Automotive NVH Recent Trends

Automotive NVH Recent Trends

Lightweight materials (crankshaft, intake manifold, exhaust manifold, pistons, connecting rod, carpets, dash insulators, trunk trim) Manufacturing methods Combination of experimental and analytical methods for faster/accurate NVH analysis Acoustic Camera Acoustic Holography Electric Powersteering Pump Advanced Isolation (Hydromounts, Active Control of Mounts) Internal Crankshaft Damper Active Noise Control Active Pulse Cancellation Hybrid Vehicles and NVH

Bio Fabrics for Car Interiors

Honda has developed bio fabrics for car interiors
TOKYO, Japan, May 25, 2006 Honda Motor Co., Ltd., announced it has succeeded in developing bio-fabric, a plant-based fabric with excellent durability and resistance to sunlight, for use as a surface material in automobile interiors. Bio-fabric offers the benefit of offsetting CO2 emissions produced during incineration in the disposal stage with CO2 absorption that occurs during the growth stage of the plants that are used as raw materials. Despite this benefit, plant-based fabric has not been used commercially for automobile interiors due to concerns about limited durability and aesthetic issues.

http://world.honda.com/news/2006/c060525BioFabric/ http://www.plastemart.com/upload/Literature/Bio-fabric-based-PLA-automotive-interiors.asp
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Lightweight Acoustic Materials for Vehicles

The striped panel is lighter, more flexible and has higher STL compared to a reference panel, as shown above. http://akseli.tekes.fi/opencms/opencms/OhjelmaPortaali/ohjelmat/MASINA/fi/Dokumen ttiarkisto/Viestinta_ja_aktivointi/Seminaarit/Materiaalitekniikka07/Tanttari.pdf
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Lightweight Acoustic Materials for Vehicles

http://akseli.tekes.fi/opencms/opencms/OhjelmaPortaali/ohjelmat/MASINA/fi/Dokumen ttiarkisto/Viestinta_ja_aktivointi/Seminaarit/Materiaalitekniikka07/Tanttari.pdf

Lightweight Acoustic Materials for Aerospace

Durette Durette Felt is a Nomex batting that is
used in duct lining, pipe lagging, and barrier lay-up applications. Durette is Nomex fiber that is stitched into a "blanket" type batting material. Durette can be conformed to fit in and around many desired applications.

Pictures from International Space Station with Acoustic Materials and Noise & Vibration Isolation

Solimide Foam SOLIMIDE foam is a

lightweight, open-celled, insulation foam that is designed for thermal and acoustic insulation. Usually yellow in color and will easily particulate when brushed or manipulated.

Bisco HT-200 Barium Impregnated Silicon

Oxide (BISCO) HT-200 is a mass barrier that is used to block sound waves. BISCO HT-200 is provided in various densities and is generally used to target lower frequencies. BISCO HT-200 can be used in conjunction with foams to achieve optimal performance. Damping foil composite is designed to reduce resonance vibration in thin sheet metal. It is constructed from lightweight aluminum bonded to a viscoelastic and pressure sensitive backing.

http://hefd.jsc.nasa.gov/acousticsnoise.htm

Acoustic Camera Passby Noise Measurement

Acoustic Camera Giant Excavator Noise Analysis

Acoustic Camera Engine Door Leakage

Electric Power Steering

Electric Power Steering (EPS) provides precise steering of a vehicle with better NVH performance.

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Crankshaft Dual Mode Damper

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Powerplant Mount Design Curves

The dynamic rate curves describe the stiffness characteristics of a powerplant across the frequency range under specified preloads and/or displacements. They are used to design the type of mount, size, shape, orientation, and elastomeric properties.

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Powerplant Mounts

Conventional Angled Mount

Switchable Hydro Mount

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Powerplant Mounts

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Powerplant Mounts
Powerplant Mount Stiffness Guidelines

Powerplant Mount Damping Guidelines

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Active Control of Mounts

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Internal Crankshaft Damper

The natural frequency of the crankshaft is excited during engine operation

due to the combustion and inertial forces. The two ends of the crankshaft experience twisting resulting in torsional vibrations. Previously, external vibration dampers integrated with the crankshaft pulley were used to reduce torsional effects. The latest internal crankshaft damper (ICD) is seamlessly integrated into the crank arm and consists of a rotating mass, spring clutch, and a damper. The housing of the ICD connects straight to the crankshaft resulting in a speed-dependent damping. Further, friction damping occurs primarily in the friction bearings, which not only absorb the rotating masses but also act as guides. Steel pressure springs provide constant spring rate over temperature and also permit higher vibration angle.

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Active Noise Control

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Active Pulse Cancellation for Hybrid Vehicles Engine Start & Stop

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Active Pulse Cancellation Reduction of Engine Start Vibration in Hybrid Vehicle

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Hybrid Vehicles -- NVH

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Hybrid Powertrains
Series hybrid uses the engine primarily to charge the battery.The wheels also charge the battery in the regenerative braking mode.

