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Article(id=1241029732154790293, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241029724655383270, articleNumber=null, orderNo=null, doi=10.16579/j.issn.1001.9669.2025.02.002, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1680278400000, receivedDateStr=2023-04-01, revisedDate=1691078400000, revisedDateStr=2023-08-04, acceptedDate=null, acceptedDateStr=null, onlineDate=1773814145363, onlineDateStr=2026-03-18, pubDate=1739548800000, pubDateStr=2025-02-15, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1773814145363, onlineIssueDateStr=2026-03-18, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1773814145363, creator=13701087609, updateTime=1773814145363, updator=13701087609, issue=Issue{id=1241029724655383270, tenantId=1146029695717560320, journalId=1227999626482147330, year='2025', volume='47', issue='2', pageStart='1', pageEnd='158', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1773814143575, creator=13701087609, updateTime=1773840259815, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1241139264176574915, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241029724655383270, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1241139264176574916, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241029724655383270, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=10, endPage=18, ext={EN=ArticleExt(id=1241029733023011241, articleId=1241029732154790293, tenantId=1146029695717560320, journalId=1227999626482147330, language=EN, title=Structural strength and life analysis of an electric drive axle shell based on the measured load spectrum, columnId=1241029725523604201, journalTitle=Journal of Mechanical Strength, columnName=Fatigue∙Damage∙Fracture∙Failure Analysis, runingTitle=null, highlight=null, articleAbstract=

Accurately predicting the fatigue life of products plays an important role in the structural strength design and reliability design of key components of electric vehicles.Starting from the measured road load spectrum of the reinforced road,a method for data processing and analysis of measured load spectrum was proposed, based on the Miner criterion, the load data of the vehicle under no-load, half-load and full load were obtained, and the key data for vibration simulation analysis and indoor bench test were obtained through time-domain frequency domain processing and damage equivalent treatment.A parallel-shaft electric drive axle was designed and developed, the statics analysis and modal analysis were carried out for key components such as the bridge shell, and the results concluded that the bridge shell would not have torsion and bending caused by road surface excitation.Based on nCode DesignLife simulation analysis software, the fatigue life and damage value distribution of the bridge shell were obtained, and the accuracy of the simulation analysis was verified by the bridge shell durability test.Based on the measured road load spectrum of the reinforced road, a 15 000 km vehicle vibration test was carried out on the vehicle vibration test bench for the electric drive axle.The test shows that the overall life and reliability of the electric drive axle meet the design requirements, and the reliability of the analysis method is verified.

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JIANG Liangxing, E-mail：
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准确地预估产品的疲劳寿命对于电动汽车关键零部件的结构强度设计以及可靠性设计具有重要作用。以实测强化路道路的载荷谱为出发点，提出了实测载荷谱数据处理与分析的方法，基于Miner准则，得出了车辆在空载、半载以及满载下的载荷数据，通过时域频域处理、损伤等效处理等，得到了可供振动仿真分析以及室内台架试验的关键数据；设计开发了一款平行轴式电驱动桥，针对桥壳等关键部件开展了静力学分析和模态分析，得出了桥壳不会因为路面激励而产生扭转和弯曲现象的结论；基于nCode DesignLife仿真分析软件得出了桥壳疲劳寿命与损伤值分布，通过桥壳耐久试验验证了仿真分析的准确性；基于实测的强化路道路载荷谱，在整车振动试验台上开展了15 000 km的强化路室内整车振动试验。试验表明，该电驱动桥产品整体寿命及可靠性满足设计要求，同时验证了分析方法的可靠性。

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姜良兴，男，1993年生，湖南平江人，硕士，工程师；主要研究方向为电驱动系统开发、传动系统开发；E-mail：。

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姜良兴，男，1993年生，湖南平江人，硕士，工程师；主要研究方向为电驱动系统开发、传动系统开发；E-mail：。

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姜良兴，男，1993年生，湖南平江人，硕士，工程师；主要研究方向为电驱动系统开发、传动系统开发；E-mail：。

