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1 Automotive Testing Expo 2010 – ECO-vehicle
NVH Challenges in context of ECO vehicles Automotive Testing Expo 2010
2 Automotive Testing Expo 2010 – ECO-vehicle
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
3 Automotive Testing Expo 2010 – ECO-vehicle
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
4 Automotive Testing Expo 2010 – ECO-vehicle
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
5 Automotive Testing Expo 2010 – ECO-vehicle
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
6 Automotive Testing Expo 2010 – ECO-vehicle
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
7 Automotive Testing Expo 2010 – ECO-vehicle
Electric VehicleNVH Impact
electric vehicles
range-extender B/FEV
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, …)
Vehicle Layout
Different weight distribution
Different powertrain component structural stiffness
Subframes
Important changes to known configurations
Accessories
Less masking (HVAC, Fan, …)
8 Automotive Testing Expo 2010 – ECO-vehicle
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
9 Automotive Testing Expo 2010 – ECO-vehicle
3 levels
Subsystems & Auxiliaries
Performance optimisation
Powertrain & Transmission transients
Powertrain & Transmission choices
Vehicle Integration
Vehicle layout modificationsPowertrain integrationNew target setting
eco-ICE electric vehicleshybrid
mild full plug-inmicro range-extender B/FEV
LMS Scadas Mobile LMS Test.Lab
10 Automotive Testing Expo 2010 – ECO-vehicle
Subsystems & AuxiliariesVariable valve train testing
Subsystems & Auxiliaries
Performance optimisation – Variable valvetrain testing
Powertrain & Transmission transients
Powertrain & Transmission choices
Vehicle Integration
Vehicle layout modificationsPowertrain integrationNew target setting
eco-ICE electric vehicleshybrid
mild full plug-inmicro range-extender B/FEV
11 Automotive Testing Expo 2010 – ECO-vehicle
ECO-ICEValidation of performance optimisation
Valvetrain Dynamic
Performance Testing
SCM + TL Test bench
Angle Domain Analysis
12 Automotive Testing Expo 2010 – ECO-vehicle
ECO-ICEValidation of performance optimisation
Variable Valvetrain
Switching Testing
SCM + TL Test bench
Source Hitachi Automotive
Systems
ECU
Time
Angle
ECU
Rpm
Oil pressure
Temperature
Time Domain Analysis
13 Automotive Testing Expo 2010 – ECO-vehicle
ECO-ICEValidation of performance optimisation
� 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
14 Automotive Testing Expo 2010 – ECO-vehicle
Vehicle integrationVehicle layout
Subsystems & Auxiliaries
Performance validation
Powertrain & Transmission transients
Powertrain & Transmission choices
Vehicle Integration
Vehicle layout modificationsPowertrain integrationNew target setting
eco-ICE electric vehicleshybrid
mild full plug-inmicro range-extender B/FEV
15 Automotive Testing Expo 2010 – ECO-vehicle
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
16 Automotive Testing Expo 2010 – ECO-vehicle
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
F Order 30.00 microfoon
300.00 2900.00Hz
0.00
12.00
Am
plit
ude
Pa
0.00
1.00
Am
plit
ude
F Order 18.00 microfoon
F Order 30.00 microfoon
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
17 Automotive Testing Expo 2010 – ECO-vehicle
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
18 Automotive Testing Expo 2010 – ECO-vehicle
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
19 Automotive Testing Expo 2010 – ECO-vehicle
Summary
Subsystems & Auxiliaries
Performance validation
Powertrain & Transmission transients
Powertrain & Transmission choices
Vehicle Integration
Vehicle layout modificationsPowertrain integrationNew target setting
LMS Scadas Mobile LMS Test.Lab
eco-ICE electric vehicleshybrid
mild full plug-inmicro range-extender B/FEV
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