The transmission system in Electric Vehicles (EVs) and Hybrid Electric Vehicles  Optimize motor operation over a broader

over a broader range of speeds.

(HEVs) plays a crucial role in transferring power from the motor (or motors) to the
drive wheels e iciently. However, its need and complexity di er significantly
between EVs and HEVs due to their distinct powertrain architectures. 2. Transmission in Hybrid Electric Vehicles (HEVs)

Let’s break this down clearly: HEVs combine an internal combustion engine (ICE) and one or more electric motors,
so the transmission must manage power from both.

Need for Transmission

1. Transmission in Electric Vehicles (EVs)
 The ICE requires a multi-speed transmission because it operates e iciently
Nature of Electric Motors
in a narrow speed range.
 Electric motors deliver high torque at zero or low speeds and maintain a wide
 The electric motor(s) can assist with torque filling, regenerative braking, and
e icient speed range.
smooth gear changes.
 This means they can often eliminate the need for multi-speed transmissions
Common HEV Transmission Types
used in Internal Combustion Engines (ICEs).
1. Power Split Transmission (eCVT) – Used in Toyota Prius and similar systems.
Typical EV Transmission Setup
o Combines a planetary gear set with electric motors to blend ICE and
 Most EVs use a single-speed reduction gear (also called a fixed gear ratio or
electric power.
single-speed gearbox).
o Provides stepless gear ratio without traditional gear shifts.
 The purpose is mainly to reduce the high-speed rotation of the motor to a
suitable speed for the wheels. 2. Parallel Hybrid Transmission (Automatic or DCT-based) – Found in many HEVs
(e.g., Hyundai Ioniq, Honda systems).
Why Transmission Is Still Needed
o Uses conventional gearboxes with electric assistance for e iciency
Even though it’s simpler, a transmission (reduction gear) is still necessary to:
and performance.
1. Match motor speed to wheel speed – Electric motors spin very fast (up to
3. Series Hybrid Configuration – The engine drives a generator, and only the
20,000 rpm), while wheel speeds are much lower.
electric motor drives the wheels, so no mechanical transmission is needed
2. Multiply torque – The gear reduction helps provide enough torque for between the engine and wheels.
acceleration and climbing.

3. Improve e iciency – Proper gearing keeps the motor operating in its most
3. Summary: Need for Transmission in EVs vs. HEVs
e icient speed range.

4. Support regenerative braking – Allows smooth transitions between driving Aspect EV (Battery Electric Vehicle) HEV (Hybrid Electric Vehicle)
and braking torque.
Power Source Electric motor only Engine + electric motor
Advanced EVs with Multi-speed Transmissions
Torque ICE needs multi-speed
High torque over wide range
Some high-performance EVs (e.g., Porsche Taycan with a 2-speed gearbox) use Characteristics gearing
multi-speed transmissions to:
Typical Multi-speed (automatic, DCT,
 Improve acceleration at low speed and e iciency at high speed. Single-speed reduction gear
Transmission or eCVT)

Page 1 of 30 Page 2 of 30
Aspect EV (Battery Electric Vehicle) HEV (Hybrid Electric Vehicle) Objective of Torque–Speed Matching

Purpose of Torque multiplication, motor Power management between Goal Description

Transmission speed reduction ICE and motor
Maximize e iciency Ensure motor/engine operates in its high-e iciency zone.
Complexity Simple Complex
Ensure drivability Provide smooth torque delivery and fast response.
Example Tesla Model 3 (single speed) Toyota Prius (eCVT)
Protect components Avoid over-speeding or over-torquing the motor or engine.

Optimize performance Achieve desired acceleration, top speed, and gradeability.

In summary

 EVs need a simple reduction gear mainly to match motor and wheel speeds.
In EVs, the electric motor directly drives the wheels (through a reduction gearbox or
 HEVs require a more complex transmission to coordinate the ICE and electric di erential). Because electric motors have inherently wide torque–speed operating
motor(s) e iciently. ranges, torque–speed matching is simpler than in internal combustion vehicles.

