Control and Design Optimization of an Electric Vehicle Transmission Using Analytical Modeling Methods

Abstract: This paper introduces a framework to systematically optimize the control and design of an electric vehicle transmission, connecting powertrain sizing studies to detailed gearbox design methods. To this end, we first create analytical models of individual components: gears, shafts, bearings, clutches, and synchronizers. Second, we construct a transmission by systematically configuring a topology with these components. Third, we place the composed transmission within a powertrain and vehicle model, and compute the minimum-energy control and design, employing solving algorithms that provide global optimality guarantees. Finally, we carry out the control and design optimization of a fixed- and two-gear transmission for a compact family electric vehicle, whereby we observe that a two-gear transmission can improve the energy consumption by 0.8 %, while also achieving requirements on gradeability and performance. We validate our framework by recreating the transmission that is mounted in the benchmark test case vehicle and recomputing the energy consumption over the New European Driving Cycle, where we notice an error in energy consumption of 0.2 %, affirming that our methods are suitable for gear ratio selection in powertrain design optimization.