Weight Optimization of Single Speed Electric Vehicle Transmission Housing

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Addis Ababa University


An electric vehicle is a vehicle powered by an electric motor, instead of an internal combustion engine, and the motor run using the power stored in the batteries. Electric Vehicles are known as zero emissions vehicles and are much environment friendly than gasoline powered vehicles. Even though electric vehicle brings an eco-friendly, green solution to the automotive industry sector, there exist drawbacks when compared to conventional gasoline-powered cars. The main drawback is that electric vehicles on average travel a shorter range than gasoline powered vehicles due to the heavy weight, and this puts pressure on the battery pack which forced to drain out faster. To optimize the energy consumption of electric vehicles the reduction of transmission housing weight is important. The main objective of this research work is to develop an optimized composite version of an existing aluminum transmission housing for single speed electric vehicle. The selected composite material characterized using AUTODESK HELIUS COMPOSITE and the free-size optimizations executed using one of the finite element analysis software ANSYS OptiSlang. The optimized T1000-3501-6Epoxy with T800-3501-6Epoxy laminate checked for the static and modal deformation. From the ANSYS Optislang optimization the weight of the transmission housing reduced by 22%, where the weight of Aluminum 6061-T6 was 5.4kg and the optimized weight by using composite + Aluminum material was about 4.19kg which satisfies the constraint conditions.



EV transmission housing, T1000-3501-6Epoxy, T800-3501-6Epoxy, ANSYS Optislang