The trend in the global automotive industry is moving towards electric vehicles that do not emit exhaust gases and use eco-friendly fuel. Electric vehicles are more eco-friendly compared to internal combustion engine vehicles, as they emit less carbon dioxide and pollutants. Research and development are actively underway to produce new electric vehicle models in the rapidly growing electric car market. In this study, a 2-speed transmission for electric vehicles, applicable to 300 Nm-class electric cars, has been developed. The 2-speed transmission structure enables efficient energy use and utilizes a planetary gear set and wet multi-plate clutch, which are effective in the power transmission process. The 2-speed transmission developed through the research results of this paper has a compact structure optimized for electric vehicles. The design feasibility of the transmission was verified through performance tests of the prototype, contributing to fuel efficiency improvement and environmental enhancement.

Wheelchairs are an important means of transportation for the elderly and disabled. However, the movement of wheelchairs on long curbs and stairs is restricted. In this study, a wheelchair for climbing stairs was developed based on a mechanical transmission system that rotates the entire driving part through a link structure and an actuator to change the speed. The first mode drives the caterpillar, and the second mode drives the wheels. When driving on flat ground, it uses landing gears and wheels, and when climbing stairs, it uses the caterpillar; accordingly, a stable driving is possible. The stability of the transmission is confirmed through stress analysis. The method used in our study makes it is possible to manufacture lightweight wheelchairs because a single motor drives both the wheel and caterpillar through the transmission system.

This paper proposes a modified harmonic cam, which is used to design a harmonic drive. Conventional harmonic drives using a sinusoidal cam type pertain to an elastic body concept and are thus difficult to design and evaluate. Unlike the conventional sinusoidal cam, the proposed harmonic cam involves a combination of four arcs. Such cams can be designed based on a rigid body concept, and thus, the tooth profile can be designed and analyzed using the established gear theory. The novel harmonic cam is designed by exploiting four-arc combinations, and guides for designing harmonic drives with involute and cycloid angular teeth are presented. A harmonic drive with a difference of two teeth between the circular spline and flex spline is designed. The operation, tooth engagement, and interference are validated through a mock-up production using a 3D printer and gear simulation program. The findings can facilitate the facile design and manufacturing of harmonic drives.

As environmental regulations have been strengthened worldwide since the Paris Climate Agreement, the automobile industry is shifting its production paradigm to focus on eco-friendly vehicles such as electric vehicles and hydrogen-battery vehicles. Governments are banning fossil fuel vehicles by law and expanding the introduction of green vehicles. The energy efficiency of electric vehicles that use a limited power source called batteries depends on the driving environment. Applying a two-speed transmission to an electric vehicle can optimize average speed and performance efficiency at low speeds, and achieve maximum speed with minimal torque at high speeds. In this study, a two-speed transmission for an electric vehicle has been developed, to be used in a compact electric vehicle. This utilizes a planetary gear of a total of three pairs, made of a single module which was intended to enable two-speed. The ring gear was removed, and the carrier was used in common. When shifting, the energy used for the speed change is small, due to the use of the simple method of fixing the sun gear of each stage. Each gear was designed by calculating bending strength and surface durability, using JGMA standards, to secure stability. The safety factor of the gears used in the transmission is as follows: all gears have been verified for safety with a bending strength of 1.2 or higher and a surface pressure strength of 1.1 or higher. The design validity of the transmission was verified by calculating the gear meshing ratio and the reference efficiency of the gear. The transmission to be developed through the research results of this paper has a simple and compact structure optimized for electric vehicles, and has reduced shift shock. In addition, energy can be used more efficiently, which will help improve fuel economy and increase drive range.

Recently, with policies aimed at strengthening domestic manufacturing and technological innovation, the robotics industry has been growing rapidly, and its applications are expanding across various industrial fields. Accordingly, the importance of high-performance speed reducers with flexibility and precision is gradually increasing. The tooth profiles used in conventional harmonic reducers have structural limitations, such as meshing discontinuity, restrictions on the radius of curvature of the tooth base, and distortion of the contact trajectory, especially when the number of teeth is small. These problems limit the design freedom of the reducer and make it difficult to secure contact stability and durability under precision driving conditions. To solve these problems, this paper proposes a new tooth profile design equation, the IH (Involute Harmonic) tooth profiles and the HTPs (Hybrid Tooth Profiles), using the cycloid curve to overcome the structural limitations of the conventional harmonic tooth profile, which is difficult to design under small-tooth-number conditions, and to enable tooth design without restrictions on the number of teeth. HTP tooth profile is a new gear tooth profile design method that utilizes IH tooth profile and cycloid curve to optimize the meshing characteristics of gears. A tooth profile design tool based on the HTP equation was developed using Python 3.13.3. The tool’s effectiveness was validated through simulations assessing tooth meshing and interference. Using the tool, an R21_z3 reducer with a single-stage high reduction ratio was designed to evaluate practical applicability. A prototype was fabricated using 3D printing with PLA material, and experimental testing confirmed the absence of meshing or interference issues, consistent with simulation results. Through this study, we verified the usefulness of the HTP tooth profile design formula and design tool using the IH tooth profile and cycloid curve, and it is expected that the proposed HTP tooth profile can be utilized as a tooth profile applicable to various reducer designs.

Wheelchairs are widely used globally and are essential for providing autonomy and mobility to elderly and disabled people who have movement restrictions. Manual wheelchairs require operation through turning the wheels or pushing the wheelchair directly, thus posing mobility limitations for the user and caregiver. In contrast, electric wheelchairs, when used by the user, allow for improved flexibility by operating the wheelchair through a single control mechanism. However, the use of electric wheelchairs poses challenges in accessing areas with stairs and curbs, limiting the range of activity and thereby diminishing the quality of life for users and those reliant on electric wheelchairs. The electric wheelchair developed in this research incorporates a single motor for lightweight design. It uses a wheel travel variation actuator, eliminating the need for synchronization and allowing for low-power operation. This design reduces power loss from the caterpillar’s idling during wheel movement and includes the implementation of a pulley system. The optimal pulley belt length was calculated, and a deceleration device was installed inside the caterpillar, enabling a design that is compact, lightweight, and capable of high deceleration. On paved roads and flat terrain, the electric wheelchair is designed for high-speed travel using two pairs of front omni wheels and drive wheels. For terrains with stairs, speed bumps, unpaved roads, and unavoidable obstacles, the wheelchair is powered by caterpillars. The electric wheelchair developed through the research presented in this paper has verified the reliability of its transmission system through gear stress and deformation analysis. Additionally, an electric wheelchair based on the proposed concept was constructed to validate the drivability, safety, operability, and convenience of its driving unit. Furthermore, a user rode the constructed electric wheelchair to confirm that there were no issues with its drivability.