Gearbox in EV - movilogo
EVs typically have no gearbox because torque is constant at any RPM.

But, if a gearbox is fitted then less powerful motor can be used. This will draw less current and thus will increase range worth same battery.

Then went still gearboxes are not fitted in EVs?


Gearbox in EV - mcb100
Porsche Taycan and Audi e-Tron GT do have a two speed transmission, but the lower ratio is only used in Sport Plus mode and full-bore racing starts.
I did see that on a TV programme on converting classics to EV that the gearbox is retained, but in not sure how often you’d have to use it.
I wonder if having a box of gears and shafts swirling about in oil would offset any potential gains from the ability to change gear?
Gearbox in EV - maz64

FWIW Gemini (Google's chatgpt) says this, I think it's quite informative:

The primary reason most electric vehicles (EVs) don't have multi-speed gearboxes like gasoline or diesel cars is due to the fundamental differences in how electric motors and internal combustion engines (ICEs) produce power:

  1. Instant and Broad Torque: Electric motors deliver maximum torque (rotational force) almost instantly from 0 RPM. This means they can provide strong acceleration from a standstill without needing to "rev up" like an ICE. They also maintain a consistent and efficient torque output across a very wide range of RPMs, often up to 10,000-20,000 RPM or more.

  2. ICE's Narrow Power Band: Internal combustion engines, on the other hand, have a much narrower "power band" where they operate most efficiently and produce optimal torque. To keep the engine within this ideal range across different speeds, traditional cars need multiple gears. These gears effectively adjust the engine's RPM relative to the wheel speed to maximize power and efficiency.

  3. Efficiency Across Speeds: Because electric motors are inherently efficient across their entire operating range, a single, fixed-ratio gearbox (often referred to as a single-speed transmission) is usually sufficient. This single gear provides a reduction in speed from the high-revving motor to the wheels, along with a corresponding increase in torque.

  4. Simplicity and Reliability: Eliminating a complex multi-speed gearbox means fewer moving parts. This leads to:

    • Reduced weight: Lighter vehicles are more efficient.
    • Lower manufacturing cost: Fewer components to produce and assemble.
    • Improved reliability: Fewer parts mean less chance of something breaking down, leading to lower maintenance costs.

    • Smoother driving experience: No gear shifts mean seamless acceleration without any jolts.

    • Quieter operation: Less mechanical noise.

While most EVs utilize a single-speed transmission, there are a few exceptions, primarily in high-performance or specialized vehicles (like some Porsche Taycan models or certain racing EVs) that might incorporate a two-speed gearbox to optimize performance at very high speeds or for specific acceleration profiles. However, for the vast majority of consumer EVs, the benefits of simplicity, efficiency, and instant torque delivery make a single-speed transmission the preferred choice.

Edited by maz64 on 12/06/2025 at 08:54

Gearbox in EV - mord

Bosch have certainly tried, adding a whole heap of complexity for not an awful lot of gain.

Continuously variable transmission with pushbelt for electric vehicles

Gearbox in EV - Big John
But, if a gearbox is fitted then less powerful motor can be used. This will draw less current and thus will increase range worth same battery.

You can't beat the laws of physics, An internal combustion engine only has useable torque/power within a certain rev range and the gearbox keeps the engine useable matching useable engine revs to the road wheel rotation speed. This is essential however the gearbox still introduces an inefficiency.

As you say "EVs typically have no gearbox because torque is constant at any RPM" This is usually due to clever motor electronic control. Adding a gearbox would simply add an inefficiency. So to achieve the same performance etc you'd effectively decrease the range of the battery.

Gearbox in EV - Andrew-T

Given the constant torque availability whatever the speed of the motor, does that mean that the only real limitation on speed is air and rolling resistance ?

Gearbox in EV - maz64

In an electric vehicle (EV) without a gearbox, the top speed is primarily limited by the maximum rotational speed (RPM) of the electric motor.

Here's a breakdown of the factors involved:

  1. Motor RPM Limit: Electric motors can spin at very high RPMs, often exceeding 10,000 RPM, with some reaching over 20,000 RPM (much higher than typical internal combustion engines). However, every motor has a physical limit to how fast it can safely and efficiently rotate before mechanical stress, bearing limitations, and electromagnetic forces become problematic. Once the motor reaches its maximum RPM, the wheels, connected through a fixed gear ratio, also reach their maximum rotational speed, which translates to the vehicle's top speed.

  2. Fixed Gear Ratio: Since there's no multi-speed gearbox, a single gear ratio connects the motor to the wheels. This means that for a given motor RPM, the wheel RPM is directly determined. To achieve higher speeds, the motor itself needs to spin faster.

  3. Power and Torque Curve: While electric motors deliver maximum torque from a standstill, their power output typically peaks at a certain RPM and then can decrease at very high RPMs. As the vehicle approaches its top speed, the power required to overcome aerodynamic drag and rolling resistance increases significantly. If the motor's power output starts to drop off at very high RPMs, it may not be able to generate enough force to push the vehicle any faster.

