基于高耐久寿命的减速器壳体轻量化实现方法

LIGHTWEIGHT REALIZATION METHOD FOR WHEEL-SIDE REDUCER BASED ON HIGH DURABILITY LEVEL

纯电动汽车随着电驱动系统的引入,整车非簧载质量大大增加,操纵稳定性恶化,轮边减速器的轻量化问题亟待解决。重点研究减速器壳体的轻量化设计方法,使其在满足高耐久寿命的前提下,最大程度实现轻量化。首先对壳体进行了受力和有限元分析,分析结果表明应力最大值远小于壳体疲劳强度,因此存在轻量化空间。依据壳体疲劳寿命的要求计算出壳体允许承受的最大应力,以该最大应力为约束,对壳体的结构进行了优化。最后应用虚拟疲劳耐久仿真方法对壳体进行了检验,结果表明壳体符合高耐久寿命要求,从而验证了轻量化的合理性。

The unsprung mass of an electric vehicle is increased because of the placement of electric driving system,which deteriorate the vehicle handling stability. Therefore,the light-weight design of the wheel-side reducer is a crucial problem that requires to be solved. The main topic of this paper is concerning light-weight design methodology for the reducer shell. The design objective is the satisfaction of high durability test life requirement while guarantee of rigidity and intensity requirements.Firstly,the main load and static strength were analyzed. Results showed that the max stress was far lower than the fatigue strength so that a light-weight design work was required. The allowable max working stress was calculated according to the fatigue life requirement. A structural optimization result was calculated by setting the max stress as the constraint and the minimum volume as the objective. Finally,the optimized shell＇s fatigue life was predicted by applying virtual fatigue simulation method. The simulation results showed that the shell was furthest light-weight designed on the basis of satisfying specified durability test requirement.