Browse Publications Technical Papers 2020-01-1421

Development of Commercial Vehicle E-Axle System Based on NVH Performance Optimization 2020-01-1421

With the continuous development of various technologies in the field of electric vehicles, more and more mature products are put into the market. Among them, electric commercial vehicle has been supported by many preferential policies because of its wide use and high energy utilization and has developed rapidly in recent years. At present, the electric drive-train systems of commercial vehicles can be divided into motor direct drive, integrated el-axle and distributed e-wheel drive. The first type only uses motor to replace the engine, and the other parts have little change. This method has low transmission efficiency and loose structure, which is a temporary transition scheme. The drive types of integrated e-axle and distributed e-wheel have their own advantages and disadvantages, which way to become the mainstream of the future has not yet been decided. This research is based on the development of an electric commercial vehicle integrated e-axle system, in which the NVH performance is the most important consideration index. Firstly, the systematic engineering analysis is carried out according to the vehicle parameters. After determining the basic structure, the macro-parameters such as transmission ratio and center distance of each gear pair is optimized. Then the meshing performance of gears is optimized by micro-modification of gears. The design and development of housing is based on structural stiffness and modal optimization. After the optimization design, the dynamic response of the e-axle assembly under the actual working conditions is evaluated and analyzed, in which the whistle and resonance are adopted as the risk aversion items. Finally, the designed sample is validated by bench test and vehicle test. The results of this study can be used as a reference for the design and development of e-axle, which has strong practical guiding significance.


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