Gear wear estimation prompting method and system for double-electric-drive-axle vehicle

Abstract

The invention discloses a gear wear estimation prompting method and system for a double-electric-drive-axle vehicle, and the method comprises the steps: obtaining the operation parameters of electric drive axles of the vehicle, including the single-axle operation time, single-axle operation mileage, torque output data distribution, torque positive and negative switching times and axle temperature data distribution of each electric drive axle; respectively processing the operation parameters to obtain wear factors of the corresponding operation parameters of the electric drive bridges; the obtained wear factors are multiplied by respective weight coefficients and then summed, and wear evaluation indexes of all the electric drive bridges are obtained; and comparing the wear evaluation index of each electric drive axle with a preset wear limit threshold, and generating early warning information and / or adjusting a drive control strategy according to a comparison result. According to the method, the wear degree is pre-judged through the wear evaluation index, so that early warning and prompting are given, and the passive mode of post-maintenance is changed; and the driving strategy is automatically adjusted by comparing the abrasion difference of the double axles, and the overall service life of the double electric drive axles is effectively prolonged.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electric vehicle drive systems, in particular to a gear wear estimation and prompting method and system for a dual electric drive axle vehicle. BACKGROUND

[0002] With the development of electric commercial vehicles, dual electric drive axle vehicles are gradually popularized. As a key component integrating drive motors, transmission mechanisms and differential mechanisms, the wear of the internal gears of the electric drive axle directly affects the safety and service life of the vehicle. Currently, the detection of electric drive axle gear wear mostly adopts a post-judgment method, such as through abnormal noise, oil debris analysis or disassembly inspection, which has problems such as complex operation, high cost and inability to provide early warning. Although there are diagnostic methods for gear wear in the prior art, such as oil analysis of fan gearboxes, the parameters and methods are not suitable for the dynamic operating environment of dual electric drive axle vehicles.

[0003] Therefore, there is an urgent need for a method and system that can monitor in real time, provide early warning and automatically adjust control strategies to balance the wear of dual electric drive axles and prolong their service life. SUMMARY

[0004] The purpose of the present application is to provide a gear wear estimation and prompting method and system for a dual electric drive axle vehicle, which solves the technical problems that the wear of the internal gears of each electric drive axle in a dual axle driven electric drive axle vehicle cannot be estimated in advance, early warning cannot be provided, the wear of the two electric drive axles cannot be balanced, and it is more difficult to prevent the wear from further increasing until failure.

[0005] The present application solves the above problems by the following technical solutions:

[0006] A gear wear estimation and prompting method for a dual electric drive axle vehicle, comprising:

[0007] Obtaining operating parameters of not less than two electric drive axles of a vehicle, the operating parameters including single axle operating time, single axle operating mileage, torque output data distribution, torque forward and reverse switching times and bridge temperature data distribution of each electric drive axle; the not less than two electric drive axles including a first electric drive axle and a second electric drive axle;

[0008] By comparing the corresponding single axle operating time, single axle operating mileage and torque forward and reverse switching times of each electric drive axle, performing normalization processing based on the minimum value, and accumulating within the corresponding set base, the wear factors of the single axle operating time, single axle operating mileage and torque forward and reverse switching times of each electric drive axle are obtained respectively;

[0009] By segmenting and statistically analyzing the torque output data and bridge temperature data of each electric drive axle, the distribution ratio of each electric drive axle falling into the corresponding segment interval is calculated. The wear factor of the torque output data distribution and bridge temperature data distribution of each electric drive axle is obtained by multiplying and accumulating the distribution ratio with the corresponding segment interval weight ratio.

[0010] The wear evaluation index of each electric drive bridge is calculated by multiplying the corresponding wear factors by their respective preset weight coefficients and summing the results.

[0011] The wear evaluation index of each electric drive axle is compared with a preset wear limit threshold, and warning information is generated and / or drive control strategy is adjusted based on the comparison results.

[0012] As a further improvement of the present invention, the method for obtaining the single-axle running time includes: the electronic control unit collects the gear information of the electric drive axle during the vehicle operation, obtains the time of each electric drive axle in neutral or gear by analyzing the gear information, and eliminates the time when two electric drive axles are running at the same time, thereby obtaining the single-axle running time of each electric drive axle during the actual operation of the vehicle.

