Abstract: To address the processability and acoustic quality deficiencies of the intermediate gear set in electric axle reducers for new energy micro-commercial vehicles, this paper proposes an integrated housing structure. This structure integrates the intermediate gear set with the housing to form a modular assembly solution, thereby improving the machining and assembly accuracy of the gear pair and enhancing the noise, vibration, and harshness (NVH) performance of the reducer. A finite element dynamic model of the reducer assembly is established, modal and harmonic response analyses are conducted, and real-vehicle road tests are performed for validation. The results show that under typical operating conditions (vehicle speed of approximately 75 km/h), compared with the traditional split structure, the peak noise of the optimized second-stage gear at the 10.98th order is reduced by 7.36 dB, with a significant overall reduction in reducer noise. The study demonstrates that the integrated housing structure effectively improves the manufacturing and assembly consistency of the reducer while reducing vibration and noise, providing a basis for the optimal design of electric drive axle reducers for new energy commercial vehicles.

Key words: noise control; integrated electric axle; reducer; modular assembly; NVH performance optimization

摘要： 针对新能源微小型商用车传动电动桥减速器中间齿轮组工艺性与声学品质不足的问题， 文章提出一种整体式壳体结构。该结构将中间齿轮组与壳体集成设计，形成模块化整体装配 方案，以提高齿轮副加工装配精度，改善减速器噪声、振动和声振粗糙度（NVH）性能。建 立减速器总成有限元动力学模型，开展模态与谐响应分析，并通过实车道路试验进行验证。 结果表明，在典型工况下（车速约为 75 km/h），与传统分体式结构相比，优化后二级齿轮 10.98 阶啮合噪声峰值降低 7.36 dB，整机噪声明显下降。研究表明，整体式壳体结构在提升减速器 制造装配一致性及降低振动噪声方面具有较好效果，可为新能源商用车电驱动桥减速器优化 设计提供依据。

关键词: 噪声控制；整体式电动桥；减速器；模块化装配；NVH 性能优化