Lightweight design and optimization of three-speed electric drive axle

Abstract In order to provide wider speed range and smaller volume, wet multi-plate clutches and planetary gears are utilized to design a three-speed transmission system, electric drive axle housing is designed according to the transmission system. Aluminum alloy is used to perform lightweight design. Firstly, the finite element (FE) models of electric drive axle housing are built. Secondly the stiffness and strength simulation results of electric drive axle housing under different conditions are obtained. According to the simulation results, the thickness of electric drive axle housing is reduced and the stiffeners are added. The FE results show that the quality of the optimized shell is greatly reduced on the basis of the original stiffness and durability.