Analysis and Optimization of Abnormal Noise of Commercial Electric Drive Axle 2023-01-1101

NVH (Noise, Vibration and Harshness) of the electric drive axle (EDA) is a key attribute in electric-vehicle development. The NVH level of the EDA directly determines the driving comfort and customer feeling of the vehicle. Especially in pure electric models, the EDA noise is more prominent without the engine noise masking. The paper aimed at the problem of the 380±50Hz resonance band on the commercial EDA and caused abnormal noise inside the vehicle. Adopted modal analysis, MASTA simulation, modulation noise analysis and exchange parts DOE, gradually refined the source of the problem to a single part, and finally locked to the source of gear parameters Rs and Fr. By adjusting the production process of gear and the second shaft, the assembly process error was avoided, and the gear parameter targets are formulated. The verification results of the whole vehicle assembly of small batch EDA showed that the optimized production process reduced the vibration and the interior noise of the EDA, and effectively optimized the abnormal noise problem of the EDA of commercial vehicles. The diagnostic ideas, test methods and optimization schemes for the abnormal noise of the EDA in this paper have important reference significance and value for the design of electric drive systems for passenger cars and commercial vehicles.