Design of Half Shafts for McMaster EcoCAR EV Considering Driveline Articulation Simulations

Integrating an electrified powertrain into a production vehicle is a complex task accompanied by an increasing number of electronic drive units being installed into vehicles. One significant aspect of the integration phase is the need for half shafts to transmit torque from the powertrain or driveline to the wheels. These shafts have a fixed set of requirements, including shaft length and angularity that must be incorporated into their design. This paper addresses the identified gap by providing a mathematical model used to find half shaft parameters. The proposed solution leverages driveline articulation simulations and returns measurements for use in manufacturing that are within the margin of error defined for the project. A 2023 Cadillac LYRIQ was integrated with an electrified powertrain, and the presented methodology was used for the design of the vehicle's half shafts. The results indicated that the mathematical model for the shaft parameters was within 98% accuracy of the required values obtained via vehicle measurement. Future work includes creating a generalized calculator that will be useful for other powertrain development projects.