Experimental Verification of High-Performance Polymer Gears in an Electric Vehicle Powertrain

Gears made of polymers increasingly gain relevance in current research and industrial practice. Due to their advantages such as low density and the possibility of cost-efficient production in large quantities, more and more efforts are made to substitute steel gears with polymer wherever possible. However, the usage of polymer gears in current vehicle systems is still almost exclusively limited to applications with restricted power transmission, like actuators. To extend the field of application to power transmissions as well, in this study a transmission was developed for use in a small electric vehicle of the 7Le power class considering the application of polymer gears. Compared to the series transmission with all gear stages out of steel, one of them was completely substituted with high-performance polymer gears. Subsequently, the load-carrying capacity of the hybrid polymer-steel transmission is investigated for functional verification on a specially developed test rig as well as inside a modified demonstrator vehicle under real-life conditions. Assuming usual operating conditions, the load-carrying capacity of the polymer gears appears suitable for the aimed application on the test rig as well as inside the demonstrator vehicle. Moreover, with increased power and under continuous sustained loading, high performance of the polymer stage as well as a stable temperature behavior can be observed. Under the given circumstances, the use of polymer gears as part of a powertrain in small electric vehicles seems possible.