Torque–Speed Matching refers to the process of ensuring that the torque and speed Key Methods Used
characteristics of di erent components in a vehicle’s powertrain (e.g., engine, motor,
transmission, and wheels) are compatible with each other to achieve e icient power Method Description Purpose
transfer and desired performance.
Most EVs use a fixed reduction
Provides correct wheel torque
In simple terms: a. Fixed Gear Ratio gear (typically 7:1–10:1). This
at low speeds while keeping
(Single-speed converts high motor speed into
It means matching the torque output and rotational speed of the power source to the the motor in an e icient
gearbox) the torque required at the
torque and speed requirements of the load (vehicle wheels). speed range at higher speeds.
wheels.

b. Motor Control
Why It Matters The inverter adjusts current and Ensures smooth torque
(Field-Oriented
voltage to control motor torque delivery and e icient motor
Every powertrain component operates e iciently only in a specific torque–speed range: Control / Vector
and speed precisely. operation.
Control)
 Electric motor: High torque at low speed, limited torque at high speed.
In dual-motor or AWD EVs,
 Internal combustion engine (ICE): Limited torque at low speed, peak torque at
torque is distributed between Improves traction, handling,
mid-speed range. c. Torque Vectoring
motors to match required wheel and e iciency.
 Wheels: Require torque and speed that depend on vehicle mass, road gradient, torque and speed.
and driving conditions.
d. Multi-speed Some EVs (e.g., Porsche Taycan, Enhances acceleration at low
To make these work together, we need torque–speed matching via appropriate:
Transmission Rimac Nevera) use a 2-speed speeds and e iciency at high
 Gear ratios (optional) gearbox. speeds.

 Power split devices (in hybrids)

 Control strategies (in EVs and HEVs)

Page 3 of 30 Page 4 of 30
Method Description Purpose How It’s Achieved in HEVs

During deceleration, the motor Method Description Purpose

e. Regenerative
operates as a generator; EMS Maintains smooth braking
Braking a. Power Split Mechanically couples the engine, Allows torque blending from
matches braking torque with and energy recovery.
Coordination Devices (e.g., motor, and wheels (e.g., Toyota engine and motor according
wheel speed.
Planetary Gear Set) Hybrid Synergy Drive). to e iciency requirements.

Determines how much torque Matches overall torque–

b. Energy
Example: each source (engine/motor) speed requirement to
Management
should supply based on e iciency optimal operating points of
At low vehicle speed: System (EMS)
maps, SOC, and load. both sources.
 The inverter commands high current → high motor torque → wheel torque via fixed
gear. Continuously varies the e ective
c. Transmission or Smooth torque delivery and
gear ratio to keep the engine in its
At high speed: e-CVT e iciency optimization.
optimal torque–speed region.
 The motor current and torque are reduced → speed increases → torque-speed
Engage or disengage motor and
curve automatically matches vehicle needs. d. Clutches and Ensures proper torque–
engine depending on driving mode
Switching speed balance during
(EV mode, hybrid mode, charge-
Mechanisms transitions.
sustain mode).
Result in EVs

 Simple mechanical system (often single-speed). Predefined e iciency maps for Guides EMS in real-time to
e. Control Maps /
engine and motor determine ideal achieve torque–speed
 Achieved mainly through electronic control of motor torque and inverter Lookup Tables
operating points. matching.
operation.

 E iciency maintained via optimal control algorithms (e.g., Maximum Torque

per Ampere or MTPA, Field Weakening). Example:

 During acceleration, EMS commands the motor to provide high torque at low
2. In Hybrid Electric Vehicles (HEVs) speed (where the engine is ine icient).

In HEVs, torque–speed matching is more complex because there are two or more  As speed increases, the engine takes over near its optimal torque–speed point,
power sources — typically an internal combustion engine (ICE) and an electric motor while the motor assists or regenerates as needed.
— that must be coordinated to drive the wheels e iciently.  The power split device or e-CVT continuously adjusts ratios to match wheel
torque demand smoothly.

Result in HEVs

 Dynamic torque distribution between sources ensures the combined system

meets wheel demands e iciently.

Page 5 of 30 Page 6 of 30
  Torque–speed matching achieved through a mix of mechanical (gear/power 3. Battery, motor, and engine longevity are preserved → avoids overloading or
split) and electronic (EMS control) means. ine icient operation.

 Keeps both the engine and motor near their peak e iciency zones, improving 4. Energy recovery (regenerative braking) is maximized → increases EV range or
fuel economy and reducing emissions. hybrid fuel e iciency.

