Development of Duty Cycle for Transmission System Components in a Two-Wheeled Electric Vehicle 2024-26-0318
Abstract
A two-wheeler is exposed to various dynamic loads transferred from roads and input given by the vehicle prime mover, which leads to the occurrence of torque on the wheel and transmission. Torque generated depends on the terrain and riding pattern of users for the majority, so it becomes important to develop a duty cycle of transmission considering multiple events enabling us to understand the durability standard of the component designed.
The tests performed were on an EV two-wheeler that uses a belt drive transmission. The paper will focus on the following aspects, which cover the customization of the torque cell for the pulley system in the transmission, followed by the testing on different selected terrain conditions and analysis methodology for generating the duty cycle for different systems in transmission of the vehicle. A customized torque cell using strain gauges was developed with locations identified from FEA(finite element analysis) performed on the wheel pulley.
Strain gauge locations are selected such that no other load crosstalks are occurring, throughout the rotation maintaining a similar strain-to-torque ratio. A telemetry system was incorporated, to perform the testing in the rotating component. The tests planned during this process was replicated to a user driveability pattern and high torque-generating conditions.
Multiple trials and events were covered helping the development of the transmission duty cycle. The wheel pulley torque data collection will also be crucial in generating a torque duty cycle for the linked components and belts in the transmission assembly. The duty cycle development of transmission will eventually help in improving the robustness of the two-wheeler electric vehicle under real-world driving conditions and provide better knowledge towards achieving an optimized structure.
