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This paper introduces a framework to systematically optimize the control anddesign of an electric vehicle transmission, connecting powertrain sizingstudies to detailed gearbox design methods. To this end, we first createanalytical models of individual components: gears, shafts, bearings, clutches,and synchronizers. Second, we construct a transmission by systematicallyconfiguring a topology with these components. Third, we place the composedtransmission within a powertrain and vehicle model, and compute theminimum-energy control and design, employing solving algorithms that provideglobal optimality guarantees. Finally, we carry out the control and designoptimization of a fixed- and two-gear transmission for a compact familyelectric vehicle, whereby we observe that a two-gear transmission can improvethe energy consumption by 0.8 %, while also achieving requirements ongradeability and performance. We validate our framework by recreating thetransmission that is mounted in the benchmark test case vehicle and recomputingthe energy consumption over the New European Driving Cycle, where we notice anerror in energy consumption of 0.2 %, affirming that our methods are suitablefor gear ratio selection in powertrain design optimization.

Control and Design Optimization of an Electric Vehicle Transmission Using Analytical Modeling Methods