  4. Inverter Limitations: The inverter is responsible for converting the DC power from the battery into AC power for the motor and controlling its frequency and voltage. The inverter has limits on the maximum voltage and current it can supply to the motor, which can indirectly limit the motor's top RPM and power output.

  5. Battery Discharge Rate: While less common as a direct top-speed limiter (it's more about sustained power and range), the battery's ability to discharge a very high current for a prolonged period at top speed can also play a role. If the battery cannot consistently supply the peak power demanded by the motor at its highest RPMs, the performance may be restricted.

  6. Aerodynamics and Rolling Resistance: Like any vehicle, an EV's top speed is also fundamentally limited by the forces of air resistance (aerodynamic drag) and rolling resistance from the tires. At higher speeds, these forces become exponentially greater, requiring more and more power to overcome. Even if the motor could spin faster, the vehicle might simply run out of power to accelerate further against these resistances.

  7. Software and Safety Limiters: Manufacturers often implement electronic speed limiters for various reasons, including:

    • Tire ratings: To ensure the vehicle doesn't exceed the safe speed limit of its tires.
    • Thermal management: To prevent overheating of the battery or motor during sustained high-speed operation.
    • Range preservation: High speeds consume significantly more energy, and a limiter can help maintain a more practical range.

In summary, the most direct limitation on an EV's top speed without a gearbox is the maximum RPM the electric motor can achieve, which is then translated to wheel speed by the fixed gear ratio, all while considering the power required to overcome drag and other inherent limitations of the electrical system.

Edited by maz64 on 12/06/2025 at 12:28

Gearbox in EV - SLO76
I do know that the Nissan Leaf has a reduction gearbox. It’s a known failure point on cars that haven’t had a reduction box oil change at some point. Mostly higher mileage cars, ex taxis and the like. It’s not a service item according to Nissan, but the likes of Cleevely recommend it. I was planning on having it done on our Leaf before it was written-off by a taxi driver.
Gearbox in EV - mcb100
Just putting numbers through a calculator, based on an EV motor spinning at a (conservative) 10,000rpm (some spin up to 20K), a 205/50-15 tyre, if you remove aero drag, friction between tyre & road, whatever other parasitic losses that may occur, you’ve an EV capable of 690mph.
But glacial acceleration. Which is why they have reduction gears.
Reduction ratios vary between manufacturers, but will be the reason most EV’s are capped to top speeds comfortably below what their power/weight ratio suggests they’re capable of.

Edited by mcb100 on 12/06/2025 at 13:01

Gearbox in EV - bathtub tom

I always wondered why the likes of Sentinel steam wagons had a gearbox, then one day I managed to speak to someone who knew. They told me it was for precise, slow speed manoeuvring.

Gearbox in EV - madf
I do know that the Nissan Leaf has a reduction gearbox. It’s a known failure point on cars that haven’t had a reduction box oil change at some point. Mostly higher mileage cars, ex taxis and the like. It’s not a service item according to Nissan, but the likes of Cleevely recommend it. I was planning on having it done on our Leaf before it was written-off by a taxi driver.

BMW had no service schedule for rear transaxle. Some reports of failures at 100k + miles. And pictures of horribly dirty oil and metal collect on magnetic drainplug.

Changed oil on mine to be safe. BMW deleted filler as a cost saver. If you need to do it, dismantle rear suspension and remove driveshaft and fill via that, ££££s Or fill via drain hole with a squirt bottle and a makeshift plug of tape. I did the latter - works a treat. Saved 10 hours of workshop dismantling and new driveshaft oil seals.. (you cannot make this up!)

Gearbox in EV - Adampr

If a less powerful motor was used, it would have to spin faster to maintain the desired wheel speed. I have no idea what the correct balance between motor speed and motor power is for efficiency, but I suspect EV manufacturers have thought about it

Gearbox in EV - Engineer Andy

What arrangement did some of the electric trains from the 1990s and especially early 2000s that sounded like they had some 'gearbox arrangement', where the sound of the motor increased in pitch as the train got off the mark, then paused for a split second (like a gear change), then it started again as if in another 'gear' as it gained speed, then repeated again as it gained more speed.

The opposite always happened as the train slowed to a stop

The newer ones don't appear, at least audibly, to have the same motor 'arrangement'. Older electric trains, such as those built around 1989/90 and originally run on the Thameslink line were just of the 'one pitch' for a particular power level, essentially louder for more power / acceleration

Gearbox in EV - bathtub tom

What arrangement did some of the electric trains from the 1990s and especially early 2000s that sounded like they had some 'gearbox arrangement', where the sound of the motor increased in pitch as the train got off the mark, then paused for a split second (like a gear change), then it started again as if in another 'gear' as it gained speed, then repeated again as it gained more speed.

