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Lightweight Design of Coaxial Direct-Connected Electric Drive Axles Based on Sensitivity Analysis of Structural Parameters

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Abstract

To improve the safety and driving range of pure electric vehicles, a multi-objective lightweight design based on fatigue life is carried out for coaxial direct electric drive axles. Firstly, the static and dynamic characteristics of the bridge casing under four operating conditions were analyzed based on ANSYS. The results show that there are large margins in the strength and stiffness of the bridge casing. Secondly, the wall thickness of the bridge shell is selected as the design variable for its weight redundancy problem and the related sensitivity analysis is performed. Then, Kriging and NSGA-II algorithms are applied to the bridge casing for fatigue life- based multi-objective optimization. After optimization, the weight reduction of the direct-connected electric drive axle is 6.64%. Finally, a vertical bending fatigue test was conducted on the optimized sample. The results show that the fatigue life of the axle housing meets the specification requirements.

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Authors and Affiliations

  1. School of Mechanical Engineering, Shenyang University of Technology, Shenyang, China

    Mingzheng Yang, Changzheng Chen & Linru Wei

  2. Liaoning Vibration and Noise Control Professional Technology Innovation Center, Shenyang, China

    Mingzheng Yang & Changzheng Chen

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  1. Mingzheng Yang
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  2. Changzheng Chen
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  3. Linru Wei
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Correspondence to Mingzheng Yang.

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Yang, M., Chen, C. & Wei, L. Lightweight Design of Coaxial Direct-Connected Electric Drive Axles Based on Sensitivity Analysis of Structural Parameters. J Fail. Anal. and Preven. 23, 1150–1161 (2023). https://doi.org/10.1007/s11668-023-01657-0

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  • DOI: https://doi.org/10.1007/s11668-023-01657-0

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