Gear Modification And Housing Optimization Of Pure Electric Vehicle For Gearbox

In recent years,relying on the dividends of relevant policies,new energy vehicles have appeared more and more frequently in people's field of vision.As a member of new energy vehicles,electric vehicles rely on their environmental protection and energy saving characteristics as a perfect substitute for fuel vehicles.The popularity of electric vehicles will be unstoppable.In this context,the use of more advanced concepts to develop electric vehicle reducers is of great significance for enhancing market competitiveness.In this paper,a single-speed reducer for a pure electric vehicle is taken as the research object.In order to expand the product coverage of the matched models,the main engine factory has newly added a high-profile version.The high-profile version has been upgraded in the drive motor and will be used in the previous regular version.The motor with a maximum torque of 180 N·m is replaced with a version of 200 N·m.In order to meet the technical requirements of the high-profile models,the internal gears are re-trained and the local position of the housing is strengthened to meet the reliability and economical requirements of the reducer.The research content mainly includes the following aspects:(1)Summarize the commonly used gear shaping methods,analyze the applicable working conditions of each profile modification parameter and the advantages and disadvantages of the three tooth modification methods,and finally select the full profile modification and drum repair.The combination of the shapes optimizes the gears of the reducer.(2)According to the gear parameters and shaft diagram of the reducer,the simulation model of the reducer drive system is established in the KISSsys integral simulation module in KISSsoft software;according to the working condition table provided by the host factory,work in the KISSsys module In the case of the table,the positive-rotation positive drive(high-torque)condition with the most time is analyzed.The calculation is performed by calculating the deformation amount and stress distribution of each axis,and the calculation data files of each gear shaft are manually introduced into the gear analysis of the next stage to improve the realism of the simulation.Taking the first gear pair as an example,KISSsoft software calculates the recommended amount of modification,combined with the previous experience of the company's modification,using the Modifications sizing module in the software to set the target parameters,and continuously refine the selection range through the software.Good repair shape.Finally,the modified gear pair is re-analyzed to calculate gear transmission error,contact stress,contact temperature,tooth surfaceline load and other parameters.After the primary gear pair gear has been modified,the transmission error fluctuation value is reduced by 0.15?m before the modification,the maximum contact stress is reduced by 106.94 MPa before the modification,the contact spot distribution is more reasonable,and other parameters are reached.Design expectations.(3)Use UG10.0 to build the shell digital model and simplify the housing according to the needs of the simulation.The finite element model of the shell was built using the pre-processing software HyperMesh;the strength analysis of the finite element model was performed using Abaqus software.According to the obtained results,compared with the allowable stress and deformation standard,it is determined that the strength of the rear housing intermediate shaft bearing seat is insufficient under the positive rotation positive drive(high twist)condition,and the housing is improved.The improved maximum stress of the rear casing is reduced from the original 144.7 MPa to 105.1 MPa,which ensures a large strength reserve.(4)The effectiveness of the reducer was verified by making a prototype and performing tests on fatigue life and transmission efficiency.