Gearbox Housing Development for Hybrid vehicle

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Customer: Tier 1 supplier to the automotive industry

Market: Light duty on highway - Asia

BRACE execution: Powertrain domain cluster

Location: BRACE office and Customer location

BRACE designed a complete new gearbox housing for the client’s new hybrid transmission. With a position within the clients new product development team, BRACE was assigned to independently develop the housings together with the clients external partner for CAD and FEA support.

Some highlights from the development:

  • Requirements set-up
  • Interface to out- and inside features
  • Reference model features (skeleton)
  • Loadcase definition and set-up
  • Excessive bearing support deformation and contact deformation
  • Shaft misalignment
  • Manufacturing and supplier involvement - including casting supplier
  • A, B, C and D-sample design and prototypes

BRACE carried the responsibility for the housing design. Mechanical engineers guided and worked the design starting with a requirements list to a validated and released product. Being integrated in the development team there is a constant flow of feedback, design reviews, FMEA’s and communication to other departments such as purchase, assembly and others.

The work package deliverables were:

  • Requirements.
  • Specifications (drawings, BOM, …).
  • Test- plans, specification, results.
  • FMEA
  • Design documents (calculations, reports, …)

The results achieved were satisfactory in a way that the methods used to get a good performing design regarding strength, stiffness and NVH performance are carried over by the customer for future new housing and support developments.