What innovative applications do aluminum die-casting gear reducers have in new energy vehicles?

The innovative application of aluminum die-casting gear reducers in new energy vehicles is mainly reflected in the following aspects

1. Lightweight materials and structural innovation

Aluminum alloy die-casting housing: Aluminum alloy is used to replace traditional steel to manufacture reducer housing, which significantly reduces weight.

High-silicon aluminum alloy material: By optimizing the alloy composition (such as adding Cu elements) and combining high vacuum die-casting technology, high-silicon aluminum alloys (such as ADC12, A380, etc.) are developed to significantly improve the hardness and wear resistance of gears and solve the problem of insufficient hardness of traditional aluminum alloys. Micro-arc oxidation technology further enhances the surface performance of gears and extends service life.

2. Integrated integrated design

Motor and reducer integrated housing: The motor housing and reducer housing are integrated by die-casting to reduce the connection parts and assembly complexity, and improve the structural rigidity and sealing. For example, the battery pack housing and electric drive housing of hybrid vehicles have adopted this design.

Large-scale integrated die-casting technology: The company integrates the lower body parts (such as battery trays, front and rear bottom plates) into a single aluminum die-casting through integrated die-casting technology, which may be extended to reducer-related structural parts in the future. This technology can reduce the number of parts by more than 30%, reduce weight by 10% and increase endurance by 14%.

3. Optimization of reducer type and transmission efficiency

Planetary gear and two-stage transmission structure: The compact planetary gear design is adopted to improve the load-bearing capacity and transmission efficiency, and meet the needs of new energy vehicles for high torque output.
Gear precision improvement: The gear precision of the reducer of new energy vehicles is improved from 6-7 levels of traditional fuel vehicles to 4-5 levels. High-precision processing (such as CNC precision processing) is used to reduce noise and extend the life of the motor