Optimization analysis of transmission errors in multi-operating conditions of electric vehicle reducer based on design of experiment

ZHAI Shuai; REN Aihua; SUN Zhangdong; GUO Huidong; ZHU Guoliang

doi:10.16578/j.issn.1004.2539.2026.06.007

Abstract：[Objective]To address the issue that traditional gear modification strategies,optimized for a single operating condition,often yield poor transmission error performance or even exacerbate it under other conditions,a compound modification optimization strategy for the multi-condition transmission error of an electric vehicle reducer was proposed to enhance its overall noise,vibration and harshness(NVH)performance across all operating conditions.[Methods]Firstly,taking the two-stage helical gear transmission system of an electric vehicle reducer as the research object,the transmission errors under five typical operating conditions were obtained using loaded tooth contact analysis(LTCA),and the high-speed stage gear was identified as the main noise source.Secondly,employing the design of experiment(DOE)method,four modification variables were selected as design variables to construct a response surface approximation model linking modification parameters and the peak-to-peak transmission errors under multiple conditions.Then,the contribution and effect of each modification parameter on the transmission error under different conditions were analyzed using Pareto plots and main effect plots.Finally,introducing operating condition weight coefficients and targeting the minimization of the weighted transmission error,the non-dominated sorting genetic algorithm Ⅱ(NSGA-Ⅱ)was used to solve for the optimal compound modification scheme.[Results]The results indicate that after applying the obtained optimal modification scheme,the peak-to-peak transmission error under each operating condition decreases by at least 15.31%compared to that of the original tooth surface.The peak tooth surface load under each condition is reduced by at least 8.39%.The noise is reduced by 7.78 dB(A)under the high-speed peak power condition.Compared with the equal-weight modification,the proposed unequal-weight modification scheme further reduces the peak tooth surface load and alleviates the tooth surface misalignment phenomenon.