NVH Challenges in context of ECO vehicles Automotive Testing Expo Automotive Testing Expo 2010 ECO-vehicle
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1 NVH Challenges in context of ECO vehicles Automotive Testing Expo Automotive Testing Expo 2010 ECO-vehicle
2 ECOLOGICAL Vehicle Engineering > 170 Hybrid and Electrical vehicles Government support EU 2012 directive Government regulations Buyers preference MPG L/100 Km US 2016 directive ~ Japan 2010 directive eco-ice hybrid electric vehicles micro mild full plug-in range-extender B/FEV 2 Automotive Testing Expo 2010 ECO-vehicle
3 ECO-Internal Combustion Engine NVH 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 3 Automotive Testing Expo 2010 ECO-vehicle
4 ECO-Internal Combustion Engine NVH Impact (Variable) Valve Train Transients Valve bounce, Valve impact noise Source Hitachi Automotive Systems Variable Compression Ratio Increased unbalance Direct Injection Injector related impulsive noise Pump related noise Exhaust Gas Recirculation Changed exhaust modes eco-ice 4 Automotive Testing Expo 2010 ECO-vehicle
5 Micro-Mild Hybrid NVH Impact Engine Start-Stop No idling noise no masking of ancillaries e.g. HVAC noise Vibration transient at engine re-start keyon-keyoff issues micro mild hybrid 5 Automotive Testing Expo 2010 ECO-vehicle
6 Full and Plug-In Hybrid NVH Impact Parallel Series (fuel cell) Power Split Starter-Alternator Vehicle Layout Different weight distribution 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 hybrid full plug-in 6 Automotive Testing Expo 2010 ECO-vehicle
7 Electric Vehicle NVH Impact Vehicle Layout Different weight distribution 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, ) Subframes Important changes to known configurations Accessories Less masking (HVAC, Fan, ) electric vehicles range-extender B/FEV 7 Automotive Testing Expo 2010 ECO-vehicle
8 Electric Vehicle NVH Impact 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 electric vehicles range-extender B/FEV 8 Automotive Testing Expo 2010 ECO-vehicle
9 3 levels Subsystems & Auxiliaries Performance optimisation Powertrain & Transmission choices Powertrain & Transmission transients LMS Scadas Mobile LMS Test.Lab Vehicle Integration Vehicle layout modifications Powertrain integration New target setting eco-ice hybrid electric vehicles micro mild full plug-in range-extender B/FEV 9 Automotive Testing Expo 2010 ECO-vehicle
10 Subsystems & Auxiliaries Variable valve train testing Subsystems & Auxiliaries Performance optimisation Variable valvetrain testing Powertrain & Transmission choices Powertrain & Transmission transients Vehicle Integration Vehicle layout modifications Powertrain integration New target setting eco-ice hybrid electric vehicles micro mild full plug-in range-extender B/FEV 10 Automotive Testing Expo 2010 ECO-vehicle
11 ECO-ICE Validation of performance optimisation Valvetrain Dynamic Performance Testing SCM + TL Test bench Angle Domain Analysis 11 Automotive Testing Expo 2010 ECO-vehicle
12 ECO-ICE Validation of performance optimisation Angle Variable Valvetrain Switching Testing ECU Time ECU Source Hitachi Automotive Systems SCM + TL Test bench 12 Automotive Testing Expo 2010 ECO-vehicle Time Domain Analysis Rpm Oil pressure Temperature
13 ECO-ICE Validation of performance optimisation LMS Value Proposition 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) TCU HCU ECU N 6 N 7 Time Data Analysis Frequency analysis Angle Domain Analysis Torsional Vibration Analysis And much more 13 Automotive Testing Expo 2010 ECO-vehicle
14 Vehicle integration Vehicle layout Subsystems & Auxiliaries Performance validation Powertrain & Transmission choices Powertrain & Transmission transients Vehicle Integration Vehicle layout modifications Powertrain integration New target setting eco-ice hybrid electric vehicles micro mild full plug-in range-extender B/FEV 14 Automotive Testing Expo 2010 ECO-vehicle
15 Electrical Vehicle Vehicle Layout [Km/h] Wind Noise ICE Road Noise Tire Noise Engine Structure born Engine Airborne [Km/h] [Hz] EV Road Noise Electric Motor Gearbox Tire Noise Wind Noise [Hz] 15 Automotive Testing Expo 2010 ECO-vehicle
16 Electrical Vehicle Road Noise & Vehicle Layout accel 2nd order excitation Strong Tonal Excitation - Little Unbalance Air Borne Structure Borne SPL SPL accel accel spectrum shape discrete frequencies 2nd order excitation harmonic pattern dyn stiffness transfer function chassis dynamics Isolation Transfer Vehicle Interior Noise db/db db/n mount characteristics Transmission Loss Σ Body Noise TF db SPL SPL Accel level & linearity discrete frequencies spectrum shape harmonic pattern F F Order microfoon Order microfoon 1.00 T1 rpm db Pa db Pa Amplitude Hz microfoon (CH1) rpm F F Order microfoon F Order microfoon 1/3 Octave Hz microfoon 1.00 Pa Amplitude Amplitude db Pa Amplitude Hz rpm T Automotive Testing Expo 2010 ECO-vehicle
17 Electrical Vehicle Road Noise & Vehicle Layout [Km/h] EV Road Noise Electric Motor Gearbox Tire Noise Wind Noise [Hz] Motor Noise TPA OPAX Energetic based TPA Time domain TPA Road Noise Multi-reference TPA Energetic based Multi-reference TPA Wind Noise PCA - ASQ 3D-Acoustic Camera 17 Automotive Testing Expo 2010 ECO-vehicle
18 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 18 Automotive Testing Expo 2010 ECO-vehicle
19 Summary Subsystems & Auxiliaries Performance validation Powertrain & Transmission choices Powertrain & Transmission transients LMS Scadas Mobile LMS Test.Lab Vehicle Integration Vehicle layout modifications Powertrain integration New target setting eco-ice hybrid electric vehicles micro mild full plug-in range-extender B/FEV 19 Automotive Testing Expo 2010 ECO-vehicle
20 NVH Challenges in context of ECO vehicles Automotive Testing Expo Automotive Testing Expo 2010 ECO-vehicle
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