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Research on durability test specifications of user-association drive axle test fields[J].China Mechanical Engineering，2022，33（14）：1670-1679.（In Chinese）, articleTitle=Research on durability test specifications of user-association drive axle test fields, refAbstract=null)], funds=[Fund(id=1241029746939712511, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241029732154790293, awardId=2021YFB2500700, language=EN, fundingSource=National Key R&D Program Project(2021YFB2500700), fundOrder=null, country=null), Fund(id=1241029747036180485, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241029732154790293, awardId=2021YFB2500700, language=CN, fundingSource=国家重点研发计划项目(2021YFB2500700), fundOrder=null, country=null)], companyList=[AuthorCompany(id=1241029738727264881, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241029732154790293, xref=1., ext=[AuthorCompanyExt(id=1241029738735653490, tenantId=1146029695717560320, 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figureFileBig=yvQEgMQUehb/GvJByKIN/A==, tableContent=null), ArticleFig(id=1241029746348315611, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241029732154790293, language=EN, label=Fig.11, caption=Vehicle vibration bench test, figureFileSmall=6a0dJGhb+uAEacSl6bStUA==, figureFileBig=gYXoN5f0CdGLCAvn/m3pSw==, tableContent=null), ArticleFig(id=1241029746428007391, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241029732154790293, language=CN, label=图11, caption=整车振动台架试验, figureFileSmall=6a0dJGhb+uAEacSl6bStUA==, figureFileBig=gYXoN5f0CdGLCAvn/m3pSw==, tableContent=null), ArticleFig(id=1241029746524476389, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241029732154790293, language=EN, label=Tab.1, caption=

Material property of the bridge shell body

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序号
Number		零件
Part		材料
Material		密度
Density ρ/(kg/m3)		屈服强度
Yield strength Re/MPa		弹性模量
Modulus of elasticity E/GPa		泊松比
Poisson ratio
1桥壳Axle caseQ460C7 8504602060.28
2轮毂轴管Hub shaft tubeSAE15277 8008852120.26
3减壳Retarder housingQT450-107 0603101690.257
4差速器壳体Differential caseQT500-77 0003201620.293
), ArticleFig(id=1241029746616751082, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241029732154790293, language=CN, label=表1, caption=

桥壳主体材料属性

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序号
Number		零件
Part		材料
Material		密度
Density ρ/(kg/m3)		屈服强度
Yield strength Re/MPa		弹性模量
Modulus of elasticity E/GPa		泊松比
Poisson ratio
1桥壳Axle caseQ460C7 8504602060.28
2轮毂轴管Hub shaft tubeSAE15277 8008852120.26
3减壳Retarder housingQT450-107 0603101690.257
4差速器壳体Differential caseQT500-77 0003201620.293
), ArticleFig(id=1241029746700637169, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241029732154790293, language=EN, label=Tab.2, caption=

Natural frequencies and corresponding mode shapes of 7th~12th orders of the axle case

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阶次
Order		固有频率
Natural frequency f/Hz		振型
Vibration mode
7189.61阶纵向弯曲振动
1st order longitudinal bending vibration
8281.71阶垂直弯曲振动
1st order vertical bending vibration
9306.42阶纵向弯曲振动
2nd order longitudinal bending vibration
10369.82阶垂直弯曲振动
2nd order vertical bending vibration
11479.53阶纵向弯曲振动
3rd order longitudinal bending vibration
12549.93阶纵向弯曲振动和1阶轴向转矩的复合振动
3rd order longitudinal bending vibration & 1st order axial torque compound vibration
), ArticleFig(id=1241029746813883383, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241029732154790293, language=CN, label=表2, caption=

桥壳第7~12阶固有频率和相应振型

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阶次
Order		固有频率
Natural frequency f/Hz		振型
Vibration mode
7189.61阶纵向弯曲振动
1st order longitudinal bending vibration
8281.71阶垂直弯曲振动
1st order vertical bending vibration
9306.42阶纵向弯曲振动
2nd order longitudinal bending vibration
10369.82阶垂直弯曲振动
2nd order vertical bending vibration
11479.53阶纵向弯曲振动
3rd order longitudinal bending vibration
12549.93阶纵向弯曲振动和1阶轴向转矩的复合振动
3rd order longitudinal bending vibration & 1st order axial torque compound vibration
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基于实测载荷谱下的某电驱动桥桥壳结构强度及寿命分析
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姜良兴 1 , 倪大成 1, 2 , 姚超 1, 2 , 黄庆 1 , 卿鑫慧 3
机械强度 | 疲劳·损伤·断裂·失效分析 2025,47(2): 10-18
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机械强度 | 疲劳·损伤·断裂·失效分析 2025, 47(2): 10-18
基于实测载荷谱下的某电驱动桥桥壳结构强度及寿命分析
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姜良兴1 , 倪大成1, 2, 姚超1, 2, 黄庆1, 卿鑫慧3
作者信息
  • 1.湖南力行动力科技有限公司，株洲　412000
  • 2.湖南大学 电气与信息工程学院，长沙　410082
  • 3.中车时代电动汽车股份有限公司，株洲　412000

