High-speed Dynamic Transmission Error Of EV’s Reducer Detection Method Research And Test System Development

Controlling and optimizing the gear transmission error is an effective means to solve the whine noise of EV reducer.At present,the academic research on the transmission error of the EV reducer is divided into two directions: simulation calculation and test detection.The test detection research mostly focuses on the static transmission error,the test equipment runs at very low speed,and cannot capture the reducer’s dynamic information at high speed.At the same time,the transmission error research is mainly based on the test detection of a single pair of gears,and the research on transmission error detection technology for secondary/multistage transmission structures such as EV reducers is relatively lacking,leading to the unknown overall transmission error law.This paper takes the EV reducer as the research object,and systematically carries out the research on the high-speed dynamic overall transmission error test and detection theory,test and detection equipment development,test and detection methods,and the overall transmission error decoupled-separation method of the EV reducer.Transmission error test and detection theoretical research.Study the coupling relationship between the transmission error of gear pair at all levels and the overall transmission error of the reducer,and deduce the overall transmission error calculation method of the reducer based on the transmission error of single gear pair calculation idea,and summarize the high-speed dynamic overall transmission error influence law.Study the high-speed dynamic transmission error of reducer testing principle and the test equipment design method,and determine the high-speed dynamic transmission error testing method and the test equipment design idea.Test and detection equipment development.Based on the test detection theory,formulate the overall design objective and overall design scheme of the test equipment.Based on the open-power-flow test bench design idea,select and determine the model and parameters of the main components of the test equipment such as motor,frequency converter,magnetic powder brake,magnetic powder brake controller,torque and speed sensor,angle sensor,signal acquisition equipment and industrial control computer.Integrate and match the components through the test bench modular system matching technology,and analyze the differences in the transmission system of the test equipment flexibility and stiffness requirements in the circumferential and axial directions.For improving the dynamic simulation accuracy of the test equipment,Connect the transmission components through the flexible interconnection technology to ensure the accuracy of the circumferential upward motion transmission while compensating the axial error of the system.Combined with the testing principle and hardware system of high-speed dynamic transmission error test,propose the overall design requirements of the test equipment software system,and divide the software modules according to the functions based on the modular design criteria.Based on the "high cohesion and low coupling" software programming idea and the industrial control software programming development technology,complete the design and development of each module of the measurement and control software and data management software through the mixed programming method of graphics and text.Combined with the hardware and software system of the test and detection equipment,complete the assembly and commissioning of the test and detection equipment.Based on the functional acceptance criteria of the test equipment,the mechanical,electrical and software performance acceptance plan of the test and detection equipment is formulated,and the performance of all aspects of the test and detection equipment is inspected according to the plan to ensure that the requirements of the subsequent test and analysis technology research are met.Experimental analysis technology research.Based on the test and detection equipment,explore the test and detection process of high-speed dynamic transmission error of electric vehicle reducer,and establish the test and detection method of highspeed dynamic transmission error of reducer.Analyze and summarize the variation rules of the high-speed dynamic transmission error test data of the reducer under different working conditions.Study the coupling law between the gear pair of the EV reducer transmission error and the overall transmission error of the reducer.Propose a decoupling and separation method of the overall transmission error based on the cycle length of different axles,through combining with the independent characteristics of the cycle period of each axle,and verify its effectiveness by numerical simulation and experiment.