The importance becomes scenario-dependent, as di erent driving conditions place

varying demands on torque and speed.
3. Summary: How Torque–Speed Matching is Achieved

Feature EVs HEVs

2. Importance in Di erent Drive Scenarios
Primary Motor control + fixed gear Power split + EMS control + variable
A. Low-Speed Acceleration / Stop-and-Go Tra ic
mechanism ratio gearing
Aspect Importance of Torque–Speed Matching
Power sources Electric motor only Engine + electric motor(s)
Motors can produce high torque at low speeds, ensuring smooth acceleration.
Matching Electronic control of inverter Coordinated control of engine and EV
Torque–speed matching keeps motor near maximum torque e iciency.
approach and motor current motor torques
Electric motor provides initial torque while ICE may remain o or idle. EMS
Mechanical Single-speed gearbox
Planetary gearset / e-CVT / clutch HEV ensures engine starts only when motor cannot meet torque demand
elements (sometimes 2-speed)
e iciently.
Maintain motor e iciency, Maintain both engine and motor in
Goal Benefit Smooth starts, energy-e icient operation, reduced battery/engine stress.
smooth torque delivery high-e iciency zones

High — requires real-time torque

Complexity Relatively simple
blending and mode switching B. High-Speed Cruising / Highway Driving

Aspect Importance

In Short: Motor operates at high speed but low torque. Matching torque–speed ensures
 In EVs, torque–speed matching is mainly achieved through motor control and a EV inverter and motor run near field-weakening e iciency zone, reducing energy
fixed (or few-speed) gearbox. loss.

 In HEVs, it is achieved through a combination of mechanical power-split ICE takes primary load at its peak torque–speed region, while motor may
HEV
devices, variable transmissions, and real-time control by the EMS to balance assist minimally. EMS optimizes power split.
engine and motor torques e iciently.
Benefit Maximized range, reduced energy consumption, and minimal thermal stress.
Torque–speed matching ensures that:

1. Powertrain components operate in their optimal e iciency range → reduces

energy losses.

2. Required wheel torque and speed are delivered smoothly → improves

drivability and acceleration.

Page 7 of 30 Page 8 of 30
C. Hill Climbing / Load Pulling F. Urban Mixed Driving (Stop-and-Go + Acceleration + Deceleration)

Aspect Importance  Torque–speed matching ensures energy-e icient operation in both low-speed
torque-demanding situations and moderate-speed cruising.
Motor needs higher torque at low speed; gear ratio may allow torque
 EMS dynamically adjusts power split in HEVs and motor torque in EVs to maintain
EV multiplication. Torque–speed matching ensures motor does not overheat or
smooth performance and range optimization.
stall.

Engine may operate in high-torque region while motor assists; EMS ensures
HEV
both sources contribute e iciently. 3. Key Takeaways

Benefit Maintains desired speed without overloading components. 1. EVs: Torque–speed matching ensures motors operate in their high-e iciency
regions, providing smooth acceleration, regenerative braking, and maximum
range.

D. Regenerative Braking / Deceleration 2. HEVs: Torque–speed matching is critical for coordinated operation of engine
and motor, enabling:
Aspect Importance
o E icient power split
Motor acts as generator; torque–speed matching ensures maximum energy
EV o Engine operation in optimal torque–speed zone
recovery without exceeding motor or battery limits.
o Smooth transition between EV and hybrid modes
Motor and ICE work together to capture kinetic energy; EMS balances torque
HEV 3. Scenario-specific benefits:
demand and engine disengagement.
o Low-speed → smooth start, battery/motor e iciency
Benefit Maximizes energy recovery, reduces wear on mechanical brakes.
o High-speed → cruising e iciency

o Hill climbing → torque su iciency without overheating

E. Aggressive / Performance Driving
o Braking → maximum regenerative energy recovery
Aspect Importance
o Aggressive driving → safe high-performance delivery
Torque–speed matching ensures rapid acceleration while keeping motor
EV
within thermal and current limits.
In short:
EMS dynamically allocates torque between engine and motor to achieve
HEV Torque–speed matching is crucial for optimizing e iciency, drivability, and
maximum performance without exceeding component limits.
component life across all driving scenarios. In EVs, it primarily optimizes motor
High responsiveness, driver satisfaction, safe operation of powertrain operation, while in HEVs, it coordinates engine-motor operation for maximum
Benefit
components. overall e iciency.

Design Considerations for EV & HEV Transmission Systems

A. Power and Torque Requirements

 Determine maximum motor torque and vehicle performance targets

(acceleration, top speed, gradeability).

