In the rapidly evolving landscape of electric vehicles (EVs), the reliability and durability of key components are paramount. A recent study led by JIANG Liangxing, published in ‘Jixie qiangdu’ (Mechanical Strength), sheds light on a critical aspect of EV design: the structural strength and life analysis of electric drive axles. This research could significantly impact the commercial vehicle sector and the broader energy industry.
The study focuses on accurately predicting the fatigue life of electric drive axles, a crucial factor in the structural and reliability design of EV components. By leveraging measured road load spectra, the research team developed a method for processing and analyzing load data. This approach, based on the Miner criterion, provides valuable insights into the performance of electric drive axles under various load conditions.
“Starting from the measured road load spectrum of the reinforced road, a method for data processing and analysis of measured load spectrum was proposed,” JIANG Liangxing explained. This method involves obtaining load data for vehicles under no-load, half-load, and full-load conditions, and then processing this data through time-domain and frequency-domain analysis, as well as damage equivalent treatment.
The research team designed and developed a parallel-shaft electric drive axle, conducting static and modal analyses on key components such as the bridge shell. The findings revealed that the bridge shell would not experience torsion or bending due to road surface excitation, a critical discovery for enhancing the durability of electric drive axles.
Using nCode DesignLife simulation analysis software, the team obtained the fatigue life and damage value distribution of the bridge shell. The accuracy of these simulations was verified through durability tests, ensuring that the analysis method is reliable and can be applied to real-world scenarios.
To further validate their findings, the researchers conducted a 15,000 km vehicle vibration test on a test bench. The results were clear: the overall life and reliability of the electric drive axle met the design requirements, confirming the robustness of the analysis method.
This research has significant implications for the commercial vehicle sector and the energy industry. As EVs become more prevalent, the need for reliable and durable components will only increase. The methods and findings from this study provide a solid foundation for designing electric drive axles that can withstand the rigors of real-world use, ultimately enhancing the performance and longevity of electric vehicles.
The implications of this research extend beyond the immediate findings. As the energy sector continues to shift towards electrification, the ability to accurately predict and analyze the fatigue life of EV components will be crucial. This study paves the way for future developments in EV design, ensuring that electric drive axles and other critical components are built to last.
The study, published in ‘Jixie qiangdu’, highlights the importance of rigorous testing and analysis in the development of reliable EV components. As the industry continues to evolve, the insights gained from this research will undoubtedly shape the future of electric vehicle design and the broader energy sector.
