Development of a measurement approach for the gear transmission error of helical gears : In-situ gearbox gear transmission error measurements at the drive unit of an all-electric vehicle

Abstract

This master thesis is based on an industry project in the field of propulsion systems for allelectric vehicles. A test rig to measure the gear transmission error of helical gears in a one speed, two stage gear box is developed. The characteristics of transmission error are discussed. Several possible test rig designs are investigated and a validation approach for the chosen measurement and test bench approach is presented. Low resolution in-expensive optical encoders are successfully applied together with a high frequency tacho acquisition card on a back-to-back test rig. The order spectrum of the transmission error and the peak-to-peak transmission error amplitude of five different gear designs are successfully assessed. The results are compared with system vibration data and transmission error calculations.