference limiting condition of inner g
44、ear top cut g4 ( X) :1 - z3/ z5 - tana4/ tan 0 e) The interference limiting condition of inner gear under cut g5 ( X) : ha*- z5sin2/ 2 - y4 0 f) The limiting condition of apex clearance of inner gearing gear g6 ( X) : ra3 - rf4 + c*m 0 2) Constraint condition of intensity a) The limiting condition o
45、f contact fatigue strength of flank of tooth g7 ,8 ( X) : H1、3H1、3- 1 0 In the formula, : H1、3 is allowable contact stress of gear 1 and 3, H1、3 is contact stress of gear 1 and 3. b) The limiting condition of bended fatigue strength of Dedendum IEEE Vehicle Power and Propulsion Conference (VPPC), Se
46、ptember 3-5, 2008, Harbin, China g9 ,10 ( X) : F1、3/F1、3 - 1 0 In the formula, F1、3 is allowable bended stress of gear 1 and 3; F1、3 is bended contact stress of gear 1 and 3. 3) The constraint condition of varible boundary g10 + i ( X) : ai xi bi , i = 1 ,2 , ,12 In the formula, ai is the minimum va
47、lue for ith design variable; bi is the maximum value for ith design variable. In the end states, this question optimizing mathematical model is min f ( x) x xT s. t . gi ( x) 0 ( i = 1 ,2 , ,32) IV. STUDY ON CASE The FPS for ATV had been designed. Its input power is P = 29.5kW. Its input speed is 50
48、00（engine）/2890（motor）r.p.m., and then the vehicle speed maximum is 80km/h. It can work for 8 hrs every day smoothly. The material of high-speed gears is 40Cr steel, quenching-tempering and surface- hardening, and the tooth surface hardness is HRC48HRC55. Low speed gear material is 45 steel, quenchi
49、ng tempering, and the tooth surface hardness is HBS200 HBS240 4,5. Through the application of matlab6.5 on IBM P960 computer, a group of optimal solution was obtained through running the program. The optimal solution is showed in table 1(all the data are rounded). Comparing the optimal design and th
50、e conventional design, it shows that the objective function reduces by 41.5%; the volume of the transmission reduces by 50. 3%, and smaller mesh angle was get, and then the efficiency of gear drive and the bending strength of gear tooth have been advanced. Table 1 gives the parameters optimization r
51、esults and comparisons1722. Tab 1 The Optimization Results and Comparisons Parameters i12 Za mn b1 m Zd Conventional Design 4.0 20 2 13.25 25 2.5 1 Optimal Design 4.7 20 2 14.18 22 2.0 1 z3 y3 y4 ha* b3 V f ( x) 146 0.1 0.368 0.70 25 9.8106 37.7 2.666 123 0.06 0.286 0.65 22 48106 34.6 1.506 V. THE C
52、ONTROL STRATEGY OF POWERTRAIN COUPLING IN THE FPS The power of engine and motor is the working state of clutches and brakes controlled by electric control device, and dynamical coupled in the FPS. Table 2 shows the control strategy of clutches-brakes and brakes system with electromagnetic controlled
53、 in the FPS. Tab.2 States of clutches & brakes system versus driving mode Drive Mode CBE BE Remarks C BE Motor drive forward rotation Vehicle advancepure electric mode Motor drive reverse Vehicle reversepure electric mode Engine drive advance Vehicle advance Hybrid drive（motor natural rotation or mo
54、tor reverse） Continuouslyvariable speed; motor aid force or running generate electricity Electric power variable torsion Great torsion low rotate speed Engine drive Reverse Vehicle reverseengine drive Regenerative braking23 Generator generate electricity Notes: “” means clutches release or brakes no
55、t braking; “”means clutches engagement or brakes braking. The relation of vehicle speed driving force at different driving modes can see figure 3 show1722. Hybrid DriveThermal Engine DriveElectric Power Variable TorsionMotor DriveFig. 3 Relation of Vehicle Speed and Driving Force at Different Drivin
56、g ModesVehicle Speed Driving Force When the hybrid ATV from a drive mode switches to another mode, the clutch-brake（CBE） and brake （BE）System with Electromagnetic Controlled began to goal-driven model of integration changes. At this time clutch control of the vehicle clutch combination of power has
57、a great influence upon the power performance of vehicle and smoothness of engagement. VI. CONCLUSION In design of FPS, by taking mechanism volume and meshing angle as twin optimizing objective, it has the advantage of global optimization. In the process of finding the minimal device, it makes the co
58、nfiguration of design parameters more reasonable. It not only decreases the size of configuration for ATV, but also improves the motion performance. Application of the FPS for ATV can make the engine and motor couple stably. It can implement continuously variable speed transfer power through adjusti
59、ng the speed of motor forward and reverse rotation. Compared with the result of the traditional optimization, the algorithm of optimizing model of the FPS was proved practicable in application example. ? The powertrain coupling system of the FPS is very effective in ATVs, delivery trucks or passenge
60、r cars; IEEE Vehicle Power and Propulsion Conference (VPPC), September 3-5, 2008, Harbin, China ? The problem is how to decrease a cost of this drive components and its numbers e.g. numbers of motors; ? The second motor is substituted by clutch - brake system, which is developed by my group; ? Plane
61、tary transmission drive needs more components not basically used presently in automotive industry; Anyway other hybrid drive system developed by us for low price city cars could be offered based on existing components with some improvements - certainly for obtaining higher operation efficiency. Manu
62、facturing preparation chose vehicles prototyping, designing and manufacturing light electric and HEV for ATV & industrialization preparation in Ningbo Saiting Electric Bicycle Science & Technology CO., LTD. Meshes the FPS to each kind in the transmission set for HEV of ATVs, the aim is to explore th
63、e movable rule. With the new theory viewpoint, compared with the systematic and elaborate principle of work, the transmission form and the basic work condition, it gives the research and development comment. Thus the design overcame shortcomings in fluctuating disc type, shaft type, slide type and d
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