[0013] As a further improvement of the present invention, the operating parameters further include: vehicle operating time; the method for obtaining the vehicle operating time is as follows: the electronic control unit collects the vehicle power-on and power-off information, and calculates the vehicle's single operating time using the time difference in the vehicle power-on and power-off information; the vehicle operating time can be obtained by accumulating the vehicle's single operating time, and the corresponding single-bridge operating time is obtained within the vehicle operating time period to serve as the set base for the single-bridge operating time.

[0014] As a further improvement of the present invention, the method for obtaining the single-axle running time of each electric drive axle is as follows: if the first electric drive axle is in gear and the second electric drive axle is in neutral during vehicle operation, the time T is recorded. 1_start Record the time T when the first electric drive axle returns to neutral or the second electric drive axle is in gear. 1_end Time T 1_start and time T 1_end The difference between the two is used to calculate the single-axle running time of the first electric drive axle; during each vehicle operation, the single-axle running time of the first electric drive axle is accumulated in real time to obtain the single-axle running time of the first electric drive axle within the corresponding vehicle operation time.

[0015] Similarly, the single-axle running time of the second electric drive axle is obtained within the corresponding vehicle running time.

[0016] As a further improvement of the present invention, the method for obtaining the single-axle operating mileage includes: the electronic control unit collecting power-on / off information, operating mileage, and vehicle speed information of the electric drive axle during vehicle operation to calculate the total mileage of a single trip; the total mileage of the vehicle can be obtained by accumulating the total mileage of a single trip, and the corresponding single-axle operating mileage is obtained within the total vehicle mileage cycle to serve as a set base for the single-axle operating mileage; and collecting the gear position information of the electric drive axle during vehicle operation, and calculating the single-axle operating mileage of each electric drive axle within the total vehicle mileage cycle using the gear position information and vehicle speed information.

[0017] As a further improvement of the present invention, the method for obtaining the wear factor of the torque output data distribution includes: statistically summarizing the acquired torque output data distribution of each electric drive axle, and obtaining the wear factor of each electric drive axle under the torque output data distribution; specifically, by segmenting the collected torque output data distribution into segments, obtaining several torque segment intervals with a certain torque output data as the interval, statistically analyzing the distribution of all torque output data of each electric drive axle falling into each torque segment interval, and calculating the torque distribution ratio of the number of torque output data distributions in each torque segment interval to the total torque output data distribution; simultaneously, assigning weight ratios to each torque segment interval according to different vehicle models and configurations; and then multiplying the statistically obtained torque distribution ratios and the corresponding weight ratios in the torque segment intervals, and summing them to obtain the wear factor of each electric drive axle in terms of torque distribution.

[0018] As a further improvement of the present invention, the method for obtaining the wear factor of the bridge temperature data distribution includes: summarizing and segmenting the acquired bridge temperature data of each electric drive bridge, dividing it into several bridge temperature segment intervals with a certain temperature interval, and calculating the proportion of bridge temperature data in each bridge temperature segment interval to the total number of bridge temperature data; assigning weight ratios to different bridge temperature segment intervals; and then multiplying the statistically calculated bridge temperature distribution proportions and the corresponding weight ratios of the bridge temperature segment intervals, and summing them to obtain the wear factor of each electric drive bridge in the bridge temperature data distribution.

[0019] As a further improvement of the present invention, the method for obtaining the wear evaluation index of each electric drive axle includes: assigning weights to the proportions of single axle running time, single axle running mileage, torque output data distribution, torque forward and reverse switching times, and axle temperature data distribution in the wear of the electric drive axle, so as to multiply the operating parameters of each electric drive axle by the corresponding weights and then add them together to obtain the wear evaluation index of each electric drive axle.

[0020] As a further improvement of the present invention, the gear wear estimation and indication method further includes:

[0021] The differences between the wear evaluation indices of each electric drive axle are compared. For electric drive axles with larger wear evaluation index values, a background alert is issued. For electric drive axles with larger wear evaluation indices, various wear factors are analyzed and compared in terms of single axle operating time, single axle operating mileage, torque output data distribution, torque forward / reverse switching times, and axle temperature data distribution. The corresponding wear factors of each electric drive axle are compared. If the comparison results show significant differences, the control strategy is adjusted during subsequent vehicle operation to suppress the continued increase of the corresponding wear factor of that electric drive axle.

[0022] Meanwhile, the present invention also solves its technical problems through the following solutions:

[0023] A gear wear estimation and warning system for a dual-electric drive axle vehicle includes: an electronic control unit that communicates with a first electric drive axle and a second electric drive axle respectively;

[0024] The first and second electric drive axles are installed on the vehicle to drive it. Both the first and second electric drive axles are electric drive axle assemblies that are integrated together by mechanically connecting the drive motor, the transmission mechanism, and the drive axle differential mechanism.

