Abstract

In the evolving landscape of electric vehicles (EVs), the gearbox plays a crucial role in efficiently transmitting power from the motor to the wheels, directly influencing vehicle performance, efficiency, and longevity. As the adoption of EVs continues to grow, optimizing gearbox design is essential to enhance durability and ensure reliable operation under varying load conditions. This research focuses on analyzing and optimizing a four-gear system with varying thicknesses and tooth counts, where precise engineering is necessary to maintain structural integrity and prevent premature failures due to torque transmission. Special attention is given to the second gear, as it experiences the highest stress levels, nearing the safety factor threshold. By conducting a comprehensive evaluation of gear performance, this study aims to improve the efficiency and lifespan of EV gear systems. 

To achieve these objectives, the modeling of the gearbox is planned using SolidWorks, ensuring accurate geometric representation and design feasibility. The structural and stress analysis of the gearbox components will be carried out using ANSYS, providing insights into their mechanical behavior under operational loads. Additionally, an analytical approach using MATLAB is planned to validate theoretical calculations and numerical simulations. This multi-software approach will allow for cross-verification of results, ensuring the accuracy and reliability of the findings. The validation process will compare theoretical, numerical, and simulated data, ultimately leading to optimized gear design and material selection. The outcomes of this study will contribute to the advancement of electric vehicle technology by enhancing gearbox efficiency, durability, and overall performance.