Design of topological flank modifications to optimize the operational behavior of stepped planetary gear stages in dynamic operating conditions under consideration of producibility

汽车变速箱设计中的一个挑战是高功率密度、高效率和低噪声排放的组合。随着动力总成的电气化，对噪声排放和效率的要求也进一步提高，因为一方面消除了内燃机的掩蔽噪声，另一方面关注于电动汽车的能效。为了满足这些要求，带有行星齿轮级的复杂齿轮箱拓扑结构被越来越多地使用。作为行星齿轮级的最新发展阶段，阶梯式行星齿轮级是解决当前变速箱技术挑战的潜在选择。目前的研究表明，行星齿轮级的显著不对中行为，特别是在制造或装配偏差的情况下。然而，动态失调行为对阶梯行星齿轮齿面接触的影响还没有得到充分的研究。在考虑制造或装配偏差的情况下，重点关注齿轮啮合和齿面修改中的接触条件的操作行为优化方法缺失。因此，本项目的目标是一种设计拓扑齿面修形的方法，以优化阶梯行星齿轮工作台的动态运行行为，同时考虑展成磨削过程中的可制造性。该项目的结果是一种经过验证的齿面修形设计方法，以优化有制造或装配偏差的阶梯行星齿轮工作台的操作行为。由于其一般的接触描述，该方法允许对多种齿轮配置(单级/多级圆柱齿轮、行星齿轮级、组合齿轮系统)的操作行为进行优化。作为动态多体模拟(MBS)和准静态接触分析(TCA)之间的接口，该方法允许在齿面修形设计中直接考虑高度详细的整体系统。根据噪声激励、承载能力(齿侧压力和齿根应力)以及基于优化算法的效率和优化算法，考虑目标变量的权重来评估操作行为。

One challenge in the design of automotive gearboxes is the combination of high power density, high efficiency and low noise emission. With the electrification of the powertrain, the requirements in terms of noise emission and efficiency increase additionally, since on the one hand the masking noise of the internal combustion engine is eliminated and on the other hand the focus is on energy efficiency for electrically driven vehicles. To meet these requirements, complex gearbox topologies with planetary gear stages are increasingly being used. As the latest development stage of planetary gear stages, stepped planetary gear stages represent a potential alternative to solve the current challenges in gearbox technology. Current research shows the pronounced misalignment behavior of planetary gear stages, especially with manufacturing or assembly deviations. However, the effects of dynamic misalignment behavior on tooth contacts in stepped planetary gears have not been adequately researched. Methods for the optimization of the operational behavior under consideration of manufacturing or assembly deviations with focus on the contact conditions in the gear meshes and tooth flank modifications are missing. The objective of this project is therefore a method for the design of topological tooth flank modifications for the optimization of the dynamic operational behavior of stepped planetary gear stages, taking into account the producibility in the generating grinding process. The result of this project is a validated method for the design of tooth flank modifications to optimize the operational behavior of stepped planetary gear stages with manufacturing or assembly deviations. Due to its general contact description, the method allows the optimization of the operational behavior of a wide range of gear configurations (single/multi-stage cylindrical gears, planetary gear stages, combined gear systems). As an interface between dynamic multi-body simulation (MBS) and quasi-static tooth contact analysis (TCA), the method allows direct consideration of the highly detailed overall system in the design of tooth flank modifications. The operational behavior is evaluated in terms of noise excitation, the load-carrying capacity (tooth flank pressure and tooth root stress) as well as the efficiency and optimized algorithm-based, taking into account a weighting of the objective variables.