[0025] The electronic control unit connects to the vehicle via a bus to collect, process, and analyze data on the operation of the first and second electric drive axles during actual vehicle operation. It then calculates the wear evaluation index and adjusts the warning and control strategies accordingly to achieve the gear wear estimation and warning method for a dual-electric drive axle vehicle as described above.

[0026] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0027] (1) The present invention uses information during vehicle operation to estimate and prompt the wear degree of gears of dual electric drive axle vehicles. It can evaluate wear failure to a certain extent, provide early warning, and dynamically adjust the control strategy to balance the wear of gears of the two electric drive axles, preventing further excessive damage or even failure under unknown conditions.

[0028] (2) During vehicle operation, this application collects, stores, analyzes, and processes the operating parameters of the electric drive axle. It then weights and sums the different operating parameters to obtain a wear evaluation index for each electric drive axle gear. This wear evaluation index is used to predict the degree of wear, providing early warnings and alerts. This changes the passive approach of post-event maintenance and allows for the early detection of potential risks. Simultaneously, by comparing the wear differences between the two axles, the application automatically adjusts the drive strategy to reduce the load on the high-wear electric drive axle, achieving proactive wear balancing and effectively extending the overall lifespan of the two electric drive axles. Attached Figure Description

[0029] Figure 1This is a schematic diagram of the structure of a gear wear estimation and indication system for a dual-electric drive axle vehicle according to the present invention.

[0030] Figure 2 This is a flowchart of a gear wear estimation and indication method for a dual-electric drive axle vehicle according to the present invention.

[0031] Reference numerals: 1. First electric drive bridge; 2. Second electric drive bridge; 3. Electronic control unit. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] Example 1:

[0034] Combined with appendix Figure 1 As shown, a gear wear estimation and warning system for a dual-electric drive axle vehicle includes an electronic control unit 3 that communicates with the first electric drive axle 1 and the second electric drive axle 2 respectively.

[0035] The first electric drive axle 1 and the second electric drive axle 2 are installed on the vehicle and serve as the driving source for the vehicle to move. The first electric drive axle 1 and the second electric drive axle 2 are both electric drive axle assemblies that are integrated together by mechanically connecting the drive motor, the transmission mechanism, and the drive axle differential mechanism.

[0036] The electronic control unit 3 is connected to the vehicle via a bus to collect, process, and analyze data on the operation of the first electric drive axle 1 and the second electric drive axle 2 during actual vehicle operation. It ultimately calculates a wear evaluation index and uses this index to provide early warnings and adjust control strategies.

[0037] Example 2:

[0038] Reference Figure 2 A method for estimating gear wear in a dual-electric drive axle vehicle, comprising:

[0039] The operating parameters of at least two electric drive axles of the vehicle are obtained. The operating parameters include: single-axle operating time, single-axle operating mileage, torque output data distribution, torque forward and reverse switching times, and axle temperature data distribution for each electric drive axle; the at least two electric drive axles include a first electric drive axle and a second electric drive axle.

[0040] By comparing the corresponding single-axle running time, single-axle running mileage, and torque forward / reverse switching times of each electric drive axle, normalization is performed based on the minimum value, and after accumulation within the corresponding set base, the wear factors of single-axle running time, single-axle running mileage, and torque forward / reverse switching times of each electric drive axle are obtained respectively.

[0041] By segmenting and statistically analyzing the torque output data and bridge temperature data of each electric drive axle, the distribution ratio of each electric drive axle falling into the corresponding segment interval is calculated. The wear factor of the torque output data distribution and bridge temperature data distribution of each electric drive axle is obtained by multiplying and accumulating the distribution ratio with the corresponding segment interval weight ratio.

[0042] The wear evaluation index of each electric drive bridge is calculated by multiplying the corresponding wear factors by their respective preset weight coefficients and summing the results.

[0043] The wear evaluation index of each electric drive axle is compared with a preset wear limit threshold, and warning information is generated and / or drive control strategy is adjusted based on the comparison results.

