A leading Indian automotive two-wheeler manufacturer is developing a new electric variant bike. Of the many challenges faced in such developmental activity, the critical aspect of belt transmission from the electric motor to the ensuing kinematics and drive train became an issue of concern. Given the speed, torque and load requirements of the drive transmission, customer reported drift in the belt axis over the drive and driven pulley. NV Dynamics was assigned the task of conducting test simulations to identify the probable causes and further to determine methods to address them.
To perform the root cause analysis (RCA), the customer provided key components of the drivetrain system, including the primary and intermediate shafts that house the motor and intermediate pulleys, respectively. After assembling the necessary fixtures to replicate vehicle operating conditions, static and dynamic tests were conducted to pinpoint the source of the issue. These tests involved adjusting belt tension to simulate various load scenarios, measuring shaft axis deflections with dial gauges, assessing flange bending angles and repeating the trials with different shaft materials. These steps helped identify the root cause of the problem the manufacturer was encountering.