    • 姜良兴，男，1993年生，湖南平江人，硕士，工程师；主要研究方向为电驱动系统开发、传动系统开发；E-mail：。

Structural strength and life analysis of an electric drive axle shell based on the measured load spectrum
Liangxing JIANG1 , Dacheng NI1, 2, Chao YAO1, 2, Qing HUANG1, Xinhui QING3
Affiliations
  • 1.Hunan Lixing Power Technology Co., Ltd., Zhuzhou 412000, China
  • 2.College of Electrical and Information Engineering, Hunan University, Changsha 410082, China
  • 3.CRRC Electric Vehicle Co., Ltd., Zhuzhou 412000, China
出版时间: 2025-02-15 doi: 10.16579/j.issn.1001.9669.2025.02.002
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摘要
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准确地预估产品的疲劳寿命对于电动汽车关键零部件的结构强度设计以及可靠性设计具有重要作用。以实测强化路道路的载荷谱为出发点，提出了实测载荷谱数据处理与分析的方法，基于Miner准则，得出了车辆在空载、半载以及满载下的载荷数据，通过时域频域处理、损伤等效处理等，得到了可供振动仿真分析以及室内台架试验的关键数据；设计开发了一款平行轴式电驱动桥，针对桥壳等关键部件开展了静力学分析和模态分析，得出了桥壳不会因为路面激励而产生扭转和弯曲现象的结论；基于nCode DesignLife仿真分析软件得出了桥壳疲劳寿命与损伤值分布，通过桥壳耐久试验验证了仿真分析的准确性；基于实测的强化路道路载荷谱，在整车振动试验台上开展了15 000 km的强化路室内整车振动试验。试验表明，该电驱动桥产品整体寿命及可靠性满足设计要求，同时验证了分析方法的可靠性。

商用车  /  电驱动桥  /  道路载荷谱  /  疲劳寿命  /  疲劳分析

Accurately predicting the fatigue life of products plays an important role in the structural strength design and reliability design of key components of electric vehicles.Starting from the measured road load spectrum of the reinforced road,a method for data processing and analysis of measured load spectrum was proposed, based on the Miner criterion, the load data of the vehicle under no-load, half-load and full load were obtained, and the key data for vibration simulation analysis and indoor bench test were obtained through time-domain frequency domain processing and damage equivalent treatment.A parallel-shaft electric drive axle was designed and developed, the statics analysis and modal analysis were carried out for key components such as the bridge shell, and the results concluded that the bridge shell would not have torsion and bending caused by road surface excitation.Based on nCode DesignLife simulation analysis software, the fatigue life and damage value distribution of the bridge shell were obtained, and the accuracy of the simulation analysis was verified by the bridge shell durability test.Based on the measured road load spectrum of the reinforced road, a 15 000 km vehicle vibration test was carried out on the vehicle vibration test bench for the electric drive axle.The test shows that the overall life and reliability of the electric drive axle meet the design requirements, and the reliability of the analysis method is verified.

