The section I contributed to the tech report

3. Solutions

 

Our solution, DVTEV, constitutes the combination of 4 proposed improvements to counter the current CVTs’ difficulty in handling high torque loads and heat management issues. To counter these issues, doubling the number of pulleys and belts, having a rougher surface finish on the CVT pulleys, and adding cooling channels in the pulleys can be implemented. Along with these modifications, the addition of an alternator can increase drivetrain efficiency.

3.1 Doubling the Belts in a CVT

Doubling the belts and pulleys can result in the forces acting in the transmission being distributed between 2 separate pulley-belt systems. Having more area in contact between the pulleys and belts can result in the transmissions being more capable of handling the torque output of electric motors.

3.2 Making the Surface Finishing of Pulleys Rougher

A rougher surface finish will increase the friction between the belts and the pulleys reducing the likelihood of belt slippage and boosting the transmission's ability to handle the high torque of EV motors. Additionally, the rougher surface boots heat dispersion from the pulley resulting in better heat management.

 

Figure 4

CVT Pulley surface finishing

Note. By James Halderman, 2019, The surface finishing of the pulleys used in CVTs currently in the market

 

3.3 Adding Cooling Channels to the Driving and Driven Pulleys

Adding cooling channels will help regulate the transmission’s temperature, resulting in an extended service lifespan for both the belt and the pulleys along with lubricating the entire transmission reducing the loss of power to friction and heat in the drivetrain.

3.4 Adding an Alternator to the End of the Transmission

In addition to these changes, an alternator working in tandem with the transmission would boost regenerative charging capabilities while driving, resulting in better energy efficiency. Most alternators start charging from RPMs as low as 2000 and can keep charging till 18000 RPM. For our application, more powerful and capable alternators would be used and implemented to boost the DVTEV’s efficiency.

3.5 The DVTEV

The digital prototype of our solution after combining the new improved parts.

 

Figure 5

Dual Variable Transmission for Electric Vehicles

Note. By Harness Solutions, 2023, Our solution, the DVTEV which includes the dual Pulley-belt system, the rougher surface finishing, the cooling channels and the alternator

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