Journal of Engineering Research

New energy light trucks are increasingly accepted by the market due to their energy-saving and low operating costs. The electric drive axle layout has been widely adopted in new energy light trucks for its lower space occupation, lighter weight and lower cost. However, occasional failures due to shortcomings for the short development cycles. This paper investigates the abnormal noise in the reducer of the electric drive axle, and through theoretical verification of differential mechanisms dimensional and material quality inspections of components, validation reviews and customer usage condition assessment, concludes that the abnormal noise originates from differential operation under special working conditions exceeding design limits, which causes ablation and damage. By optimizing vehicle control program, this solution resolves the reducer noise problem.

New energy; Electric rear axle; Drive axle reduction gear; Abnormal noise