Commercial vehicle  /  Electric drive axle  /  Road load spectrum  /  Fatigue life  /  Fatigue analysis
姜良兴, 倪大成, 姚超, 黄庆, 卿鑫慧. 基于实测载荷谱下的某电驱动桥桥壳结构强度及寿命分析. 机械强度, 2025 , 47 (2) : 10 -18 . DOI: 10.16579/j.issn.1001.9669.2025.02.002
Liangxing JIANG, Dacheng NI, Chao YAO, Qing HUANG, Xinhui QING. Structural strength and life analysis of an electric drive axle shell based on the measured load spectrum[J]. Journal of Mechanical Strength, 2025 , 47 (2) : 10 -18 . DOI: 10.16579/j.issn.1001.9669.2025.02.002
正文
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0　引言
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在双碳政策驱动下，未来新能源车底盘将更多地采用电驱动桥的传动形式，通过系统集成化设计释放更多底盘空间，且伴随整车质量的减小，传动效率得到有效提升。电驱动桥是针对电动汽车设计开发的一种集成机、电一体化电驱动系统，具有集成化程度高、系统体积小、系统能耗低等优点[1-2]。作为电动汽车的关键核心部件，其动力系统的性能指标将直接影响整车的动力性和经济性[3]。
电驱动桥按照具体的结构形式可以分为分布式电驱动桥和集中式电驱动桥[4]，其中分布式电驱动桥按照基本构型可以分为轮边驱动和轮毂驱动两大类；集中式电驱动桥按照基本构型可以分为垂直式电驱动桥、同轴式电驱动桥和平行轴式电驱动桥。集中式电驱动桥结构复杂，但具有成本低、对传动系统设计影响小以及开发难度低等优点[5]，本文所设计的电驱动桥为集中式电驱动桥中的平行轴式电驱动桥（后文统一描述为电驱动桥）。
电驱动桥主要包括桥壳、驱动电动机、主减速器、差速器、半轴等几个部分。驱动桥桥壳主要起支撑汽车载荷的作用，同时将驱动系统载荷传递给车轮，是汽车底盘系统中的主要承载结构之一，因此要求驱动桥桥壳必须具有足够的强度、刚度和疲劳寿命[6-7]。车辆在正常行驶过程中桥壳主要承受来自路面的各种复杂交变载荷作用，由此导致的疲劳破坏是电驱动桥桥壳的主要失效形式之一[8]。桥壳作为电驱动桥系统中的主要承载部件之一，其疲劳寿命的大小既反映了自身的疲劳可靠性，又在一定程度上决定了整车系统的可靠性[9]，因此，对桥壳疲劳寿命的研究将为电驱动桥的结构设计提供重要依据。
桥壳的疲劳寿命研究一直是工程研究中的一个热点问题。米承继等[10]通过将矿用自卸车后桥壳动力学分析结果作为疲劳寿命分析的随机载荷，得出了水平路面普通工况下的疲劳寿命云图；朱茂桃等[11]借助有限元法研究了某轻型车后桥壳体的疲劳寿命，并将数值分析结果与试验结果进行了比对；TOPAC等[12]结合试验和有限元分析方法，提出了改善后桥壳应力集中位置处的桥壳厚度来提高桥壳整体寿命；卢剑伟等[13]根据Miner累计损伤准则，对桥壳在循环工况下的疲劳累积损伤进行了计算，并对其疲劳可靠性进行了评估；王雪梅等[14]基于有限单元法对重载车辆驱动桥桥壳进行了优化设计，同时结合试验，验证了分析的可行性。
如何在保证桥壳疲劳寿命的基础上对其结构进行最优化设计以及轻量化设计，是电驱动桥系统设计中面临的一个关键问题，其主要原因是基于静态工况分析桥壳的寿命无法对疲劳进行预估，相关结论与在实际路面激励作用下的桥壳寿命会出现较大偏差。为解决这一问题，本文以某商用车电驱动桥为研究对象，实测了其在随机路面载荷作用下桥壳的动态响应情况，并针对循环行驶工况下桥壳的疲劳寿命展开了仿真分析，同时结合试验对比，验证了相关可行性，相关仿真分析方法和结论可为电驱动桥产品桥壳的设计提供相关经验或借鉴。
