Challenge
All acceleration and deceleration of the vehicle depend on this gearbox, so a formal PPAP capabilities study was conducted. This resulted in the original drawings having to be adjusted, specifically tolerances, in order to properly cast and realistically manufacture the parts.
Adding to the challenge was meeting pressure tight requirements of the gearbox where sealing impregnation needs to take place. Also, the gearbox has to transfer torque from the electric motor and apply it to torque at the wheel as it supports reverse torque to brake the vehicle.
The gearbox cases and covers require all tolerances — both dimensional and positional — to be extremely tight. To meet requirements (and the short lead time) Stecker partnered with tooling vendors to design custom tooling. Stecker’s engineering and quality teams needed to design and build fixturing as well as develop robust processes in order to make this project a success.
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