An Investigation into the Nonlinear Dynamic Behavior of High-Speed Helical Gears for Electric Vehicle Reducers

The drive system of pure electric vehicles is characterized by high transmission efficiency and a rapid torque response, with the centralized drive configuration being the most commonly adopted. To improve the dynamic performance and reliability of such systems, this study investigates the nonlinear dynamic characteristics of high-speed helical gear reducers used in electric vehicles. A coupled bending–torsional–shaft dynamic model is established, in which the time-varying mesh stiffness is calculated using an improved potential energy method. The system responses under varying mesh errors, backlash, and damping ratios are obtained through numerical integration via the variable-step Runge–Kutta method. The results demonstrate that at high input speeds, the helical gear system exhibits complex nonlinear behavior. Small backlash and minor manufacturing errors lead to stable periodic or quasi-periodic motion, whereas increasing these parameters induces dynamic instability. Moreover, enhancing the mesh damping ratio effectively suppresses chaotic responses and improves overall system stability.