1　道路载荷谱的采集及工程处理
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1.1　道路载荷谱的采集
在现有工程应用中，通常把表示道路随机载荷统计特性的图形、表格、数字和矩阵等统一称为道路载荷谱[15]，具体的表现形式有：①表示各种不同大小道路随机载荷出现次数的载荷频次图或累积频次图；②表示不同频率下道路随机载荷能量分布的功率谱图；③表示各级载荷相对出现频次的直方图等。电驱动桥道路载荷谱的采集主要是指通过在试验车辆上布置传感器测量的与具体行驶路面状态相关的动态响应信号。本文所指的道路载荷谱是通过数据采集系统在某汽车试验场强化道路路面所采集的加速度、位移和应变响应等信号。
按照某汽车试验场可靠性试验规程和实际可靠性试验情况在某试验场强化路上进行试验。强化路主要包括11种路面，如扭曲路、石板路、条石路等。测量所需仪器包括数据采集系统、笔记本电脑、数字万用表、温湿度计、胎压仪及兆欧表等。数据采集系统如图1所示，传感器的安装布局如图2所示。
1.2　载荷谱数据的处理与分析
载荷谱试验数据处理与分析主要包含测试原始数据、数据有效性预处理、时域数据分析、频域数据分析、目标信号加速及加速效果评估等内容。具体流程如图3所示。
对试验车开展空载、半载和满载3种加载状态下的试验场道路载荷谱采集试验，其中某加载状态下的原始数据如图4所示。
检查测试数据中的所有信号，将通道信号进行分类，分为不可修复、漂移和毛刺突变。舍弃不可修复的通道数据，保留可修复的通道数据；对测试数据中的漂移、毛刺及偶然突变等信号进行探测及修复；使用相同材料特性曲线对不同载重状态下的所有测量数据进行损伤估计，得到极值统计；通过多次测试相同通道下的损伤数据除以平均损伤，对数据进行归一化处理后交互显示，得到不同试验数据的极值与损伤值的对应关系，最终确定测试序列作为模拟振动仿真或试验的迭代目标信号。
1.3　目标信号的编辑与加速
结构的疲劳破坏一般是由于结构在动载荷作用下出现塑性、疲劳损伤累积的结果，累积塑性、疲劳损伤一般是由循环载荷作用导致的。载荷谱编辑加速即删除信号中对损伤贡献不大的载荷循环（如连接路面、损伤小的路面等）以缩短时间，并且保证损伤等指标尽量与原始信号接近。分析方法如下：
利用应变幅值εa与对应的应力幅值σa的关系式（循环应力-应变曲线表达式）求解应力-应变响应曲线：
式中，εa为应变幅值；为弹性应变幅值；为塑性应变幅值；σa为应力幅值；E为弹性模量；K为循环强度系数；n为循环应变硬化指数。
利用式（2）求解相应载荷水平下的疲劳寿命，即该载荷水平下的损伤：
式中，σf为疲劳强度系数；Ni为各载荷水平下的疲劳寿命；b为疲劳强度指数；εf为疲劳延性系数；c为疲劳延性指数。
对于材料损伤的累积，采用Miner线性损伤累积原则，表达式为
式中，ni为各载荷水平下的循环次数；Ni为各载荷水平下的疲劳寿命；N为疲劳寿命循环次数；D为疲劳总损伤。
在保证信号编辑前后损伤相等或相近的前提下，对目标信号的处理包括去除测试序列中试验场连接辅路、道路模拟试验台性能影响分析及保留百分比疲劳损伤加速等3个部分，按照以下3个步骤进行信号的编辑与加速。
1）以目标通道信号为基础，对目标信号按照道路工况进行时域数据切割，去除测试序列中的连接辅路部分，计算各个测点的结构损伤与信号编辑后的损伤保留率。
2）由于道路模拟振动试验系统主要复现0.6~50 Hz的频率成分，除扭曲路、波形路等极低频道路工况外，对目标信号进行带通滤波，计算各个测点的结构损伤与损伤保留。
3）采用雨流计数法对目标信号进行循环载荷分析，以保留95%的疲劳损伤为准则，删除信号中损伤较小的载荷。
2　桥壳的结构强度分析
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2.1　电驱动桥总体方案介绍
本文所设计的电驱动桥为集中式电驱动桥中的平行轴式电驱动桥（图5），驱动电动机转矩/转速输出后经两级平行轴减速进入差速器大齿圈，经差速器和半轴输出至两端轮端，轮端采用的是盘式制动。
