Precision Metrology's Increasing Role In EV Gear Manufacturing
By Michael Schmidt, Zygo Corporation
It has become abundantly clear that not only are electric vehicles (EVs) becoming more prevalent on the roads but that almost all automotive companies are announcing plans where EVs will eventually dominate their product portfolio. As the shift from internal combustion (IC) to electric continues, the number of drivetrain components will dramatically lessen. And the remaining components found in cars of all types will be more so critical to the vehicle’s operation and longevity. One such area are the gear components necessary to convert the high-force torque from electric motors to the RPMs at the wheel.
Two factors of the vehicle’s operation are related to these new gear packs for electric cars – efficiency, or ‘rangeability,’ and gear noise. To appeal to consumers, electric vehicles will need to reach similar mileage as their internal combustion counterparts. Accomplishing this will require gears with lower surface texture, where surface friction is reduced, thereby increasing the vehicle’s overall range. Second, the sound from the IC engine typically masked the noise from the drivetrain. Efforts to dampen sound in the passenger cabin were designed into the vehicle frame and the passenger compartment. Yet, with the shift to electric engines, gear noise could again become prominent if it were not for a change to new manufacturing methods and processes.
With recent processing developments and tighter specifications on EV gears, precision metrology can play a fundamental role. ZYGO’s work with industry partners, such as the Ford Motor Company, has helped advance these processes by establishing a reliable method to measure and monitor these surfaces, allowing for even tighter specifications and stringent quality control.
Get unlimited access to:
Enter your credentials below to log in. Not yet a member of Photonics Online? Subscribe today.