Design principle of active load spectrum for shafting components in wheel hub reducer of electric vehicle

Design principle of active load spectrum is proposed for the lightweight design of shafting components. The characteristics of fatigue and the strengthening effect of low-amplitude load are conducted according to the material properties of the shafting components. The stress-life curve and three-dimensional surface of low-amplitude strengthening load are established for the life calculation of shafting components. Fast calculation method of working stress for variable size of shafting components is obtained considering the road cycle in Shanghai, the load spectrum is extrapolated, the torque working condition which is equivalent to load spectrum of 3000 km is achieved, and the fatigue damage and strengthening proportion of working stress spectrum of shafting components are adjusted, finally the minimum size of shafting components is designed to meet the requirement of service life. The design principle of active load spectrum can provide a new idea for the lightweight design of automotive components.