电驱动桥桥壳可以看成是一空心简支梁，两端经轮毂轴承支撑于车轮上，在桥壳板簧座处桥壳承受整车的簧上载荷，而沿左、右车轮胎中心线，地面给轮胎以反向支撑力，桥壳承受此力与车轮重力之差。
在对桥壳进行强度分析之前，需要将桥壳复杂的受力情况简化成3种典型工况，即桥壳承受最大垂向力（当汽车满载并行驶于不平路面上，承受冲击载荷，动载荷系数按照2.5评估）；桥壳承受最大切向力（当汽车满载时，以最大驱动力行驶或紧急制动）；车轮承受最大侧向力（当车辆满载时侧滑）。只要在这3种工况下桥壳的强度都满足，就可以认为电驱动桥的桥壳在各行驶工况下的可靠性是没问题的。由于该电驱动桥的应用场景特殊性与工况复杂性，电驱动桥并不只是在单一工况下运行，经常是两种或多种工况同时存在，故需要对组合工况下的电驱动桥桥壳进行强度计算或仿真分析，由于篇幅有限，本文主要针对桥壳在承受最大垂向力与最大切向力组合工况下进行强度计算与仿真分析。
桥壳板簧座所承受的最大垂向力为
式中，F为单个板簧座承受的最大垂向力；m为轴载质量；m′为汽车行驶过程中桥的负荷转移系数；δ为动载荷系数；g为重力加速度，g=9.8 m/s2。
地面对左、右车轮的最大切向反力为
式中，Pmax为最大切向力；Temax为驱动系统最大转矩；i0为电驱动桥传动系统速比；ηT为传动系统传递效率；rr为轮胎滚动半径。
2.2　桥壳的静强度分析
在有限元计算分析过程中，施加的边界条件是否合理将直接影响其分析结果的准确性与可信性。参考标准QC/T 533—2020，目前针对驱动桥桥壳的约束与载荷施加方式主要有两种：一种是约束桥壳上的板簧座，在两轮端轮胎中心的轴管处施加载荷和力矩；另一种是约束桥壳两端轴管，在板簧座上施加载荷和力矩。本文所采用的加载方式为第二种。
在桥壳两端轴管任意一端中心节点上约束其X、Y、Z轴方向上的位移和绕Y、Z方向上的轴转动，在另一端轴管中心节点上约束其Y、Z轴方向上的位移和绕Y、Z方向上的轴转动，在两端桥壳板簧座上以均布载荷的形式施加桥壳的最大垂向力[16]。
桥壳主体材料属性如表1所示。通过有限元分析，可以得出桥壳和轴管的应力及应变云图，分别如图6和图7所示。
由图6可知，桥壳上最大应力为134.1 MPa，发生在桥壳与轮毂轴管连接位置处，桥壳材料Q460C的屈服强度为460 MPa，安全因子大于2；轮毂轴管最大应力为283.94 MPa，发生在左轮毂轴管中间轴径变化位置，轴管材料SAE1527的屈服强度为885 MPa，安全因子大于2。
由图7可知，满载时桥壳体垂直方向最大变形为0.53 mm，该电驱动桥轮距为1.87 m，单位长度变形量为0.28 mm/m，满足标准QC/T 533—2020中对于驱动桥桥壳垂直弯曲刚性试验评价指标的要求，即在满载荷时驱动桥桥壳每米轮距最大变形不超过1.5 mm[17]。
2.3　桥壳的模态分析
桥壳在工作过程中，主要承受路面不平度带来的激励，以及由于轮胎本身的不平衡所产生的激励，工况相对较差。疲劳分析方法的选用主要取决于结构所承受的动态载荷与其动态特性之间的关系。为了准确考察电驱动桥桥壳作为一个线性振动结构系统的特性，需要特别针对桥壳开展模态分析。
基于在前期电驱动桥壳静强度仿真分析中已建立的桥壳有限元模型，对桥壳开展自由模态仿真分析。为有效缩短仿真计算的时间及成本，本文首先提取了电驱动桥壳的前12阶固有特性，由于自由状态下的前6阶所计算的都是桥壳的刚体模态，其频率范围一般接近于0，所以去除了前6阶刚体模态，第7~12阶的固有频率和模态振型结果如表2所示。
通过仿真分析得出的第7~12阶模态如图8所示。
通过分析得知，集成桥第7~12阶模态主要为整体模态，由桥壳贡献，也符合电驱动桥桥壳整体的振动特性。汽车振动系统所承受的来自路面作用的激励主要为0~50 Hz的垂直振动，驱动桥壳的第7~12阶模态明显高于50 Hz，因此不会在实际过程中出现因为路面激励而导致的桥壳扭转和弯曲现象的发生。
3　桥壳的疲劳分析及耐久试验
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3.1　桥壳的疲劳分析
