As the main power form of new energy vehicles, e-axle systems
are has been widely used in passenger vehicles and commercial
vehicles. A passenger car equipped with an e-axle, in constant speed and low
torque conditions, there is a noticeable rattle noise, through experimental
investigation and comparative analysis, it is confirmed that the connection
spline of motor and reducer is the main influencing factor. Then, Through the
qualitative analysis of simulation, it is found that both spline clearance and
misalignment have an amplification effect on the motor speed, thereby
stimulating the gear pair of the reducer to produce rattle. The amplification
effect of spline clearance is stronger than that of spline misalignment.
Therefore, improving the stiffness and application amount of lubricating grease
while controlling the spline sample to meet the design requirements can
effectively solve the problem of rattle, improve the accuracy of spline
alignment, and significantly reduce the probability of rattle. An engineering
solution has been proposed for the problem of gear rattle in e-axle, effectively
improving the NVH level of similar e-axle products.