[0044] In an optional embodiment, the gear wear estimation and indication method specifically includes the following steps:

[0045] Step S1: Collect and calculate the wear factor of single-bridge running time:

[0046] Furthermore, the specific method of S1 includes:

[0047] S11. The electronic control unit 3 collects vehicle power-on / off information and electric drive axle gear information during vehicle operation. It calculates the vehicle's single-run time using the time difference in the power-on / off information. The vehicle's total running time is obtained by accumulating these single-run times. The corresponding single-axle running time is acquired within the vehicle's running time cycle and used as a base value for the single-axle running time. By analyzing the electric drive axle gear information, the time each electric drive axle is in neutral or in gear is obtained, and the time when two electric drive axles are running simultaneously is eliminated and accumulated. This allows the acquisition of a base value for actual vehicle operation, such as running for 1 hour, the single-axle running time t1 of the first electric drive axle 1, and the single-axle running time t2 of the second electric drive axle 2.

[0048] The electronic control unit 3 collects vehicle power-on and power-off information and calculates the vehicle running time information for each operation. Specifically, it records the vehicle start-up time T based on the vehicle user key start-up information. day_start Record time T based on the time the customer turns off the power and locks the vehicle. day_end By subtracting the two times, the total vehicle running time T for each use can be recorded. day .

[0049] During each vehicle use, the gear position information of the electric drive axle is collected. The gear position information is used to identify whether the vehicle is in neutral or in gear. Based on the gear position, the actual vehicle operation process is obtained, such as the single-axle operation time t1 of the first electric drive axle 1 and the single-axle operation time t2 of the second electric drive axle 2 during 1 hour of operation.

[0050] Specifically, if during vehicle operation, the first electric drive axle is in gear and the second electric drive axle is in neutral, record the time T. 1_start Record the time T when the first electric drive axle returns to neutral or the second electric drive axle is in gear. 1_end The difference between the two is used to calculate the single-bridge running time of the first electric drive axle once; during each vehicle use, the single-bridge running time t1 of the first electric drive axle 1 is calculated in real time according to the above method.

[0051] Similarly, if during vehicle operation, the second electric drive axle is in gear and the first electric drive axle is in neutral, record the time T. 2_start When the second electric drive axle returns to neutral or the first electric drive axle is in gear, record the time T. 2_end The difference between the two is used to calculate the single-bridge running time of the second electric drive axle. During each vehicle use, the single-bridge running time t2 of the second electric drive axle 2 is calculated in real time using the above method.

[0052] S12. By comparing the single-bridge operating times t1 and t2, and normalizing based on the smaller of t1 and t2, the wear factors x11 and x12 of the first electric drive bridge 1 and the second electric drive bridge 2 in terms of single-bridge operating time are calculated. The calculation formula is as follows:

[0053] Reference time t min =min(t1, t2);

[0054] x11=t1 / t min x12=t2 / t min ;

[0055] A higher wear factor indicates that the bridge has been in operation for a longer period of time and that the potential wear is more severe.

[0056] S2. Collect and calculate the wear factor of a single bridge operating mileage;

[0057] Furthermore, the specific method of S2 includes:

[0058] S21. The electronic control unit 3 collects the power-on / off information of the electric drive axle, the mileage, and the vehicle speed during the vehicle's operation to calculate the total mileage of a single trip. The total mileage of the vehicle can be obtained by accumulating the total mileage of a single trip. The corresponding single axle mileage is obtained within the total mileage period of the vehicle and used as the set base for the single axle mileage.

[0059] The gear status of the electric drive axle during operation is collected, and the single-axle running mileage of each electric drive axle is calculated based on the gear status information and vehicle speed information. The single-axle running mileage includes: the single-axle running mileage s1 of the first electric drive axle 1 and the single-axle running mileage s2 of the second electric drive axle 2.

[0060] Specifically, based on the power-on information from the vehicle key start, the vehicle start time T is recorded. day_start Record time T based on the customer's power-off and vehicle locking times. day_end By subtracting the two times, the total running time T of each vehicle operation during each usage process can be recorded. day ;

[0061] If, during this vehicle usage, the first electric drive axle is in gear and the second electric drive axle is in neutral, the vehicle speed and mileage at any given moment will be recorded in real time from this moment onwards. 1_start When the first electric drive axle returns to neutral or the second electric drive axle is in gear, stop recording the vehicle speed and record the mileage (s) at that time. 1_send , will s 1_send With s 1_start The difference between the two is calculated and verified against the mileage obtained by integrating the vehicle speed, thereby calculating the single-axle mileage of the vehicle during this period of operation. Following the above method, once the above conditions are met during each vehicle use, the mileage is accumulated in real time to obtain the single-axle mileage s1 of the first electric drive axle 1 during the vehicle use, such as 1000 kilometers.