Here, the motor is in between the engine and the transmission and is used to assist the engine by applying additional torque to the wheels for conditions requiring higher engine RPM. Technology used in Honda Insight. Here, the engine and the generator are along the same axis and connect through a planetary gear set. The output of the ring gear interfaces with the motor through a shaft, which is geared to the differential. When the wheels are stationary, the motor will not be rotating. Technology used in Toyota Prius. 22

Conventional vs Hybrid Electric Vehicles (HEVs)

1. HEVs use the engine and motors to apply torque to the wheels through a power split device while conventional vehicles with IC engines apply torque directly to the wheels. Operating conditions in HEVs include engine off/on with motor+/or generator applying/not applying torque to the wheels (totally 3 different conditions) For HEVs, it is important to collect data even when the engine is not running, for example, when the vehicle is stationary as the motor+/or generator might be applying torque to the wheels. HEVs typically have 5 control units -- engine, power transfer unit (motor, generator, and planetary gear), battery, regenerative braking, and overall vehicle system control. For each control unit, it is important to understand the range of command, start/shut down conditions and its effect on/coordination with other control units. HEVs are drive by wire and as such the pedal position and throttle position controls might be different as the focus is to gain maximum fuel efficiency by running the engine at peak torque. It is important to measure both engine RPM and also vehicle speed as the engine may be off in certain conditions.
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2.
3.

4.

5. 6.

7.

Noise & Vibration Issues for HEVs

Adapted Technology for Hybrid System Engine Efficiency Improvement Changing Engine Operating Area - High expansion ratio cycle - Friction loss reduction - Mass reduction -EV driving in light load area - High torque operation at low engine speed - Engine stop during vehicle stop - MG2 regenerative braking Associated NV Issues - Engine noise

-MG noise & vibration - Body vibration/drone noise at low speed - Engine start/stop vibration - MG magnetic noise

Energy Regeneration

1. 2. 3. 4. 5.

HEV engine adopts high expansion ratio cycle and friction loss reduction accompanied by lowered maximum engine speed Results in engine noise. HEV is driven by electric motor with the engine stopped in low thermal efficiency area of light engine load operation Results in Motor Generator (MG) noise & vibration. The engine is operated in high torque areas even when it is run at low engine speed -Results in body vibration/drone noise at low speed. Vehicle vibration during frequent engine start and stop -- Results in engine start/stop vibration. MG2 regenerative braking for energy recovery -- Results in MG magnetic noise 24

Engine Start Vibration Sources

Countermeasure Principle Vibration Generating Source - Cranking A reaction force
- Pumping pressure in cylinder

Hybrid System

Engine Mounting System

Optimization of mounting method/dimensi on and mount spring constant

- Intake air restriction with VVT-i - Cranking torque optimization with Motor Generator 1 (MG1)

Rapid engine torque increase after spark

Ignition timing and fuel injection control

Engine start vibration occurs in two instances (phases A and B in the figure above)
After cranking torque has been applied and before fuel injection has not been started cranking reaction force and pumping pressure in cylinder during engine motoring cause annoying vibrations

After spark ignition

Rapid engine torque increase causes annoying vibrations

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HEVs NVH Countermeasures for Motor/Generator Noise and Vibration

Source: Vehicle vibration/noise due to motor/magnetic noise at low speeds and in the regenerative braking mode
Specific motor revolution nth order component = xth order electric angle X yth pair of magnetic poles). For example, torque ripple due to 24th order component of revolution is caused by 6th order electric angle X 4th pair of magnetic poles due to magnetic flux components of 5th and 7th order components.

Countermeasure: Hybrid System Modification

A wave whose amplitude equals the 5th order component of the magnetic flux, but has OPPOSITE PHASE, is superimposed on the basic current wave for motor control. Results in 3-6 dB reduction in motor/generator noise during regenerative braking. Also results in lower vehicle vibration levels in low speed EV driving.

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Engine Start (Vehicle in Neutral)

Engine Speed (RPM)

Seat Track Accel (g)

In cranking phase, the vehicle moves backward and then forward with F/A oscillations

Cranking Phase Initial Combustion Phase

In combustion phase, the vehicle jerks forward and then has F/A oscillations

Half-Shaft Torque (Nm)

P/T Block Top F/A Accel (g)

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Engine Stop
Engine Speed (RPM)

Seat Track Accel (g)

Half-Shaft Torque (Nm)

Torque magnitude is higher than for engine start and oscillates about zero

P/T Block Top F/A Accel (g)

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NVH Enablers for Engine Start Before Ignition

1.

2. 3.