Page 9 of 30 Page 10 of 30
  Transmission must handle high instantaneous torque (EV motors produce full
torque from zero rpm).
F. Compactness and Weight Reduction
 HEVs require torque blending between ICE and electric motor — smooth
 Minimize weight for better energy e iciency and range.
transitions are key.
 Integrate motor, gearbox, and di erential into a compact “e-axle” unit.

 Use lightweight materials (aluminum, composites).

B. Gear Ratio and Speed Range

 EVs:
Usually use single-speed reduction gear (fixed ratio ~8:1–12:1) to optimize G. Lubrication and Sealing
motor e iciency.
 Proper lubrication to reduce wear and noise.
In high-performance EVs, 2-speed gearboxes improve both acceleration and
e iciency.  Must ensure sealing compatibility with electric components — prevent oil
contamination of motor windings.
 HEVs:
Often use planetary gear sets for power-split or eCVT (electronic continuously  Some systems use dry gearboxes to eliminate risk of electrical leakage.
variable transmission).
Must optimize ratios for both ICE e iciency and electric operation.
H. Control and Integration

 Close integration with vehicle control systems:

C. E iciency and Loss Minimization
o Torque vectoring
 Critical for maximizing driving range.
o Regenerative braking coordination
 Reduce frictional, bearing, and gear mesh losses.
o Motor speed and gear synchronization
 Use high-e iciency lubricants and optimized gear tooth design.
 In HEVs, power management between ICE and electric motor requires real-time
control algorithms.
D. NVH (Noise, Vibration, Harshness)

 Electric motors are quiet, so gear whine and bearing noise become more
I. Safety and Reliability
noticeable.
 Isolation between high-voltage components and mechanical system.
 Design smooth gear profiles, ensure precise alignment, and use damping
materials.  Fail-safe design for motor over-speed or inverter fault.

 Long life and low maintenance targets (~300,000 km).

E. Thermal Management

 Motors, inverters, and gears generate heat under high loads. J. Manufacturing and Cost

 Transmission housing may be integrated into a shared cooling system.  Simplicity and cost-e ectiveness are vital.

 Use thermal analysis to prevent overheating of lubricants and bearings.  Fewer moving parts than ICE transmissions, but high precision required for e-
axle gears and bearings.

Page 11 of 30 Page 12 of 30
  Modular designs help scalability across EV models. 5. Summary of Key Design Priorities

Priority EV HEV
3. Comparison: EV vs HEV Transmission
E iciency Critical Critical
Parameter EV Transmission HEV Transmission
NVH Important Important
Power Source Electric motor(s) only ICE + electric motor(s)
Compactness High priority Medium
Single-speed reduction / 2- eCVT, planetary, dual-clutch
Type Control Complexity Low High
speed hybrid

Complexity Simple Complex Cost Medium High

Torque Torque split between ICE and Integration High (e-axle) Very High (engine + motor)
Motor directly controls torque
Management motor

Motor speed and torque Coordinated engine–motor Transmission in vehicles is used to transmit power from the engine to the wheels and
Control Strategy
control control adjust torque and speed according to driving conditions.

Maintenance Low Moderate A. Manual Transmission (MT)

Typical Example Tesla Model 3 (single-speed) Toyota Prius (power-split eCVT)  Driver manually selects gears using a clutch and gear lever.

 Uses dog clutches and gear pairs to vary speed and torque.

 Advantages: Simple, e icient, low cost.

4. Example – EV Transmission Layout (E-Axle)
 Examples: Traditional cars, trucks.
Components:
Types:
 Electric motor
1. Sliding mesh gearbox
 Reduction gear (single-stage or two-stage)
2. Constant mesh gearbox
 Di erential gear
3. Synchromesh gearbox
 Power electronics (inverter)

 Cooling system
B. Automatic Transmission (AT)
Advantages:
 Gear shifting occurs automatically based on speed, throttle, and load.
 High e iciency (95%+)
 Uses a torque converter, planetary gear sets, and hydraulic control.
 Compact, modular design
Advantages: Smooth shifting, easier driving.
 Simplified powertrain architecture
Disadvantages: More complex and expensive.

Page 13 of 30 Page 14 of 30
C. Continuously Variable Transmission (CVT) 1. Basic Idea
 Provides infinite gear ratios within a range (no discrete gears). In a CVT, instead of shifting between a set number of gears, the transmission
continuously changes its e ective gear ratio to keep the engine running at its most
 Uses a belt and pulley system or toroidal rollers.
e icient RPM for any given speed.
 Advantages: Smooth acceleration, optimal e iciency.

