Analysis and optimization of abnormal noise in the main reducer of light truck electric drive axle
轻卡电驱动桥主减异响分析及优化

摘要

新能源轻卡以节能、运营成本低越来越被市场接受，电驱桥布置占用空间小、重量轻、成本低被新能源轻卡广泛应用，但因开发时间短，偶发故障。本文就某轻卡电驱动桥减速器异响问题，通过对差速器理论校核、零部件尺寸及材质检测、开发验证、客户工况等方面分析，发现异响是在特殊工况下轮边差速工况超过差速设计限值，引起零部件烧蚀、损坏，导致电驱桥失效。通过对整车控制程序优化，从而解决差速器损坏导致主减异响问题。

Abstract

New energy light trucks are increasingly accepted by the market due to their energy-saving and low operating costs. The electric drive axle layout has been widely adopted in new energy light trucks for its lower space occupation, lighter weight and lower cost. However, occasional failures due to shortcomings for the short development cycles. This paper investigates the abnormal noise in the reducer of the electric drive axle, and through theoretical verification of differential mechanisms dimensional and material quality inspections of components, validation reviews and customer usage condition assessment, concludes that the abnormal noise originates from differential operation under special working conditions exceeding design limits, which causes ablation and damage. By optimizing vehicle control program, this solution resolves the reducer noise problem.