Dynamic Performance Experiment on Star Reducer of New Energy Vehicle Based on Composite Modification

DENG Jing; WANG Zilin; JIANG Chuang; SU Jianxin

doi:10.15926/j.cnki.issn1672-6871.2025.03.002

Abstract：Aiming at the meshing performance problem caused by the deformation of planetary pin shaft in the transmission system of new energy vehicle reducer,the optimization path of gear topology modification on the vibration characteristics of the system was explored.Based on a certain type of new energy commercial vehicle reducer,a helical gear modification model including spiral modification,second-order tooth profile correction and tooth direction topology optimization was constructed,and nonlinear factors such as idler shaft deformation were comprehensively considered.The rigid-flexible coupling modeling method was used to establish the transmission system simulation model in Masta software,and the meshing simulation and loading vibration experiment were used to verify the influence of the combined modification on the meshing performance of the reducer.The experiment results show that the vibration amplitude of the optimized reducer decreases from 0.023 mm·s-2 to 0.015 mm·s-2 by 34.70％.The contact mark area of the tooth surface is expanded,the contact stress of the internal and external meshing pairs is reduced by 20.50％and 11.62％respectively,and the stress distribution is uniform.The measured contact spots are in good agreement with the simulation prediction.The proposed comprehensive topology modification method can effectively improve the dynamic meshing performance.The established rigid-flexible coupling model can provide a reliable analysis tool for the optimization design of gear transmission system under complex working conditions.The modification optimization strategy has engineering guidance value for noise reduction and vibration reduction of new energy commercial vehicle transmission device.