Electric Axle Demonstrator Vehicle

Faculty Mentor: Dr. John Ziegert Supporters: : Brian Lee, Cartsen Ohr, Adam Blocker, Ben Smith
Zachary Alexander Huy Dien Zachary Hunt Ana-Paula Llanos Brenden Oneyear Daniel Rambarran
Senior Design 1, Fall 2017
zalexan2@uncc.edu hdien@uncc.edu zhunt2@uncc.edu allanos@uncc.edu boneyear@uncc.edu drambarr@uncc.edu

Overview Overall Transmission Design Chain Drive System Design

Goal: To build and design a transmission with a
cycloidal speed reducer and cycloidal differential and Pros: Cons:
Housing components:
integrate it into an electric vehicle. To prove the Accessibility to parts Significant space
1. Two half housings
feasibility of the concept. Ease of design increase
2. Cycloidal gear reduction
More compatible operating Requires tensioner
3. Cycloidal differential
Requirements & Specifications environment Rigorous maintenance
4. Chain drive
Employ original 1.9 kW electric motor Affordability
5. Motor adaptor plate
Meet a top speed of 14 mph 6. Flanges
Components:
Constrained to underbody space in 2001 36V EzGo 22/23 teeth sprockets
electric golf cart Floating tensioner
12.44:1 speed ratio Standard ANSI 40-1 roller chain

Technology
Instrumentation
What is a Cycloidal Drive?
Cycloidal drives use three main elements: Data Acquisition:
An input shaft (red) Housing Temperature
An eccentric cam driving a cycloidal disk (blue) Output Speed Ratio Confirmation
Cycloidal lobes rotating around static ring pins (yellow) Road Tests
Mechanical Power Output
Why Choose a Cycloidal? Housing Vibration & Temperature
The unique profile of a cycloidal drive achieves a high Rear-Wheel Speed / Turn Radius
gear-ratio in a compact package, is able to withstand heavy
loads and provides a quiet and low wear operation. Real Time Display:
Housing
Onboard PCDesign
will display real time data taken
from testing equipment.
Housing Design Labview will be used for data processing and
Considerations: output
Two part housing for ease of assembly Senior Design 2 Timeline
All openings sealed to contain lubrication
Ease of machinability
3D Scanning Accommodate space for instrumentation
Structural Scanning:
Use of Romer Arm scanner to Motor Plate Design:
develop a 3D scan of the stock Motor interface geometry obtained from scan was applied to the design of a
transmission housing. new motor adapter plate
Scan aided in understanding space Detachable motor plate for ease of machinability and assembly
available
Constraints Used: Flange Plate Design:
Distance between stock half axles Two newly designed flange plates required to reuse original hollow axle tubes.
and hollow axle tubes Uses 8 bolt circular pattern to attach onto housing
Original motor mounting geometry
Original motor and half axle splines