Automotive Powertrain Concept Development, Design and Analysis
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Automotive Powertrain Concept Development, Design and Analysis

KBE+, Inc. is an internationally recognized source of gear design, analysis, prototype manufacture and test of gears and mechanical power transmission systems. We have a wealth of deep technical, analytic and practical knowledge addressing all aspects of gears and systems development.

Because NVH and predictions of life service are typically problematic for our clients, we have developed very sophisticated analytic tools that have been vetted through test and validation. We also provide full test services for the analysis and development of gears, gear systems and power transmission systems all the way to complete gear-box evaluation.

Gear Services Available;

 

  • Vast experience in automotive design, analysis, testing and manufacturing
  • Extensive practical experience in off-highway, construction and agricultural industries
  • Internationally recognized team of gear train forensic engineers
  • Comprehensive gear measurement and mapping capabilities
  • Complete metallurgical analysis capabilities
  • Experienced with multiple gear design and analysis packages;
    • KISSsoft
    • UTS
    • PowerGear
    • AGMA Rating Suite
    • LDP
    • To name a few

A Powertrain Development Success Story

Tesla Motors is dedicated to proving that electric cars can be better than gasoline-powered cars. With instant torque, incredible power, and zero vehicle emissions, Tesla’s products are to be cars without compromise. Each new generation of model will be more affordable than its predecessor, driving the mission of the company: to accelerate the world’s transition to sustainable transport.

 

One issue with electric cars is that gear noise (NVH) is much more noticeable than in cars with traditional IC engines, given the considerably lower ambient noise from electric vehicles . KBE+ was contracted by Tesla Powertrain Engineers to address this problem in their designs. The first generation vehicles used a purchased design from a Tier 1 supplier that unfortunately had not considered this issue. After extensive modelling and analysis, KBE+ engineers determined that the original transmission design was excited by a number of driving frequencies generated by the electric machine. We successfully executed a complete redesign of the geartrain, transaxle case and coupling that completely eliminated the problem. We also discovered several manufacturing issues during this development cycle and our engineers worked with the international supply chain and vendors to correct these problems.

 

KBE+ still collaborates closely with the powertrain group at Tesla to develop, design and manufacture some of the quietest transmissions in the world.