 Examples: Honda, Toyota hybrid cars.

2. Main Components

A typical belt-type CVT (used in scooters and cars) has:

D. Semi-Automatic / Automated Manual Transmission (AMT)
1. Primary Pulley (Drive Pulley):
 Mechanically similar to manual transmission but uses actuators for clutch and
gear selection. o Connected to the engine crankshaft.

 Controlled electronically (ECU). o Has two conical sheaves that can move closer or farther apart.

 Example: Maruti Suzuki AMT. 2. Secondary Pulley (Driven Pulley):

o Connected to the driven shaft or wheels.

E. Dual-Clutch Transmission (DCT / DSG) o Also has two movable conical sheaves.

 Two separate clutches for odd and even gears → faster and smoother gear 3. Belt or Chain:
changes. o A steel or rubber V-belt transmits power between the two pulleys.
 Combines e iciency of manual with convenience of automatic. 4. Control System:
 Examples: VW DSG, Ford PowerShift. o Hydraulic, mechanical, or electronic system adjusts the pulley positions
to vary the gear ratio.

F. Electric and Hybrid Vehicle Transmissions

 EVs: Usually single-speed reduction gearbox or 2-speed transmission. 3. Working Principle

 HEVs: Use eCVT (electronic continuously variable transmission) or planetary Step 1: Varying Pulley Diameters
gear-based power split system.  Each pulley has two conical faces.

 When the cones move closer together, the belt rides higher on the pulley,
The Continuously Variable Transmission (CVT) is a type of automatic transmission increasing its e ective diameter.
that provides a stepless (infinite) range of gear ratios between a minimum and  When the cones move apart, the belt rides lower, decreasing its e ective
maximum value — unlike traditional gearboxes that have a fixed number of gear ratios. diameter.

Step 2: Changing Gear Ratio

 The primary (drive) pulley and secondary (driven) pulley adjust inversely:

o If the drive pulley diameter increases, the driven pulley diameter

decreases, and vice versa.
Page 15 of 30 Page 16 of 30
  This maintains constant belt tension and changes the speed ratio smoothly.

Step 3: Engine Operating E iciency 6. Advantages

 The CVT keeps the engine at its optimal RPM: Infinite gear ratios → smooth and jerk-free acceleration.
o During acceleration → lower ratio (high torque). Engine always operates at best e iciency → better fuel economy.
Compact and lightweight design.
o During cruising → higher ratio (low torque, high speed).
Fewer mechanical parts → reduced wear and maintenance.
 Result: Smooth acceleration and better fuel e iciency.

7. Disadvantages
4. Example of Operation
Belt wear and heat buildup under heavy loads.
Drive Pulley Driven Pulley Not ideal for very high-torque applications.
Condition Gear Ratio E ect
Diameter Diameter Less “sporty” feel (no gear shifts).

Vehicle Low ratio (High Better More expensive and complex control system.
Small Large
Start torque) acceleration

High ratio (Low Torque Converter – Construction and Working

Cruising Large Small Higher speed
torque)
Definition
Climbing More torque to A torque converter is a fluid coupling device that transmits and multiplies torque from
Small Large Low ratio
Hill wheels the engine (or motor) to the transmission input shaft.
It allows the vehicle to start smoothly, multiply torque when needed, and transmit
power without a direct mechanical connection (as in a clutch).
5. Control Mechanisms
It is primarily used in automatic transmission vehicles to replace the conventional
a) Mechanical / Centrifugal CVT clutch.

Used in scooters and small vehicles.

 Centrifugal weights move pulleys as RPM increases. Construction of a Torque Converter

 Springs return pulleys at lower speeds. A torque converter consists of three main rotating components enclosed in a sealed
b) Hydraulic CVT housing filled with transmission fluid:

Uses oil pressure to control pulley positions. 1. Pump (Impeller)

c) Electronic CVT (eCVT)  Connected to the engine crankshaft.

Used in hybrid vehicles (e.g., Toyota Prius).  It spins with the engine and pushes transmission fluid outward by centrifugal
force.
 Combines planetary gears with electric motor control.
 The impeller’s curved blades direct fluid toward the turbine.
 Doesn’t use belts but achieves similar variable ratio function via electronic
power splitting.
Page 17 of 30 Page 18 of 30
2. Turbine  The speed di erence between the impeller and turbine decreases.

