Theoretical,Simulation And Experimental Study On Churning Loss Of Electric Vehicle Reducer Design

As an important intermediate link connecting the vehicle power input and output,the performance of the automobile transmission system directly affects the transmission efficiency,dynamic performance and economic performance of the automobile.Among them,churning loss of the reducer is an important part of the total energy consumption.However,for its dynamic energy consumption characteristics of in-depth research is not much all over the world.Because of the influencing factors of churning loss,the solution is quite complicated.At present,the churning loss of drive system is often regarded as fixed or coarse in the field of vehicle performance simulation,energy management or energy saving optimization control,by ignoring the effect of the reducer churning loss on the research objectives.Based on the research background of electric vehicle,this paper use for reference on the energy consumption of gear drive and automobile transmission system all over the world,and makes a theoretical study,simulation analysis and experimental test verification of the churning consumption power.The specific research contents are as follows:1.Firstly,analyzed the main characteristics of the churning loss in the process of power transmission.To understand the domestic and foreign scholars in the study of churning loss of the gear meshing transmission,including theoretical derivation,simulation and experimental research.In addition,elaborated the main research content and technical route of this subject.2.Based on the previous theory of calculation formula and semi-empirical formula of power consumption,a physical model of churning loss in a pair of gears is established.According to the pressure form,the loss can be divided into two parts:P_d anP_d_p.The mathematical model of hydrodynamics for each part of churning loss is established.3.To study the transient mechanism of tip clearance volume in the gear meshing period,Based on UG/motion simulation software,a pair of spur gears meshing simulation model is established.To solve the tip clearance volume of synthesis transient curves between the tip clearance volume meshing and the angle of engagement.Based on CFD/FLUENT in fluid simulation software,simulation analysis was carried out in order to obtain the internal flow field contours of gearbox.4.In order to accurately predict the churning loss of gear transmission under different working conditions,a multi-function test device for measuring churning loss is designed,and the experimental study on churning loss of gearbox based on thecondition is carried out.This test device can be used to analyze the churning loss which impacted by the gear tooth width,the number of teeth or immersion oil depth and other factors.And analyzed the churning loss of different tooth profile or non-standard spur gear.Finally,by changing the parameters such as tooth width,number of teeth,depth of immersion oil and lubricating oil,the churning loss value in a single gear and a pair of gears are respectively tested.Through the derivation of churning loss in meshing zone to deduce the influence of different parameters on churning loss of meshing zone.