[0062] Similarly, during this vehicle operation, the second electric drive axle was in gear, and the first electric drive axle was in neutral. From this moment on, the vehicle speed and mileage were recorded in real time. 2_start When the second electric drive axle is returned to neutral, or the first electric drive axle is in gear, stop recording the vehicle speed and record the mileage (s) at that time. 2_send , will s 2_send With s 2_start The difference between the two is calculated and verified with the mileage obtained by integrating the vehicle speed to calculate the single-axle running mileage of the vehicle during this period of operation. Using the above method, the single-axle running mileage s2 of the second electric drive axle 2 is calculated in real time during each vehicle use to obtain the set base of 1000 kilometers during the vehicle use.

[0063] S22. By comparing the single-bridge operating mileages s1 and s2, normalization is performed based on the smaller value of the single-bridge operating mileages s1 and s2 to obtain the wear factors x21 and x22 of the first electric drive bridge 1 and the second electric drive bridge 2 in terms of single-bridge operating mileage.

[0064] Base mileage S min =min(S1, S2);

[0065] X21=S1 / S min x22 = S2 / S min .

[0066] S3. Collect and calculate the wear factor of torque output data distribution;

[0067] Furthermore, the specific method of S3 includes:

[0068] S31. The torque output data distribution of the electronic control unit 3 collects and stores the torque values ​​of the motors of each electric drive bridge during operation. Specifically, it collects the torque value m1 of the first electric drive bridge 1 and the torque value m2 of the second electric drive bridge 2.

[0069] S32. Then, the torque data of each electric drive axle is statistically summarized, specifically including: collecting the torque value m1 of the first electric drive axle 1 and statistically summarizing the torque data; collecting the torque value m2 of the second electric drive axle 2 and statistically summarizing the torque data, and calculating the wear factors x31 and x32 of the first electric drive axle 1 and the second electric drive axle 2 under the torque output data distribution.

[0070] Specifically, the collected torque values ​​m1 and m2 are categorized and statistically analyzed, segmented in 50Nm intervals into various torque ranges such as 0Nm, 50Nm, 100Nm, 150Nm, 200Nm, etc., up to the maximum peak torque. The distribution of all torque points of the first electric drive axle 1 and the second electric drive axle 2 within each segment is then statistically analyzed. Simultaneously, different intervals are assigned weight ratios of 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, ..., and so on, with a maximum of 1.

[0071] In a specific embodiment, if the torque values ​​of the first electric drive axle during this operation are collected from a total of 1000 points (i.e., a total of 1000), then n1 torque values ​​fall within the range of 0 Nm to 50 Nm, n2 torque values ​​fall within the range of 50 Nm to 100 Nm, and so on. The percentage of torque values ​​within each segment is then counted. The percentage of each segment is then divided by the total number of values ​​collected (e.g., 1000 in the example above) to obtain the percentage of each segment. For example, n1 / 1000 gives the percentage of the segment between 0 Nm and 50 Nm, i.e., the percentage of the segment "greater than or equal to 0 Nm and less than 50 Nm". This method can be used to calculate... Similarly, by calculating the percentage of each segment interval, we can obtain the percentage of all torque values ​​collected by the first electric drive axle 1 and the second electric drive axle 2 during vehicle operation within different torque segment intervals. Furthermore, based on different vehicle models and configurations, weight ratios for different segment intervals are assigned, such as 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, ... and so on. That is, the weight ratio for the 0Nm~50Nm segment is 0.1, the weight ratio for the 50Nm~100Nm segment is 0.15, the weight ratio for the 100Nm~150Nm segment is 0.2, the weight ratio for the 150Nm~200Nm segment is 0.25, and so on. The format after the statistics are completed is shown in the table below.

[0072]

[0073] S33. After the statistics are completed, the proportion of torque distribution of the first electric drive axle 1 and the second electric drive axle 2 and the corresponding weight ratio in the segment interval are multiplied and summed to calculate the wear factors x31 and x32 generated by the first electric drive axle 1 and the second electric drive axle 2 in terms of torque distribution. These factors reflect the accelerating effect of high torque conditions on gear wear.

