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Test based Optimization of
NVH for hybrid and electric
vehiclesGert Sablon, Director Business Development, STS TEST
Realize innovation.Unrestricted © Siemens AG 2017
Unrestricted © Siemens AG 2017
Page 2 Siemens PLM Software
Optimizing NVH performance when fuel economy rules the world
Main drivers in Powertrain Development
Increase fuel efficiency Reduce emissionsReduce NOX, CO2
BUT keep performanceHP, Torque, Driving Pleasure,…
Unrestricted © Siemens AG 2017
Page 3 Siemens PLM Software
Main drivers in Powertrain Development…
…Resulting in technology and innovation boost
Use of smart electronics & controls Complete new powertrains
Adapt fuel injection method / timing
Cylinder de-activation
Complex CVT transmission
…
Fully electric
Hybrid
Fuel cells
…
Unrestricted © Siemens AG 2017
Page 4 Siemens PLM Software
Main drivers in Powertrain Development…
…Leading to new challenges for the NVH engineer
How to handle new noise
sources?How to keep control on NVH?
Avoid reduced NVH while improving
performance and fuel efficiency?
Electric motor noise
Battery cooling noise
Power electronics noise
…
While keeping/increasing
development efficiency?
How to reduce development time?
How to design-right-first time?
Unrestricted © Siemens AG 2017
Page 5 Siemens PLM Software
From Combustion engine towards electric drive
So what is the difference?
2600.000.00 Hz
mic (CH1)
3500.00
900.00
rpm
Tacho1 (
T1)
80.00
-20.00
dB
(A)
Pa
AutoPower mic (A) WF 126 [981.36-3466.8 rpm]
Motor order
ICE driven Electric driven (more high frequency content)
Resonance
Motor orderResonance
Off-zero harmonics. Origin?
Is the Sound Quality better for EV?
Unrestricted © Siemens AG 2017
Page 6 Siemens PLM Software
Ancill. Noise EM/TM
Wind Noise
Inverter
Hybrid - Electrical Vehicle
Frequency ranges of interest
[Km/h]
[Hz]200 1000 8000
[Km/h]
[Hz]200
Engine – Structure B.
1000 8000
Road Noise – Tire Noise
Wind Noise
2000
Road Noise – Tire Noise
Engine – Air B.
60
100
40
100
2000
400
400
ICE
EV
Unrestricted © Siemens AG 2017
Page 7 Siemens PLM Software
Shift in NVH development for electric vehicles
Unrestricted © Siemens AG 2017
Page 8 Siemens PLM Software
Ancill. Noise EM/TM
Wind Noise
Inverter
Hybrid - Electrical Vehicle
Frequency ranges of interest
[Km/h]
[Hz]200 1000 8000
[Km/h]
[Hz]200
Engine – Structure B.
1000 8000
Road Noise – Tire Noise
Wind Noise
2000
Road Noise – Tire Noise
Engine – Air B.
60
100
40
100
2000
400
400
ICE
EV
Unrestricted © Siemens AG 2017
Page 9 Siemens PLM Software
But even new ICE are impacting NVH testing
How 4 separate measurement systems have become one system
Acquisition System 1
NVH Analysis
Acquisition System 2
Torsional Vibration Analysis
Acquisition System 3
Online Angle Domain /
Combustion Analysis
Acquisition System 4
ECU Communication
CCP / XCP
How 4 separate systems
have become 1 system for
the NVH engineer
Unrestricted © Siemens AG 2017
Page 10 Siemens PLM Software
Balancing the NVH against other performance parameters
Past Present
RPM
To
rqu
e
Engine Map = Noise in function of RPM and Torque
No
ise
Performance
Torsion
Unrestricted © Siemens AG 2017
Page 11 Siemens PLM Software
Ancill. Noise EM/TM
Wind Noise
Inverter
Hybrid - Electrical Vehicle
Frequency ranges of interest
[Km/h]
[Hz]200 1000 8000
[Km/h]
[Hz]200
Engine – Structure B.
1000 8000
Road Noise – Tire Noise
Wind Noise
2000
Road Noise – Tire Noise
Engine – Air B.
