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

高功率密度、高效率和低噪声是汽车变速箱设计面临的挑战之一。随着动力总成的电气化，在噪声排放和效率方面的要求也随之提高，因为一方面要消除内燃机的掩蔽噪声，另一方面要关注电动汽车的能源效率。为了满足这些要求，越来越多地使用具有行星齿轮级的复杂齿轮箱拓扑结构。阶梯式行星齿轮作为行星齿轮的最新发展阶段，代表了解决当前齿轮箱技术挑战的一种潜在的替代方案。目前的研究表明，行星齿轮阶段的显着不对准行为，特别是与制造或装配偏差。然而，对于阶梯式行星齿轮中动态失位行为对齿接触的影响，目前还没有充分的研究。在考虑制造或装配偏差的情况下，对齿轮啮合和齿面修改的接触条件进行优化的方法是缺乏的。因此，这个项目的目标是一种设计拓扑齿面修改的方法，以优化阶梯式行星齿轮阶段的动态操作行为，同时考虑到生成磨削过程中的可生产性。该项目的结果是一种有效的设计方法，用于齿面修改设计，以优化具有制造或装配偏差的阶梯式行星齿轮级的运行行为。由于其一般接触描述，该方法允许广泛的齿轮配置（单/多级圆柱齿轮，行星齿轮级，组合齿轮系统）的操作行为的优化。作为动态多体仿真（MBS）和准静态齿面接触分析（TCA）之间的接口，该方法可以在齿面修形设计中直接考虑高度详细的整体系统。考虑客观变量的权重，从噪声激励、承载能力（齿侧压力和齿根应力）以及效率和优化算法等方面对其运行行为进行了评估。

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.