Torsional Impact Fatigue Test Method for Electric Vehicle Differentials

doi:10.3969/j.issn.1004-132X.2021.11.015

Abstract

Abstract: According to the actual load situation of the differential which were the key component of the electric vehicle transmission systems, a torsional impact fatigue test system for the differentials of the electric vehicles was designed based on hydraulic servo. The stress concentration parts of the key components of the differentials were analyzed under the current test technical conditions, and the loading waveform, loading frequency, loading amplitude and loading frequency were researched in theory and load characteristics. The torsional impact fatigue strain test system and test method of electric vehicle differentials were constructed, and a large number of strain tests were carried out. The test data of different frequencies and amplitudes were statistically analyzed. Combined with the analysis results and the material stress-life (S-N) curve, a complete torsional impact fatigue test method of electric vehicle differentials was established. The results indicate that the fatigue failure site and form of differentials are consistent with those of real vehicles and stress concentration measuring points.

Key words: electric vehicle differential, impact fatigue, stress-life (S-N) curve, loading

摘要： 针对电动汽车传动系的关键零部件差速器的实际受载情况，设计了基于液压伺服的电动汽车差速器扭转冲击疲劳试验系统。在此基础上，依照目前的试验技术条件，分析了差速器关键部件的应力集中部位，对加载波形、加载频率、加载幅值和加载频次进行了理论和载荷特征研究，构建了电动汽车差速器扭转冲击疲劳应变测试系统和测试方法，并对其进行了大量应变测试，对不同频率和不同幅值的测试数据进行了统计分析，结合分析结果和材料应力寿命(S-N)曲线，建立了完整的电动汽车差速器扭转冲击疲劳试验方法，并进行了试验验证。结果表明，差速器的疲劳破坏部位和形式与实车行驶时疲劳破坏部位和形式以及应力集中测点部位均一致。

关键词: 电动汽车差速器, 冲击疲劳, 应力寿命曲线, 加载

CLC Number:

TH123

ZOU Xihong, LI Jinxiao, HU Qiuyang, XI Shuaijie, FU Lingfeng, YUAN Dongmei. Torsional Impact Fatigue Test Method for Electric Vehicle Differentials[J]. China Mechanical Engineering, 2021, 32(11): 1377-1385.

邹喜红, 李金晓, 胡秋洋, 席帅杰, 付凌锋, 袁冬梅. 电动汽车差速器扭转冲击疲劳试验方法[J]. 中国机械工程, 2021, 32(11): 1377-1385.

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