Simulation results of indicated torque show that when the intake valve closes at 90 deg ABDC, the air intake volume decreases, leading to reduced intake manifold pressure and thus reduced fluctuations in the cylinder pumping pressure. When the intake valve timing is delayed to close at 150 deg ABDC, there is almost zero pressure in the intake manifold, resulting in minimum cylinder pressure fluctuations. The second figure shows significantly reduced floor vibration levels as the intake valve close timing is delayed. Optimum value is found to be 115 deg ABDC to balance 29 between reliable combustion and minimum engine start vibration.

NVH Enablers for Engine Start Before Ignition

1. 2.

Tests confirmed that floor vibration at motoring start is reduced when piston position is close to TDC. Motor A is precisely controlled to ensure that the piston stop position is close to TDC during engine stop.
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NVH Enablers for Engine Start Before Ignition

1. 2.

Local minimum in cylinder head vibration observed at the torque raise rate of 3 Nm/8ms. Also, higher peak cranking torque showed lower vibration levels.

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NVH Enablers for Engine Start After Ignition

1. 2. 3.

The fuel is enriched after start by fuel injection control to stabilize combustion. The spark is delayed by ignition timing control to decrease engine torque. The VVT advance is significantly increased to relieve intake air volume change.

The floor vibration levels are significantly reduced due to the above enablers.

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NVH Enablers for Engine Start Engine Mount Tuning

1. Asian OEMs use C.G. based mount architecture while U.S. OEMs use torque-roll axis based mount design. Right and left mounts are placed on the front side members; torque rod (top roll restrictor) is placed on the front suspension member. All engine mounts are placed on the surface of which the powerplant C.G. is located. The power plant principal elastic axis of rolling coincides with its principal inertia axis and can effectively reduce not only the power plant C.G. vibration but also vehicle vibration excited by torque input.

2.

3. 4.

Engine Mounting System 1

#1 Mount LHS hydromount #2 Mount Front Active Control Mount (ACM) #3 Mount -- RHS hydromount #4 Mount Rear restraint bushing #5 Mount Top roll restrictor

Engine Mounting System 2

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Hybrid Vehicle NVH

Noise floor is significantly lower at engine shut down condition posing a serious challenge to NVH engineers !! Engine start-stop at regular intervals requires different engine and transmission mount tuning compared to a conventional vehicle to ensure smooth vibration transition Requirement for electrical accessories so functionality is assured during engine stop
Electric water pump Electric AC compressor Electric or electro-hydraulic power steering Electro-hydraulic braking

High Voltage Battery Thermal Management System (BTMS) Transmission Motor NVH and cooling Transmission gear NVH Exhaust Tuning is different on hybrid vehicle compared to conventional vehicle due to different torque-rpm characteristics and also to meet stringent emission requirements for hybrid vehicles Acoustic package needs to be thicker to absorb low frequencies34

Hybrid Vehicle NVH

Engine & Transmission Hydro Mounts

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Hybrid Vehicle NVH

Electric Motors: Cooling and NVH Measures

MG1 (Generator) Water/oil-cooled permanent-magnet machine 134kW @ 13,000 rpm (180 hp)

MG2 (Motor) Water/oil-cooled permanent-magnet machine 147 kW @ 5,615-13,000 rpm (197 horsepower) 275 N-m @ 03,840 rpm (203 lb.-ft..) 14,400 maximum rpm 36

Hybrid Vehicle NVH

HV Battery: Thermal Management System

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Hybrid Vehicle NVH

Electric Power Steering - DC/DC converter converts
288 VDC to 42 VDC - EPS ECU orders steering boost based on speed and VDIM demand

- Variable Gear Ratio 12.4 -17.2 : 1

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Hybrid Vehicle NVH

Electric AC Compressor

Component Level Noise Test

Microphone position

Micro phone

Vehicle Level Noise Test

1m
Inside(passenger)
Passenger side Pillar

insidedriver

1000mm
Fender Side

870mm

Distance between microphone and Component: 1meter

1000mm

1100m m 1000mm
Vehicle Front Driver side Pillar B

870mm

870mm

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Hybrid Vehicle NVH

Regenerative Brake NVH

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Hybrid Vehicle NVH

Intake Manifold for I-4 engine

Intake Resonator

Electric Power Steering

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Hybrid Vehicle NVH

Integrated Exhaust Manifold & Large Catalytic Converter for PZEV

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Hybrid Vehicle NVH

Front Engine Hydro Mount

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Hybrid Vehicle NVH

Right Engine Hydro Mount

Electric AC Compressor
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Hybrid Vehicle NVH

Quarter Panels w/ 3M Thinsulate (Thicker for Hybrid vehicle!!)

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Hybrid Vehicle NVH

Interior Dash Insulator Same Shape on Both Non-Hybrid and Hybrid But Different Properties
Hybrid: Recycled material with microfiber better Acoustic properties

Non-Hybrid: Recycled material with no microfiber

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Thank You

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