[0074] S4. Collect and calculate the wear factor based on the number of torque forward / reverse switching cycles;

[0075] Furthermore, the specific method of S4 includes:

[0076] S41. The electronic control unit 3 collects the torque of each electric drive axle, compares it with 0, and records the number of times the torque decreases from a positive value to 0 and then to a negative value, and the number of times the torque increases from a negative value to 0 and then to a positive value. During the vehicle's power-on process, each occurrence is incremented by 1, and the data is not lost when the power is off. After power-on again, the recording continues; so as to obtain the number of times the torque of the first electric drive axle 1 is switched forward and reverse, n1, and the number of times the torque of the second electric drive axle 2 is switched forward and reverse, n2.

[0077] S42. Store the cumulative torque forward and reverse switching times n1 and n2. When the cumulative forward and reverse torque switching times reach 50, compare and judge the torque forward and reverse switching times n1 and n2, take the smaller value of the two as the benchmark, and perform normalization processing to calculate the wear factors x41 and x42 of the first electric drive bridge 1 and the second electric drive bridge 2 in terms of the number of torque forward and reverse switching times.

[0078] Number of times n of reference torque forward / reverse switching min =min(n1, n2);

[0079] X41=n1 / n min x42 = n2 / n min .

[0080] This wear factor reflects the impact wear caused by frequent acceleration, deceleration, and reversing.

[0081] S5. Collect and calculate the bridge temperature data distribution and wear factor;

[0082] Furthermore, the specific method of S5 includes:

[0083] S51, the electronic control unit 3 collects vehicle power-on and power-off information, collects bridge temperature data of each electric drive axle, and stores it; specifically, it collects the bridge temperature z1 of the first electric drive axle 1 during operation and the bridge temperature z2 of the second electric drive axle 2 during operation, and stores them.

[0084] S52, the electronic control unit 3 summarizes and segments the bridge temperature data collected and stored for each electric drive bridge, dividing it into several bridge temperature intervals at certain temperature intervals. It then calculates the proportion of bridge temperature data in each interval relative to the total number of bridge temperature data points, and assigns weights to different temperature intervals. For example, it divides the temperature into intervals of less than or equal to 110°C, greater than 110°C and less than or equal to 120°C, greater than 120°C and less than or equal to 130°C, greater than 130°C and less than or equal to 140°C, assigning weights of 0.1, 0.15, 0.4, 0.6, and 0.8 respectively. Higher temperatures result in higher weights, as higher temperatures exacerbate lubricant failure and material fatigue.

[0085] S53. The bridge temperature information of the first electric drive bridge 1 and the second electric drive bridge 2 is statistically analyzed according to the interval of the distribution in S52, and summarized according to the weight ratio and statistical results to obtain the wear factors x51 and x52 of the first electric drive bridge 1 and the second electric drive bridge 2 based on the bridge temperature data distribution.

[0086] S6. Calculate the overall wear evaluation index;

[0087] The wear evaluation index for each electric drive axle is calculated by assigning weights to its proportion in the wear of the electric drive axle based on factors such as single-axle operating time, single-axle operating mileage, torque output data distribution, torque forward / reverse switching frequency, and axle temperature data distribution. The operating parameters of each electric drive axle are multiplied by their respective weights and then summed to obtain the wear evaluation index for each electric drive axle. For example, the weights are assigned K1, K2, K3, K4, and K5, and the overall wear evaluation indices y1 and y2 for the first electric drive axle 1 and the second electric drive axle 2 are calculated. The specific calculation formula is as follows:

[0088] y1=K1⋅x11+K2⋅x21+K3⋅x31+K4⋅x41+K5⋅x51;

[0089] y2=K1⋅x12+K2⋅x22+K3⋅x32+K4⋅x42+K5⋅x52.

[0090] S7. Wear assessment and control strategy adjustment;

[0091] Electronic control unit 3 performs the following judgments and operations:

[0092] If either the wear evaluation index y1 or y2 exceeds the wear limit Y_alarm, the electric drive bridge is considered to be severely worn and needs to be inspected soon.

[0093] If neither the wear evaluation index y1 nor y2 exceeds the limit Y_alarm, the current electric drive bridge is considered to be in good condition and can still operate normally.

