QDSJ015_重卡电驱桥关键技术和发展趋势及DeepWay电驱桥解读_18页_2mb

Summary of Content on Heavy-Duty Truck Electric Drive Axles

Key Development Process

• 需求管理及分解: Gathers overall vehicle requirements and decomposes them down to sub-systems and components.
• 系统设计及优化: Involves multi-parameter optimization for electric drive and transmission, maximizing efficiency in various operating conditions; includes mechanical design, component integration, supplier selection for items like sensors, actuators; covers system architecture, communication protocols, and wiring harness design.
• 软件开发及标定: Focuses on developing software and calibration for the electric drive system.
• 数字孪生及仿真: Develops digital twins based on integrated test benches and vehicle data for performance, durability, and predictive maintenance simulations.
• 集成测试及验证: Conducts functional and durability testing at system and component levels; includes bench performance and efficiency tests, support for vehicle initialization, debugging, and whole-vehicle validation.

Development Trends

• 高速化 (High-Speed): Electrified drive axles aim for higher rotational speeds (e.g., up to 110,000 RPM), driven by demands for smaller size and higher power; challenges include rotor dynamics (vibration and noise), bearing issues (corrosion and lifespan), cooling (stator, rotor, bearing heat dissipation), low-loss design (iron and copper losses), and structural integrity (critical speed resonance).
• 多挡化 (Multi-Speed): Electric motors are coupled with multi-speed transmissions to reduce performance demands on the motor itself, improving acceleration, hill-climbing ability, fuel efficiency, and cost-effectiveness by optimizing gear ratios and shift patterns.

Representative Configurations and Technologies

• Motor Designs: Single-motor systems with high-speed capability, such as those integrating flat-wire motors with high-voltage silicon carbide controllers for efficiency; four-speed AMT transmissions offer multiple gears for better power delivery, ensuring smooth performance and avoiding issues like power interruption on slopes.
• Company Examples:
  • DeepWay: Develops self-researched electric drive axles, including single-motor four-speed models with torque up to 51,000 N.m and power up to 300 kW; features include mechanical power take-off and innovative gear designs for consistent performance.
  • Daimler: Implements distributed electric drive systems with redundancy, allowing precise wheel-level control for uninterrupted power during shifts, enhancing safety and efficiency in heavy-duty applications.
• Cost Considerations: Four-speed single-motor axles involve specific components like motors, gear sets, controllers, and cooling systems; cost is influenced by integration and performance requirements.

Overall Impact on Technology

The focus is on improving Chinese electric drive systems through advanced designs, digital modeling, and practical applications in heavy trucks, addressing challenges like efficiency, reliability, and cost to meet growing market demands.