 Connected to the transmission input shaft.  The torque multiplication e ect reduces, but e icient torque transfer
continues.
 The fluid from the pump strikes the turbine blades, causing it to rotate.
 The stator still helps redirect some returning fluid but with less resistance.
 The turbine’s motion transmits torque to the transmission.

3. Stator (Reaction Member)

3. Coupling Stage (Cruising Speed)
 Placed between the pump and turbine.
 At higher speeds, the turbine speed approaches the impeller speed.
 Mounted on a one-way clutch, allowing rotation in one direction only.
 The fluid flow becomes smooth, and torque multiplication ceases.
 Redirects the returning fluid from the turbine to the pump e iciently, increasing
torque at low speeds.  The torque converter now acts as a fluid coupling, e iciently transmitting torque
with minimal loss.
 Plays a crucial role in torque multiplication.
 In modern systems, a lock-up clutch engages, creating a direct mechanical
4. Transmission Fluid
connection between the engine and transmission to prevent slippage and
 Acts as the medium that transfers torque from the pump to the turbine. improve fuel e iciency.
 Also cools and lubricates internal parts.

Key Features and Functions

Working Principle of Torque Converter Function Description

The torque converter operates in three main stages depending on the vehicle’s speed
Torque Multiplication Provides high torque during vehicle start-up.
and load:
No need for a mechanical clutch —
Automatic Clutching
engages/disengages automatically.
1. Stall Stage (Vehicle Starting)
Vibration Dampening Smoothens power transmission.
 The engine runs, but the vehicle is stationary.
Overload Protection Prevents engine stalling under heavy load.
 The impeller spins rapidly, pushing fluid onto the turbine.

 The turbine resists motion (due to vehicle load), so fluid bounces back toward Lock-up Clutch (in modern Improves e iciency by eliminating slip at cruising
the impeller. systems) speed.

 The stator redirects this returning fluid, creating a reaction force that
multiplies torque (up to 2–3 times the input torque).
Advantages
 This allows smooth vehicle start and high torque at low speeds.
Smooth acceleration and power transfer
Provides torque multiplication at low speeds
2. Acceleration Stage No need for a clutch pedal

 As the vehicle begins to move, the turbine starts rotating.

Page 19 of 30 Page 20 of 30
 Reduces engine stalling during idling 1. Construction of a Planetary Gearbox
Self-cooling and self-lubricating system
A planetary gear set consists of the following main components:

1. Sun Gear (S):

Disadvantages o The central gear of the system.
Less e icient than a manual clutch at high speeds (due to fluid slip) o Usually connected to the generator (Motor-Generator 1 or MG1) in
More complex and expensive HEVs.
Generates heat, requiring a cooling system
2. Planet Gears (P):
Heavier design increases vehicle weight
o Small gears that revolve around the sun gear.

o Mounted on a planet carrier and mesh with both the sun and ring gears.
Applications
o Connected to the drivetrain via the carrier shaft.
 Automatic transmission cars and SUVs
3. Planet Carrier (C):
 Hybrid vehicles (in combination with electric motors)
o Holds the planet gears in position and allows them to rotate.
 Heavy-duty vehicles (buses, trucks, and construction machinery)
o Typically connected to the wheels (output shaft) in HEVs.

4. Ring Gear (R):

Summary
o The outer gear that encircles the planet gears.
A torque converter transfers and multiplies torque from the engine to the transmission
o Usually connected to the Internal Combustion Engine (ICE) or Electric
using fluid dynamics. It enables smooth vehicle start-up, torque boost at low speed,
Motor (MG2).
and automatic coupling at high speed.
With the addition of a lock-up clutch, modern torque converters achieve higher 2. Working Principle in an HEV
e iciency and performance comparable to manual transmissions.
The planetary gearset in HEVs acts as a Power Split Device (PSD) — it distributes
power between the engine, generator, and drive motor depending on driving
conditions.
Planetary Gearbox in Hybrid Electric Vehicles (HEVs)
Power Flow
Introduction
 The engine, electric motors, and wheels are mechanically linked through the
A planetary gearbox (also called an epicyclic gear train) is a compact, high-
planetary gears.
e iciency transmission system commonly used in Hybrid Electric Vehicles (HEVs).
 By controlling the speeds of the sun gear, ring gear, and carrier, the vehicle can
In HEVs, it plays a critical role in power splitting, torque transmission, and speed
seamlessly switch between:
control between the Internal Combustion Engine (ICE), Electric Motor/Generator,
and Drive Wheels. o Electric drive
The most famous example is the Toyota Hybrid Synergy Drive, which uses a planetary o Engine drive
gear set as a power-split device.
o Hybrid (combined) drive

o Regenerative braking

Page 21 of 30 Page 22 of 30
 Mode 5: Idle or Charging Mode

3. Modes of Operation in HEV Using Planetary Gearbox  The engine runs but does not drive the wheels.

Mode 1: Electric Vehicle (EV) Mode  The ring gear (engine) drives the sun gear (MG1), generating electrical power.

