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<p>At present, the development of the new energy vehicle industry is accelerating due to the depletion of global oil resources, worsening environmental pollution, and increasing energy-saving standards. As a core component of electric vehicles, the electric drive system directly affects vehicle performance. However, the internal flow field of electric vehicle reducers, which mostly rely on oil splash lubrication, is poorly controllable, leading to significant power losses and reduced efficiency. This study aims to investigate the power loss mechanisms and flow field characteristics of electric drive reduction systems for commercial vehicles. By constructing numerical models for helical gear meshing friction, bearing friction, and gear train oil churning power losses, the influencing factors of power loss were analysed. A CFD simulation model was established using the Smooth Particle Hydrodynamics (SPH) method to simulate the characteristics of the splash flow field under different operating conditions. To further validate the effectiveness of the model and simulation results, 12 typical operating conditions were selected (covering low/medium/high speeds: 10/30/60/100&#xa0;km/h; torque: 16/64/128&#xa0;Nm; oil volume: 4.3/5.1/6.3&#xa0;L). Point-by-point comparisons were conducted between experimental and simulated data for three key metrics: efficiency, temperature, and oil volume. The numerical model was further validated through temperature measurements and oil flow lubrication experiments. Findings indicate: gear meshing friction accounts for the largest loss proportion, followed by bearing friction and oil churning losses; simulated helical gear meshing efficiency deviates ≤ 0.25% from experimental values, with total system efficiency deviation ≤ 0.4%; The SPH method effectively simulates splash flow fields, with total oil volume deviation within the reducer housing ≤ 1% and effective bearing area oil volume deviation ≤ 11.8% (primarily due to oil mist diffusion at high speeds); The deviation between simulated and experimental values for maximum bearing temperature is ≤ 4.5%, while oil sump temperature deviation is ≤ 2.4%, consistent with power loss variation patterns. Simulation reveals that oil distribution in the bearing region is primarily influenced by high-speed gear pairs.</p>

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Power loss and splash lubrication flow field characteristics in the electric drive reduction system of commercial vehicles

  • 期刊论文

  • 发表日期：

    2026年2月11日

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  • Zhaoyuan Ning,
  • Jingliang Jiang,
  • Hao Yang

摘要

At present, the development of the new energy vehicle industry is accelerating due to the depletion of global oil resources, worsening environmental pollution, and increasing energy-saving standards. As a core component of electric vehicles, the electric drive system directly affects vehicle performance. However, the internal flow field of electric vehicle reducers, which mostly rely on oil splash lubrication, is poorly controllable, leading to significant power losses and reduced efficiency. This study aims to investigate the power loss mechanisms and flow field characteristics of electric drive reduction systems for commercial vehicles. By constructing numerical models for helical gear meshing friction, bearing friction, and gear train oil churning power losses, the influencing factors of power loss were analysed. A CFD simulation model was established using the Smooth Particle Hydrodynamics (SPH) method to simulate the characteristics of the splash flow field under different operating conditions. To further validate the effectiveness of the model and simulation results, 12 typical operating conditions were selected (covering low/medium/high speeds: 10/30/60/100 km/h; torque: 16/64/128 Nm; oil volume: 4.3/5.1/6.3 L). Point-by-point comparisons were conducted between experimental and simulated data for three key metrics: efficiency, temperature, and oil volume. The numerical model was further validated through temperature measurements and oil flow lubrication experiments. Findings indicate: gear meshing friction accounts for the largest loss proportion, followed by bearing friction and oil churning losses; simulated helical gear meshing efficiency deviates ≤ 0.25% from experimental values, with total system efficiency deviation ≤ 0.4%; The SPH method effectively simulates splash flow fields, with total oil volume deviation within the reducer housing ≤ 1% and effective bearing area oil volume deviation ≤ 11.8% (primarily due to oil mist diffusion at high speeds); The deviation between simulated and experimental values for maximum bearing temperature is ≤ 4.5%, while oil sump temperature deviation is ≤ 2.4%, consistent with power loss variation patterns. Simulation reveals that oil distribution in the bearing region is primarily influenced by high-speed gear pairs.