Reducing gear noise in electric vehicle (EV) drivetrains is crucial due to the absence of internal combustion engine noise, making even minor acoustic disturbances noticeable. Manufacturing parameters significantly influence gear-generated noise, yet traditional analytical methods often fail to predict these complex relationships accurately. This research addresses this gap by introducing a data-driven approach using machine learning (ML) to predict gear noise levels from manufacturing and sensor-derived data. The presented methodology encompasses systematic data collection from various production stages—including soft and hard machining, heat treatment, honing, rolling tests, and end-of-line (EOL) acoustic measurements. Predictive models employing Random Forest, Gradient Boosting (XGBoost), and Neural Network algorithms were developed and compared to traditional statistical approaches. The analysis identified critical manufacturing parameters, such as surface waviness, profile errors, and tooth geometry deviations, significantly influencing noise generation. Advanced ML models, specifically Random Forest, XGBoost, and deep neural networks, demonstrated superior prediction accuracy, providing early-stage identification of gear units likely to exceed acceptable noise thresholds. Integrating these data-driven models into manufacturing processes enables early detection of potential noise issues, reduces quality assurance costs, and supports sustainable manufacturing by minimizing prototype production and resource consumption. This research enhances the understanding of gear noise formation and offers practical solutions for real-time quality assurance.
Krisztián Horváth (Wed,) studied this question.
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