The opposite always happened as the train slowed to a stop

The newer ones don't appear, at least audibly, to have the same motor 'arrangement'. Older electric trains, such as those built around 1989/90 and originally run on the Thameslink line were just of the 'one pitch' for a particular power level, essentially louder for more power / acceleration

I was under the impression that East Midland back then, ran one and two car trains that were basically a diesel lorry, torque converter. At least, that's what they felt like. I expect someone will come along and tell us the model number.

I understand later, larger and hence heavier trains need too much torque for a mechanical gearbox and hence diesel-electric power.

Gearbox in EV - Engineer Andy

What arrangement did some of the electric trains from the 1990s and especially early 2000s that sounded like they had some 'gearbox arrangement', where the sound of the motor increased in pitch as the train got off the mark, then paused for a split second (like a gear change), then it started again as if in another 'gear' as it gained speed, then repeated again as it gained more speed.

The opposite always happened as the train slowed to a stop

The newer ones don't appear, at least audibly, to have the same motor 'arrangement'. Older electric trains, such as those built around 1989/90 and originally run on the Thameslink line were just of the 'one pitch' for a particular power level, essentially louder for more power / acceleration

I was under the impression that East Midland back then, ran one and two car trains that were basically a diesel lorry, torque converter. At least, that's what they felt like. I expect someone will come along and tell us the model number.

I understand later, larger and hence heavier trains need too much torque for a mechanical gearbox and hence diesel-electric power.

Sorry, but my query was regarding pure electric trains. Looking back on it, I think the London Tube also has/had similar 'sounding' ones (definitely those running in the 2000s/2010s), namely the Jubilee Line ones, as if they are 'changing gear' when accelerating and stopping.

Gearbox in EV - galileo

What arrangement did some of the electric trains from the 1990s and especially early 2000s that sounded like they had some 'gearbox arrangement', where the sound of the motor increased in pitch as the train got off the mark, then paused for a split second (like a gear change), then it started again as if in another 'gear' as it gained speed, then repeated again as it gained more speed.

The opposite always happened as the train slowed to a stop

The newer ones don't appear, at least audibly, to have the same motor 'arrangement'. Older electric trains, such as those built around 1989/90 and originally run on the Thameslink line were just of the 'one pitch' for a particular power level, essentially louder for more power / acceleration

I was under the impression that East Midland back then, ran one and two car trains that were basically a diesel lorry, torque converter. At least, that's what they felt like. I expect someone will come along and tell us the model number.

I understand later, larger and hence heavier trains need too much torque for a mechanical gearbox and hence diesel-electric power.

Sorry, but my query was regarding pure electric trains. Looking back on it, I think the London Tube also has/had similar 'sounding' ones (definitely those running in the 2000s/2010s), namely the Jubilee Line ones, as if they are 'changing gear' when accelerating and stopping.

My friend Google produced this:

  • Variable frequency control:

    Electric trains often use variable frequency drives (VFDs) to control the speed and power of the electric motors. These VFDs adjust the frequency of the electrical current supplied to the motor, which in turn alters the motor's speed. The changes in frequency can create a sound that some people might interpret as gear changes.

Gearbox in EV - Engineer Andy

What arrangement did some of the electric trains from the 1990s and especially early 2000s that sounded like they had some 'gearbox arrangement', where the sound of the motor increased in pitch as the train got off the mark, then paused for a split second (like a gear change), then it started again as if in another 'gear' as it gained speed, then repeated again as it gained more speed.

The opposite always happened as the train slowed to a stop

The newer ones don't appear, at least audibly, to have the same motor 'arrangement'. Older electric trains, such as those built around 1989/90 and originally run on the Thameslink line were just of the 'one pitch' for a particular power level, essentially louder for more power / acceleration

I was under the impression that East Midland back then, ran one and two car trains that were basically a diesel lorry, torque converter. At least, that's what they felt like. I expect someone will come along and tell us the model number.

I understand later, larger and hence heavier trains need too much torque for a mechanical gearbox and hence diesel-electric power.

Sorry, but my query was regarding pure electric trains. Looking back on it, I think the London Tube also has/had similar 'sounding' ones (definitely those running in the 2000s/2010s), namely the Jubilee Line ones, as if they are 'changing gear' when accelerating and stopping.

My friend Google produced this:

  • Variable frequency control:

    Electric trains often use variable frequency drives (VFDs) to control the speed and power of the electric motors. These VFDs adjust the frequency of the electrical current supplied to the motor, which in turn alters the motor's speed. The changes in frequency can create a sound that some people might interpret as gear changes.

It seems YouTuber LU enthusiast Jago Hazzard (great name) has the answer:

www.youtube.com/watch?v=_4ANmUkGIJc

Apparently the thyristors that change the frequency you spoke of, and is unique to the Jubilee Line trains due to when they were designed / built.

Whether other 'overground' trains have similar devices that do the same (though not as loudly), I'm not sure, as it wasn't covered in the video.