 The engine (ICE) is o .  The generated electricity charges the battery or powers MG2.

 The electric motor (MG2) drives the ring gear directly. Engine charges the battery via generator without moving the car.

 The planet carrier transmits torque to the wheels.

 The sun gear (connected to the generator) may remain stationary. 4. Advantages of Planetary Gearbox in HEVs

Only electric power drives the vehicle. Feature Benefit

Compact design High power density in a small space

Mode 2: Engine Drive Mode
Smooth power split E icient blending of engine and motor torque
 The ICE drives the ring gear.
No conventional gearbox Continuous variable-like performance
 The planet carrier (connected to the wheels) receives power directly.

 The sun gear speed is adjusted by MG1 to control engine speed. E icient regenerative
Improved energy recovery
braking
Vehicle is driven mainly by the engine, with generator assistance.
Seamless transitions Between electric, hybrid, and engine drive modes

Balanced load distribution among multiple planet

Mode 3: Hybrid (Combined) Mode Durability
gears
 Both engine and electric motor (MG2) supply torque.

 The engine drives the ring gear, while the motor assists via the planet carrier.
5. Disadvantages
 The generator (MG1) controls power flow between components.
Complex control algorithms required
Both sources provide propulsion power (power-split mode).
High manufacturing precision needed
Di icult to repair or modify
Mode 4: Regenerative Braking Slight e iciency losses due to friction and fluid coupling (if present)

 During braking, the vehicle’s kinetic energy drives the planet carrier backward.

 This motion drives MG2 (motor) as a generator, converting mechanical energy 6. Applications
into electrical energy.  Toyota Prius, Camry Hybrid, RAV4 Hybrid
 The recovered energy is stored in the battery.  Lexus Hybrid models
Converts braking energy into electrical energy.  Ford Escape Hybrid

 Hyundai Ioniq Hybrid (similar power-split concept)

Page 23 of 30 Page 24 of 30
 3. Construction of a Driveshaft

Summary A typical driveshaft assembly consists of the following main parts:

Component Connected To Function Component Description

Controls engine speed and power Hollow cylindrical steel or composite tube that transmits
Sun Gear (S) Generator (MG1) Shaft Tube
generation torque.

Ring Gear (R) Engine / Motor (MG2) Provides main drive power Allow angular movement and flexibility between
Universal Joints (U-joints)
components.
Planet Carrier Output Shaft /
Delivers combined torque to wheels
(C) Wheels Slip Joint / Splined Shaft Allows length variation due to suspension travel.

Flanges / Yokes Connect the shaft to motor, gearbox, or di erential.

The planetary gearbox serves as the heart of the hybrid transmission, allowing Center Bearing (if long
seamless power blending, energy recovery, and optimized fuel e iciency. Supports the driveshaft in multi-section systems.
shaft)

1. Introduction to Driveshaft
Material Used
A driveshaft (also called propeller shaft or cardan shaft) is a mechanical component
 High-strength steel or aluminum alloy for conventional vehicles.
used to transmit torque from the motor or transmission to the driven wheels.
It forms a crucial part of the drivetrain in both Electric Vehicles (EVs) and Hybrid  Carbon fiber composites in performance EVs for lightweight and e iciency.
Electric Vehicles (HEVs).

Although the power source di ers — electric motor in EVs, and engine + motor
4. Driveshaft in Electric Vehicles (EVs)
combination in HEVs — both require driveshafts to deliver torque e iciently and reliably
to the wheels. a) Configuration

In an EV, the electric motor is the main source of propulsion.

