Xiaoyu Ding

Wheel load is a critical information source reflecting the status of vehicle load distribution and motion. Yet, existing in-wheel motor products are primarily designed as propulsion units and inherently lack the load-sensing capabilities required by intelligent vehicles. To address this research gap, this paper presents a novel intelligent electric drive wheel (i-EDW) with an integrated transmission system and a load-sensing unit (LSU). The i-EDW adopts an Axial Flux Permanent Magnet Synchronous Motor (AFPMSM), while the integrated LSU ensures high-precision measurement of six-dimensional wheel forces and moments. According to this multi-axis force information, a real-time estimation and stability control method based on the tire–road friction circle concept is proposed. Instead of the complex decoupling and multi-objective optimization with the multi-actuator systems, this paper focuses on minimizing the tire load rate of i-EDWs, which significantly advances the state of the art in terms of calculation efficiency and respond speed. To validate this theoretical framework, a full-vehicle model equipped with four i-EDWs is developed. In the MATLAB R2022A/Simulink co-simulation environment, a virtual prototype is tested under typical driving scenarios, including the straight-line acceleration and double-moving-lane (DML) steering. The simulation results prove a reliable safety margin from the friction circle boundaries, laying a solid foundation for precise motion control and improved system robustness in future intelligent vehicles.

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.

This paper presents a novel power electronic module (PEM) for chassis-by-wire in passenger cars. The PEM is supposed to be installed in a close-to-wheel position, which provides electrical interfaces with a power harness and signal harness. When the vehicle is driving, the PEM works as a dynamic vibration absorber (DVA) to diminish the negative effects of un-sprung mass. Based on the vibration system model, the mechanical principles are analyzed and the design parameters are mathematically optimized. For a comparison of different configuration schemes with an in-wheel motor (IWM), we take the condition of a vehicle driving at a speed of 15 m/s on a C-class road to examine indicators of vehicle body acceleration, wheel dynamic load, and suspension dynamic deflection. The calculation results prove that the system has advantages in ride comfort and wheel grounding characteristics. For the detailed design of the machine, we build a digital virtual prototype for simulation. Compared to the initial state, the optimized DVA configuration has obvious suppression in component vibration, including the vehicle body, the IWM, and the PEM. The frequency sweep analysis proves a robust result, which ensures that the frequency and amplitude are both within the vibration tolerance range of PEM operations.

This paper provides a comprehensive analysis of the electric-drive-wheel (EDW) with idler gear. From the perspective of automotive engineering, the EDW is an integrated execution unit that combines the function of powertrain and suspension. As a result, the research on EDW involves the intersection of multiple disciplines. The evolution of idler gear configuration requires some geometric constraints. Under this premise, the longitudinal and vertical dynamic characteristics of the system were studied, respectively. There are several factors that influence the system performance, such as the gear parameters, the position of the electric motor, and the suspension K&C value. The principles of each parameter on the output indicators were studied, with an optimized plan and simulation comparison to check the correctness of theory. In the end, the prototype was equipped with a test bench, covering a wide range of working operations to examine the expected performance of EDW design. The step response test of the EDW result showed a balanced performance in transmission smoothness and responsiveness agility.