[0094] By comparing the difference between wear evaluation indices y1 and y2, a background alert is issued for the electric drive axle with a higher wear evaluation index. Furthermore, for the electric drive axle with a higher wear evaluation index, analysis is performed on various wear factors in terms of operating time, single-axle mileage, torque output data distribution, torque forward / reverse switching frequency, and axle temperature data distribution. For wear factors with significantly higher or more prominent values, the control strategy is adjusted during subsequent vehicle operation to suppress further increases in these wear factors, narrowing the gap with the better electric drive axle in these aspects, protecting the electric drive axle, preventing further wear aggravation, and making the wear of the two electric drive axles more similar and balanced. Specifically, if the wear evaluation index y1 is greater than y2, then the wear of the first electric drive axle 1 is greater than that of the second electric drive axle 2. Comparative analysis reveals that the wear factors of the second electric drive axle in terms of both operating time and output torque are significantly greater than the corresponding wear factors of the first electric drive axle. Therefore, during subsequent vehicle operation, by adjusting the control strategy, adjusting the operating time of the first electric drive axle 1 and the torque output of the second electric drive axle 2, the difference between the wear evaluation indices y1 and y2 can be gradually reduced, making their wear coefficients closer and the wear more balanced. This prevents the first electric drive axle 1 from further increasing its wear or even failing.

[0095] This application collects, monitors, analyzes, and processes the operating parameters during the operation of the electric drive axle to obtain the overall wear evaluation index of each electric drive axle gear. Based on the overall wear evaluation index, it makes a prediction of the degree of wear, provides early warnings and prompts, and adjusts the control strategy to reduce the use of the electric drive axle with more severe wear, balance the lifespan of the two axles, and prevent further excessive damage or even failure under unknown conditions.

[0096] Although the present invention has been described herein with reference to illustrative embodiments, the above embodiments are merely preferred embodiments of the present invention, and the implementation of the present invention is not limited to the above embodiments. It should be understood that those skilled in the art can devise many other modifications and implementations, which will fall within the scope and spirit of the principles disclosed in this application.

Claims

1. A method for estimating and indicating gear wear in a dual-electric drive axle vehicle, characterized in that, include: The operating parameters of at least two electric drive axles of the vehicle are obtained. The operating parameters include: single-axle operating time, single-axle operating mileage, torque output data distribution, torque forward and reverse switching times, and axle temperature data distribution for each electric drive axle; the at least two electric drive axles include a first electric drive axle and a second electric drive axle. By comparing the corresponding single-axle running time, single-axle running mileage, and torque forward / reverse switching times of each electric drive axle, normalization is performed based on the minimum value, and after accumulation within the corresponding set base, the wear factors of single-axle running time, single-axle running mileage, and torque forward / reverse switching times of each electric drive axle are obtained respectively. By segmenting and statistically analyzing the torque output data and bridge temperature data of each electric drive axle, the distribution ratio of each electric drive axle falling into the corresponding segment interval is calculated. The wear factor of the torque output data distribution and bridge temperature data distribution of each electric drive axle is obtained by multiplying and accumulating the distribution ratio with the corresponding segment interval weight ratio. The wear evaluation index of each electric drive bridge is calculated by multiplying the corresponding wear factors by their respective preset weight coefficients and summing the results. The wear evaluation index of each electric drive axle is compared with a preset wear limit threshold, and warning information is generated and / or drive control strategy is adjusted based on the comparison results.

2. The method for estimating and indicating gear wear in a dual-electric drive axle vehicle according to claim 1, characterized in that, The method for obtaining the single-bridge running time includes: The electronic control unit collects the gear position information of the electric drive axles during vehicle operation. By analyzing the gear position information, it obtains the time when each electric drive axle is in neutral or in gear, and eliminates the time when two electric drive axles are running simultaneously, thereby obtaining the single-axle running time of each electric drive axle during the actual operation of the vehicle.

3. The method for estimating and indicating gear wear in a dual-electric drive axle vehicle according to claim 2, characterized in that, The operating parameters also include: vehicle running time; The method for obtaining the vehicle running time is as follows: the electronic control unit collects the vehicle power-on and power-off information, and calculates the vehicle's single running time using the time difference in the vehicle power-on and power-off information; the vehicle running time can be obtained by accumulating the vehicle's single running time, and the corresponding single-bridge running time is obtained within the vehicle running time period to serve as the set base for the single-bridge running time.

4. The method for estimating and indicating gear wear in a dual-electric drive axle vehicle according to claim 3, characterized in that, The method for obtaining the single-bridge running time of each electric drive bridge is as follows: If, during vehicle operation, the first electric drive axle is in gear and the second electric drive axle is in neutral, record the time T. 1_start Record the time T when the first electric drive axle returns to neutral or the second electric drive axle is in gear. 1_end Time T 1_start and time T 1_end The difference between the two is used to calculate the single-bridge running time of the first electric drive bridge. During each vehicle operation, the single-axle operation time of the first electric drive axle is accumulated in real time to obtain the single-axle operation time of the first electric drive axle within the corresponding vehicle operation time. Similarly, the single-axle running time of the second electric drive axle is obtained within the corresponding vehicle running time.