由于电驱动桥壳工作在交变的载荷下，疲劳破坏是其主要的破坏形式[18]，桥壳发生疲劳破坏时，其所承受的应力往往小于其壳体材料的屈服强度和抗拉强度。有限元分析的结果虽然表现出桥壳的强度和刚度都满足要求，但桥壳仍然存在出现疲劳破坏的可能，因此在实际电驱动桥产品的正式应用推广前需要对桥壳整体进行疲劳强度仿真，验证电驱动桥桥壳的合理性。
金属的疲劳破坏一般分为疲劳裂纹萌生、裂纹扩展和失稳断裂3个阶段。常见的疲劳寿命的计算方法可以分为名义应力法和局部应力法[19]。电驱动桥桥壳的弯曲疲劳试验属于低应力高周疲劳，一般采用的分析方法为名义应力法。名义应力法一般指的是以材料或零件的S-N曲线为基础，对照试件或结构疲劳出现危险部位的应力集中系数和名义应力，应用疲劳累积损伤理论，校核试件或结构疲劳强度或计算其疲劳寿命。
Miner线性疲劳累积损伤理论由于表达式简单，且在多数情况下寿命估算与试验结果吻合程度较高，所以是目前应用较为普遍的疲劳寿命预测方法。
根据Miner疲劳累积损伤理论，总损伤量为
式中，ni为在应力Ri作用下的实际工作循环次数；Ni为R-N曲线上对应于应力Ri的破坏循环次数。
根据Miner理论，当材料整个损伤完毕时，D=1，就发生疲劳破坏。
在电驱动桥桥壳的疲劳寿命仿真分析中，考虑到焊缝材料的不均匀性，以及与桥壳壳体材料的不一致性，忽略了桥壳上的各焊缝结构，简化了桥壳模型，将桥壳作为一个整体结构进行分析。利用nCode DesignLife分析软件，结合前期静强度仿真分析结果开展应力疲劳仿真计算，得出桥壳疲劳仿真寿命分布结果，如图9所示。
由图9可以看出，桥壳危险区域主要为轴管与桥壳承接过渡位置以及板簧座与桥壳之间的过渡区域，桥壳整体最小寿命值为8.503×105，满足QC/T 533—2020标准中驱动桥壳垂直弯曲中疲劳寿命80×104的指标要求，且远大于最低寿命50×104的要求，证明电驱动桥桥壳的结构符合疲劳寿命的使用标准。
3.2　桥壳的耐久试验
针对通过各项分析后的电驱动桥，对桥壳进行试制生产，根据QC/T 533—2020，从同一批次中的电驱动桥桥壳中随机抽取3个试验样品，分别编号为1号、2号和3号，同时将电驱动桥壳系统的其他附件逐一安装，按照标准要求，对桥壳两端轴管安装固定工装进行约束，在板簧座上施加交变载荷（为保障形成对比，交变载荷的施加与在有限元分析中的施加一致），桥壳耐久试验现场如图10所示。
1号样品在经过86万次循环后断裂，3号样品在经过98万次循环后断裂，两个样品的断裂位置都在轴管与桥壳承接过渡处，主要失效现象是过渡位置焊缝出现疲劳裂纹，故其破坏原因是在经历多次循环交变载荷作用后，在桥壳与焊缝应力集中部位形成了微小裂纹，再经过不断的应力循环后出现了永久性损伤，导致其出现断裂。2号样品在经过74万次循环后断裂，断裂位置在板簧座与桥壳过渡处，主要失效形式是桥壳出现压溃现象，主要原因可能是桥壳自身材料的一致性不够，或是桥壳本身厚度不均匀。
3个样品台架试验结果与疲劳仿真分析过程中最大损伤出现的位置基本吻合，证明仿真分析与试验结果的拟合度较好，准确性较高，且实际桥壳的试验寿命高于仿真寿命，故可以认为该产品的设计基本满足使用要求。
3.3　电驱动桥的耐久性试验
考虑到桥壳台架试验的局限性，在电驱动桥正式装车投入应用前，需要针对电驱动桥系统部件开展道路耐久性试验，道路耐久性试验是测定和验证汽车及关键部件可靠性的重要手段[20]。如按照整车在普通路面上正常行驶直至薄弱环节失效，一般需要行驶几万甚至几十万千米，这无疑需要耗费巨大的人力和物力。因此，为了缩短试验周期，同时节省开发成本，道路耐久性试验一般会选择在具有各种特征强化路面的试验场或者在能够满足全指标考核能力的室内试验室进行，如满足扭曲路、石板路、条石路等多工况加载的试验室。
基于电驱动桥产品开发前期实测的道路载荷谱数据，将其通过预处理、编辑、等效、加速以及损伤补偿处理后，应用在电驱动桥的室内耐久性试验考核中。根据Miner准则进行加速归一计算，计算式为
式中，w2为加速后的振动能量；w1为强化路试验的振动能量；T2为台架加速后的振动试验时间；T1为强化路行驶的振动试验时间；m为加速因子。
按照式（8）对不同路面的均方根（Root Mean Square，RMS）谱进行加权计算，最终得到应用于台架加速试验的功率谱密度（Power Spectral Density，PSD）和RMS谱。
