Extreme variable working conditions were proposed, and the thermal-structural coupling analysis of the rotor was conducted with an electric drive system as the research object to make the structural strength of the rotor of a vehicle motor satisfy all operating conditions as much as possible. The overall temperature rise characteristics of the electric drive system were obtained through simulation, and the accuracy of simulation results was verified through testing. On the basis of material tests at different temperatures, the interference fit, and the rotating centrifugal force as loads, a comparative analysis of the strength of the rotor was conducted for variable working conditions and single working conditions. Results show that the stress value in the variable working condition is 74.9 MPa greater than that in the single working condition. This finding indicates that the analysis of rotor stresses under variable working conditions has more engineering importance.

提出了极端可变工况，以电驱动系统为研究对象，进行转子的热-结构耦合分析，使汽车电机转子的结构强度尽可能满足所有工况。通过仿真获得了电驱动系统的整体温升特性，并通过测试验证了仿真结果的准确性。在不同温度、过盈配合和旋转离心力作为载荷的材料试验的基础上，对可变工况和单一工况下的转子强度进行了对比分析。结果表明，可变工况下的应力值比单一工况下的应力值大74.9 MPa。