Measuring the pressure distribution of the wheel-side housing end surface of an electric drive axle using a flexible thin-film sensor

Abstract Sealing pressure distribution data can be obtained through finite element simulation calculations, which are essential for reliable product designs. An accurate, statically measured sealing pressure data distribution must be developed to calibrate the simulation model. In this study, a measurement approach for the pressure distribution in the wheel-side housing of an electric drive axle is proposed, based on a flexible thin-film sensor. A fitting algorithm is implemented to obtain the pressure and contact surface bandwidth of the wheel-side housing end surface for up to 200 measurement units, spanning the circumferential direction under a torque load range of 14–70 Nm. The comparisons between the simulation and experimental results indicate an excellent correlation, and the simulation model is comprehensively verified. This study demonstrates the practicality of the method—via both simulations and experiments—for determining the pressure distribution on the wheel-side housing end surface of an electric drive axle.