式中，w2_Total为所有路面加权后的振动能量；w2_i为第i种强化路面加速后的振动能量；ki为第i种路面的加权因子；Li为试验场第i种强化路面的长度；LTotal为试验场强化路面的总长度。
参考国际标准ISO 19453-3：2018，选择加速因子为5，按照强化路行驶里程10 000 km，台架加速后振动试验22 h进行考核，整车振动台架试验情况如图11所示。
参考国家标准GB/T 13043—2022，针对整车考核15 000 km强化路（等效振动台上3 000个循环），试验完成度100%，试验车部分附件出现振坏脱落或更换的情况，但针对电驱动桥上各关键部件，如桥壳、减速器壳、轴管等关键件及桥壳焊缝、接头焊缝等都没有出现裂纹、开裂等现象，桥壳各端面结合面上无漏油或渗油现象，电动机结构件及其安装支架无损坏变形或失效等，满足客车定型试验规程的指标要求，电驱动桥振动耐久性试验考核合格。
4　结论
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通过以上分析研究，得出如下结论：
1）以某商用车电驱动桥为研究对象，利用相关数据采集系统，在试验场实地测量了其强化路的道路载荷谱，并提出了实测路谱数据处理与分析的方法，为后续实测载荷谱数据的采集以及处理与分析提供了参考。
2）针对产品开发需求，设计开发了一款电驱动桥，并针对电驱动桥桥壳开展了静力学分析以及模态分析，针对静力学分析与动力学分析中需要关注的考核方式或考核点做了介绍，为后续类似桥壳产品开展静力学分析以及动力学分析提供了仿真建议。
3）针对电驱动桥桥壳产品的疲劳寿命，利用相关仿真分析软件开展了应力疲劳分析，同时，针对桥壳开展了应力疲劳试验，将疲劳分析结果与疲劳试验结果进行了对比，从而验证了桥壳的相关仿真分析具有一定的准确性，相关仿真分析方法和结论可为电驱动桥桥壳的设计提供经验或借鉴。
4）基于实测载荷谱，利用Miner准则和文中所提的整车振动台加速试验方法，在室内试验室内模拟整车强化道路考核了电驱动桥的耐久性试验方法，为后续类似电驱动桥整车振动室内台架试验的加速方法或考核方法提供相关经验。
基金
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2025年第47卷第2期
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文章信息
doi: 10.16579/j.issn.1001.9669.2025.02.002
  • 接收时间：2023-04-01
  • 首发时间：2026-03-18
  • 出版时间：2025-02-15
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出版历史
  • 收稿日期：2023-04-01
  • 修回日期：2023-08-04
基金
National Key R&D Program Project(2021YFB2500700)
国家重点研发计划项目(2021YFB2500700)
作者信息
    1.湖南力行动力科技有限公司，株洲　412000
    2.湖南大学 电气与信息工程学院，长沙　410082
    3.中车时代电动汽车股份有限公司，株洲　412000
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2种不同金属材料的力学参数
科
Family		 属数
Number of
genus		 种数
Number of
species		 占总种数比例
Percentage of
total species (%)		 属
Genus		 种数
Number of
species		 占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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