60
100
40
100
2000
400
400
ICE
EV
Unrestricted © Siemens AG 2017
Page 12 Siemens PLM Software
Full support for the Sound Quality Engineering
Noise Signature Design of Electric Powertrain
Operation Condition Test
Field validation with SCADAS XS &
LMS 3D binaural headset
Problem identification
Sound Diagnosis
Inverter control optimization
Sound QualityAnalysis &
Metrics
Unrestricted © Siemens AG 2017
Page 13 Siemens PLM Software
Noise Signature Design of Electric Powertrain
Measured Sound
~8000Hz Strong tonal component
~4000Hz Large number of closely spaced
tonal with the same amplitude =>
Modulation
Sound recording & field validation Sound analysis & features identification
Sound Design: AMESim for control strategy modification + Sound Quality metrics for validation
Strategy 1: get rid of the tonal
components with a random control
Strategy 2: Shift up in frequency the tonal
components, to less audible frequencies
Prominence ratio
Loudness
Sharpness
Prominence ratio
Loudness
Sharpness
Still sounds annoying Target sound
Unrestricted © Siemens AG 2017
Page 14 Siemens PLM Software
Complexity of Hybrid powertrains
Multiple rotating shafts
Unrestricted © Siemens AG 2017
Page 15 Siemens PLM Software
Gear whine becomes much more apparent
Source of gear whine comes internal excitation within
the gearbox (e.g. stiffness variations, geometric
excitation, … ) = microscopic phenomena at the level of
teeth design and teeth accuracy
Effects of modifications to the gearbox can be analyzed
on test benches with SCM-RV4 module and incremental
encoders (transmission error measurement)
Gear transmission error test rig in Leuven
Unrestricted © Siemens AG 2017
Page 16 Siemens PLM Software
Ancill. Noise EM/TM
Wind Noise
Inverter
Hybrid - Electrical Vehicle
Frequency ranges of interest
[Km/h]
[Hz]200 1000 8000
[Km/h]
[Hz]200
Engine – Structure B.
1000 8000
Road Noise – Tire Noise
Wind Noise
2000
Road Noise – Tire Noise
Engine – Air B.
60
100
40
100
2000
400
400
ICE
EV
Unrestricted © Siemens AG 2017
Page 17 Siemens PLM Software
Road noise Reduction
TPA
Challenge/objectives
• Reduce road noise in passenger compartment
• Find smart and effective solutions that do not reduce
handling performance or add too much weight or cost
Solution
• Support of all techniques for force identification
• Use of strain AND acceleration for road noise TPA
Benefits
• Gain insight into vehicle road noise behavior via the
source-transfer-receiver methodology
• Allow separation of airborne and structure-borne
contributions as well as detailed front and rear
axle/suspension contributions
• Map improvement potential by verifying modifications
Unrestricted © Siemens AG 2017
Page 18 Siemens PLM Software
More requirement for Transient TPA
Addressing root cause analysis of drivability
…Transfer Path Analysis (TPA)
Insights in contribution
to NVH Comfort
…in “full NVH Context”
To link transient loads
to Dynamic Interface Forces…
Transient Load identification
Strain gage technology
Low frequency
Tip-inStrain responses (right) during Tip-in
Typical Tip-in / Tip-out
ResponseTransient torque
oscillations in the driveline
Amplified by P/T,
suspension and body
modes
Resulting seat and
steering-wheel vibrations
Time-domain Transfer Path Analysis for Transient Phenomena Applied to Tip-in/Tip-out (Shock & Jerk)
H. Shiozaki, Y.Iwanaga, MMC, T. Geluk ,F. Daenen, J, Van Herbruggen, LMS, SAE 2012-01-1545
Unrestricted © Siemens AG 2017
Page 19 Siemens PLM Software
Ancill. Noise EM/TM
Wind Noise
Inverter
Hybrid - Electrical Vehicle
Frequency ranges of interest
[Km/h]
[Hz]200 1000 8000
[Km/h]
[Hz]200
Engine – Structure B.
1000 8000
Road Noise – Tire Noise
Wind Noise
2000
Road Noise – Tire Noise
Engine – Air B.
60
100
40
100
2000
400
400
ICE
EV
Unrestricted © Siemens AG 2017
Page 20 Siemens PLM Software
Aero-Acoustic TestingTrend to capture as much as possible during expensive wind tunnel tests
Unrestricted © Siemens AG 2017
Page 21 Siemens PLM Software
Aero-Acoustic TestingIntegrated solution for aero-acoustic testing - Combine different technologies
Unrestricted © Siemens AG 2017
Page 22 Siemens PLM Software
Aero-Acoustic TestingValue of fully integrated solution
Where does an external source leak into the
vehicle?
Large Array from Daimler AG presentation by Ralph Buckisch, 10th
FKFSconference, September 2015
Overall 3DCam results
Top Array Result
3DCam results related to source
selected outside
Unrestricted © Siemens AG 2017
Page 23 Siemens PLM Software
Ancill. Noise EM/TM
Wind Noise
Inverter
Hybrid - Electrical Vehicle
Frequency ranges of interest
[Km/h]
[Hz]200 1000 8000
[Km/h]
[Hz]200
Engine – Structure B.
1000 8000
Road Noise – Tire Noise
Wind Noise
2000
Road Noise – Tire Noise
Engine – Air B.
60
100
40
100
2000
400
400
ICE
EV
Unrestricted © Siemens AG 2017
Page 24 Siemens PLM Software
From NVH point of view, HVAC systems are very complex
Multiple potential noise & vibration sources
Compressor, Condenser, Tubing, HVAC module with blower & motor, Ducts & vents
Multiple potential transfer paths & mechanisms
Unrestricted © Siemens AG 2017
Page 25 Siemens PLM Software
Validating modifications to battery cooling unit design without
need for full vehicle validation
UNIT LEVELVEHICLE LEVEL
Modification at unit
projected to in-vehicle
SOURCE
Inlet & Outlet Ducts
located in cabin interior
Transfer
between sources and
cabin microphones
RECEIVER
Cabin Sound Pressure
Level