Depending on drivetrain design, the driveshaft configuration varies:
2. Function of a Driveshaft
EV Drivetrain Type Driveshaft Usage
 Transfers rotational power from the output shaft (motor, gearbox, or
di erential) to the wheels. Front-Wheel Drive
Short driveshafts (half-shafts) connect motor to front wheels.
 Compensates for misalignment and movement between components (FWD)
(especially in vehicles with suspension travel).
Rear-Wheel Drive Longer driveshaft connects rear-mounted motor or central
 Maintains smooth torque delivery with minimal vibration. (RWD) motor to rear di erential.

All-Wheel Drive Front and rear driveshafts link multiple motors or axles for
(AWD) torque distribution.

In-Wheel Motor EVs No driveshaft required (torque delivered directly to each wheel).

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 HEV Type Driveshaft Function
b) Working Principle
Both engine and motor can deliver torque through a shared
Parallel Hybrid
 The electric motor produces torque and rotation. driveshaft.

 The driveshaft transmits this torque to the di erential, which then distributes it Series-Parallel Hybrid Power is combined through a planetary gearset, then
to the wheels. (Power-Split) transmitted via driveshaft to wheels.
 Because EV motors deliver instant torque, the driveshaft and joints must
withstand high torque spikes without vibration or failure.
b) Working

 The engine or electric motor (or both) provide torque.

c) Design Features
 The transmission or planetary gearbox outputs rotational power to the
 Lightweight design to improve e iciency and range.
driveshaft.
 Low NVH (Noise, Vibration, Harshness) due to the silent operation of EV
 The driveshaft delivers this torque to the di erential and then to the drive
motors.
wheels.
 Compact layout, as EVs often integrate motor, gearbox, and di erential into a
 During regenerative braking, the driveshaft also transmits reverse torque back
single e-axle unit, reducing driveshaft length.
to the motor (acting as a generator).

Example:
c) Design Considerations in HEVs
 Tesla Model S (RWD): Central motor → driveshaft → rear di erential → wheels.
 Must handle variable torque inputs (from both motor and engine).
 Audi e-tron (AWD): Front and rear e-axles with independent driveshafts.
 Must support bidirectional torque flow (propulsion + regenerative braking).
 Rivian R1T: Quad-motor system (no conventional driveshafts — torque directly
 Designed for smooth torque blending between the two power sources.
to each wheel).

Example:
5. Driveshaft in Hybrid Electric Vehicles (HEVs)
 Toyota Prius (Power-Split HEV): Engine + motor torque combined through a
a) Configuration planetary gearset → driveshaft → wheels.
In HEVs, both an Internal Combustion Engine (ICE) and an Electric Motor can drive  Honda Accord Hybrid: Uses two motors with a lock-up clutch → driveshaft to
the wheels — either independently or together. wheels in hybrid and engine modes.
The driveshaft transmits power from whichever source (or combination) is active.

HEV Type Driveshaft Function

6. Comparison: Driveshaft in EV vs HEV
Electric motor drives wheels directly → may not need a long
Series Hybrid Aspect EV HEV
driveshaft.
Power Source Electric motor only Engine + Electric motor

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Aspect EV HEV 9. Summary

Torque Flow Unidirectional (motor → Bidirectional (engine ↔ motor ↔ Vehicle

Driveshaft Role
Direction wheels) wheels) Type

Planetary or multi-speed hybrid Transfers torque from electric motor (or e-axle) to drive wheels; often
Transmission Often single-speed reduction EV
system shorter and lighter.

Typically shorter (e-axle May be longer (engine + motor Transfers combined torque from engine and motor via hybrid transmission
Driveshaft Length HEV
integration) layout) to wheels; designed for bidirectional torque flow.

Torque
Instant, high torque Variable, combined torque
Characteristics Conclusion
Moderate (due to engine In both EVs and HEVs, the driveshaft remains a vital link in the powertrain, ensuring
NVH Levels Very low
operation) e icient torque transfer, smooth performance, and durability under high torque and
regenerative loads.
Regenerative Yes, managed through hybrid As EV technology advances, driveshafts are becoming lighter, quieter, and more
Yes, through motor
Braking control unit
integrated, especially in e-axle architectures where motor, inverter, and transmission
are combined into one compact unit.

7. Advantages of Driveshaft in EVs and HEVs

E icient torque transfer

Supports flexible motor/engine placement
Allows power distribution in AWD systems
Enhances stability and traction control
Enables regenerative braking integration

8. Challenges

Increased torque demands in EVs → requires stronger materials

Heat dissipation and vibration management
Space constraints in compact EV platforms
Cost and complexity in hybrid layouts

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