Lightweight design of gears in the wheel-side reducer based on Shanghai road driving cycle

The development of wheel-side reducer with proper durability is important for electric vehicles equipped with a wheel-side reducer system. Based on the Shanghai road driving cycle, a novel conversion method is proposed from vehicle speed to load, which provides a theoretical foundation for lightweight design and a durability analysis of the key components of the wheel-side reducer system. With the gears of the wheel-side reducer as an example, an electric drive system durability test specification is also developed on the basis of the Miner linear cumulative damage theory considering the material strengthening under low-amplitude loads. The durability test shows that the second round of the prototype design no longer has an infinite life compared with the first round of the prototype design. The method based on active load spectrum is more effective than the traditional design method.