5. The method for estimating and indicating gear wear in a dual-electric drive axle vehicle according to claim 1, characterized in that, The method for obtaining the single-bridge operating mileage includes: The electronic control unit collects information on the power-on / off of the electric drive axle, the mileage, and the vehicle speed during vehicle operation to calculate the total mileage of a single trip. The total mileage of the vehicle can be obtained by accumulating the total mileage of a single trip. The corresponding single axle mileage is acquired within the total mileage period of the vehicle and used as a base for setting the single axle mileage. It also collects the gear position information of the electric drive axle during vehicle operation, and calculates the single-axle running mileage of each electric drive axle within the total mileage cycle of the vehicle using the gear position information and vehicle speed information.

6. The method for estimating and indicating gear wear in a dual-electric drive axle vehicle according to claim 1, characterized in that, The method for obtaining the wear factor of the torque output data distribution includes: The torque output data distribution of each electric drive axle was statistically summarized, and the wear factor of each electric drive axle under the torque output data distribution was obtained. Specifically, the collected torque output data distribution is segmented and statistically analyzed. Several torque segment intervals are obtained by dividing the data into segments with a certain interval. The distribution of all torque output data for each electric drive axle within each torque segment interval is statistically analyzed, and the proportion of torque output data in each torque segment interval relative to the total torque output data distribution is calculated. Simultaneously, weights are assigned to each torque segment interval based on different vehicle models and configurations. The statistically calculated torque distribution proportions and the corresponding weights within each torque segment interval are then multiplied and summed to obtain the wear factor of each electric drive axle in terms of torque distribution.

7. The method for estimating and indicating gear wear in a dual-electric drive axle vehicle according to claim 1, characterized in that, The method for obtaining the wear factor of the bridge temperature data distribution includes: The acquired bridge temperature data for each electric drive axle are summarized and segmented, with a certain temperature interval to obtain several bridge temperature segment intervals. The proportion of bridge temperature data in each segment interval relative to the total number of bridge temperature data is calculated. Weight ratios are assigned to different bridge temperature segment intervals. The statistically calculated proportion of bridge temperature distribution and the corresponding weight ratios of bridge temperature segment intervals are then multiplied and summed to obtain the wear factor of each electric drive axle in the bridge temperature data distribution.

8. The method for estimating and indicating gear wear in a dual-electric drive axle vehicle according to claim 1, characterized in that, The method for obtaining the wear evaluation index of each electric drive axle includes: The proportions of single-axle running time, single-axle running mileage, torque output data distribution, torque forward / reverse switching times, and axle temperature data distribution in the wear of electric drive axles are weighted and assigned, respectively. The operating parameters of each electric drive axle are multiplied by their corresponding weights and then summed to obtain the wear evaluation index of each electric drive axle.

9. The method for estimating and indicating gear wear in a dual-electric drive axle vehicle according to claim 1, characterized in that, The gear wear estimation and indication method also includes: The differences between the wear evaluation indices of each electric drive axle are compared. For electric drive axles with larger wear evaluation index values, a background alert is issued. For electric drive axles with larger wear evaluation indices, various wear factors are analyzed and compared in terms of single axle operating time, single axle operating mileage, torque output data distribution, torque forward / reverse switching times, and axle temperature data distribution. The corresponding wear factors of each electric drive axle are compared. If the comparison results show significant differences, the control strategy is adjusted during subsequent vehicle operation to suppress the continued increase of the corresponding wear factor of that electric drive axle.

10. A gear wear estimation and indication system for a dual-electric drive axle vehicle, characterized in that, include: An electronic control unit that communicates with the first electric drive bridge and the second electric drive bridge respectively; The first and second electric drive axles are installed on the vehicle to drive it. Both the first and second electric drive axles are electric drive axle assemblies that are integrated together by mechanically connecting the drive motor, the transmission mechanism, and the drive axle differential mechanism. The electronic control unit is connected to the vehicle via a bus to collect, process, and analyze data on the operation of the first and second electric drive axles during the actual operation of the vehicle. Finally, it calculates the wear evaluation index and makes early warnings and adjusts the control strategy accordingly, so as to realize the gear wear estimation and prompting method for a dual electric drive axle vehicle as described in any one of claims 1-9.

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