The Modularized Development of a Wheel-Side Electric Drive System Using the Process of Hobbing and Form Grinding

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Abstract
The wheel-side electric drive system is a melding of a vehicle powertrain and suspension system, which saves chassis space and can adapt to different models. To achieve the goal of highly modularized development, the system is supposed to meet the requirements of various working conditions without changing the interface state. The electric motor drives the wheel through two-stage fixed axis helical gears, so the transmission is short in path and acts as the suspension arm at the same time. As a result, the gears are critical to output robustness and NVH performance. The modeling accuracy is decisive for simulations and tests, so it is necessary to build a precise geometric model instead of the data-fitting estimation. The gears are manufactured by a hobbing and form grinding process, which is described functionally along with the relationship between the tooling parameters and tooth profile curves. Based on the rain flow methodology and extrapolation theory, a comprehensive load spectrum with nine stages is formulated, which can cover the working conditions of a basic version, a NVH version, and a durability version. According to the Miner cumulative damage hypothesis, the equivalent durability mileage of 150,000 km is converted. The prototype machine is simulated and verified on the test bench, and the test results show that the wheel-side electric drive system has a reliable output performance. The equivalent damage of the comprehensive load spectrum is 63.27%, where the 2# stage driving gear is the most vulnerable component of the whole system. The research in this paper can provide data support for damage calculation and lightweight optimization with modularized development and applications in the future.
Funding Information
  • National Natural Science Foundation of China (5227052034)

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