NVH Challenges in context of ECO vehicles ATE · PDF file1 Automotive Testing Expo 2010 – ECO-vehicle NVH Challenges in context of ECO vehicles Automotive Testing Expo 2010

1 Automotive Testing Expo 2010 – ECO-vehicle

NVH Challenges in context of ECO vehicles Automotive Testing Expo 2010


ECOLOGICAL Vehicle Engineering> 170 Hybrid and Electrical vehicles

Government regulations

Buyers preference

Government support

0

10

20

30

40

50

60

70

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

L/100 Km

MP

G

EU 2012directive

US 2016

directive~

Japan 2010 directive

eco-ICE electric vehicleshybrid

mild full plug-inmicro range-extender B/FEV


ECO-Internal Combustion EngineNVH Impact

Downsizing

Increased unbalance - Higher dynamic motion causing more vibrations at mounts

Increased torsional vibrations

Cylinder de-activation

Increased transients - driveline torsional vibrations

Increase risk for crankshaft or engine bending mode excitation

Homogeneous Charge Compression Ignition

High combustion noise - Impulsive combustion noise

Increased Peak-to-Mean torque – more torsional vibrations

Optimized Turbo-charging

Series-Parallel configuration may lead to modulation

eco-ICE


ECO-Internal Combustion EngineNVH Impact

(Variable) Valve Train

Transients

Valve bounce, Valve impact noise

Variable Compression Ratio

Increased unbalance

Source Hitachi Automotive Systems

Direct Injection

Injector related impulsive noise

Pump related noise

Exhaust Gas Recirculation

Changed exhaust modes

eco-ICE


Micro-Mild HybridNVH Impact

hybrid

micro

Engine Start-Stop

No idling noise – no masking of ancillaries e.g. HVAC noise

Vibration transient at engine re-start – keyon-keyoff issues

mild


Full and Plug-In HybridNVH Impact

hybrid

Vehicle Layout

Different weight distribution

full plug-in

Multiple powering units

Transient/non-stationary N&V, even for stationary conditions

Gearbox

Whining noise, no longer masked by ICE

Roadnoise – Windnoise

Less masking by EM

Changed tire design – Increased tire pressure

Electric motor & power electronics noise

Starter-AlternatorSeries (fuel cell)

Power SplitParallel


Electric VehicleNVH Impact

electric vehicles

range-extender B/FEV

Vehicle Layout


Different powertrain component structural stiffness

Body

Reduction of body weight – more composites

Different connection points

Transparency for Mid-High frequency noise

Interior sound design (Active noise control, …)

Vehicle Layout


Different powertrain component structural stiffness

Subframes

Important changes to known configurations

Accessories

Less masking (HVAC, Fan, …)


Electric VehicleNVH Impact

electric vehicles

range-extender B/FEV

Electrical Motor & Power electronics

High torsional load at low rpm

Electro-Magnetic excitation of motor-housing

Operation as motor or generator

Very well balanced

Off-zero modulation (power electronics)

Batteries

Battery cooling NVH

Additional accessories (pump)

Road noise – Wind noise

See Hybrid

Pedestrian safety

Warning sounds


3 levels

Subsystems & Auxiliaries

Performance optimisation

Powertrain & Transmission transients

Powertrain & Transmission choices

Vehicle Integration

Vehicle layout modificationsPowertrain integrationNew target setting



LMS Scadas Mobile LMS Test.Lab


Subsystems & AuxiliariesVariable valve train testing


Performance optimisation – Variable valvetrain testing



Vehicle Integration





ECO-ICEValidation of performance optimisation

Valvetrain Dynamic

Performance Testing

SCM + TL Test bench

Angle Domain Analysis



Variable Valvetrain

Switching Testing

SCM + TL Test bench

Source Hitachi Automotive

Systems

ECU

Time

Angle

ECU

Rpm

Oil pressure

Temperature

Time Domain Analysis



� Accuracy

• Sampling rates & angular resolution

• Synchronized acquisition of linear & rotational vibrations, ECU and slow parameters

� Integrated solution - Convenience

• Single box for all quantities, analog-digital or IE tacho devices, dynamic and static, analog or digital (ECU), NVH and other

• Single Multi-domain solution

• Single provider for Hardware and Software

� Process automation - Productivity

• Automatic data clean-up

• User-programmable metrics

• Minimal user-interaction

• Test scheduling (test bench integration)

Time Data Analysis

Frequency analysis

Angle Domain Analysis

Torsional Vibration Analysis

And much more

LMS Value Proposition

N6

N7

HCU

TCU ECU


Vehicle integrationVehicle layout


Performance validation



Vehicle Integration





Electrical VehicleVehicle Layout

[Km/h]

[Hz]200 1000 8000

[Km/h]

[Hz]200

Engine – Structure born

1000 8000

Road Noise

Wind Noise

2000

Road Noise

Wind Noise

Tire Noise

Engine – Airborne

ICE60

100

40

100

Electric Motor

Gearbox

2000

EV

400

400

Tire Noise


Electrical VehicleRoad Noise & Vehicle Layout

Air B

orn

eS

tructu

re B

orn

e

Isolation Transfer VehicleInterior Noise

Σ

2nd order

excitation

accel

spectrum

shape

SP

L

discrete

frequencies

SP

L

2nd order

excitation

accel

harmonic

pattern

accel

mount

character-

istics

dyn

stiffn

ess Body

Noise TF

dB

/N

level &

linearity

dB

discrete

frequencies

SP

L

spectrum

shape

SP

L

harmonic

pattern

Accelchassis

dynamics

tra

nsfe

rfu

nction

Trans-

mission

LossdB

/dB

0.00 26000.00Hz

microfoon (CH1)

1000.00

5800.00

rpm

T1

10.00

110.00

dB Pa

18.00

30.00

12250.00

1000.00 5800.00rpm

60.00

130.00

dBPa

0.00

1.00

Am

plit

ud

e

F Order 18.00 microfoon


300.00 2900.00Hz

0.00

12.00

Am

plit

ude

Pa

0.00

1.00

Am

plit

ude



1000.00 5800.00rpm

T1

50.00

100.00

dBPa

0.00

1.00

Am

plit

ude

F 1/3 Octave 12500.00 Hz microfoon

Strong

Tonal

Excitation

-

Little

Unbalance


Electrical VehicleRoad Noise & Vehicle Layout

Motor Noise Energetic based

TPA

Road Noise Multi-reference TPA – Energetic based Multi-reference TPA

Wind Noise

Time domain

TPA

TPA

3D-Acoustic CameraPCA - ASQ

[Km/h]

[Hz]200 1000 8000

Road Noise

Wind Noise

40

100

Electric Motor

Gearbox

2000

EV

400

Tire Noise

OPAX


Electrical Vehicle - Road Noise & Vehicle Layout 3D Acoustic Camera

� One shot sound sources localization in complex

3D sound field

� Geometry scanning: exact geometry can be

automatically scanned.

� Clear understandable geometry, with picture

superimposed, based results

� One solution from low to mid frequency

Import or scan geometry Photo realistic Interactive analysis Animated reporting


Summary


Performance validation



Vehicle Integration


LMS Scadas Mobile LMS Test.Lab




NVH Challenges in context of ECO vehicles Automotive Testing Expo 2010

Documents

NVH Challenges in context of ECO vehicles ATE · PDF file1 Automotive Testing Expo 2010 – ECO-vehicle NVH Challenges in context of ECO vehicles Automotive Testing Expo 2010