Acoustics and Vibration Web FEV
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Transcript of Acoustics and Vibration Web FEV
CONTACTFEV Motorentechnik GmbHNeuenhofstraße 181 52078 Aachen ∙ GermanyPhone +49 (0) 241/56 89 - 0Fax +49 (0) 241/56 89 -119 E-Mail [email protected]
FEV Engine Technology, Inc.4554 Glenmeade Lane Auburn Hills, MI 48326-1766 ∙ USAPhone +1 (0) (248) 373- 60 00Fax +1 (0) (248) 373- 80 84 E-Mail [email protected]
FEV China Co., Ltd.No.35 Xinda Street QixianlingHigh Tech Zone ∙ 116023 Dalian ∙ ChinaPhone +86 (0) 411/84 82-16 88Fax +86 (0) 411/84 82-16 00E-Mail [email protected]
Internet http://www.fev.com
Acou
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2007
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ACOUSTICS AND VIBRATION
VEHICLE AND POWERTRAIN
2
FEV has over 30 years of experience conducting industrial and scientific NVH projects worldwide. The Vehicle Physics and Acoustics division employs more than 100 highly qualified NVH specialists in Germany and the United States. We have a solid reputation as a reliable engineering partner to OEMs and suppliers.
Our scope of work includes a variety of projects such as single engine component optimization, low noise engine development from concept to SOP, vehicle integration and full vehicle NVH development. We also tackle challenges outside the automotive field, such as NVH optimization of industrial machinery.
Our partnership with universities, such asthe Technical University of Aachen with its internationally renowned Institute for Internal Combustion Engines, as well asour continuous involvement in industrial and public research projects ensures that our methodologies are always up to date and thorough.
We believe that today’s NVH challenges can be solved efficiently using a full systems approach that is in close cooperation with our clients.
The high quality standard of our work is ensured by modern testing equipment and facilities combined with cutting-edge NVH simulation tools and methods.
Vehicle Physics and AcousticsFEV‘s Expertise Delivers Success
The partnership with our clients is characterized by:
Open partnership High flexibility and short response timing On-site testing and resident engineers Full data compatibility Transfer of NVH expertise and methods
3
FEV’s NVH activities cover a wide range of automotive and industrial development tasks:
High quality benchmarking and target setting of components, transmissions, engines and vehicles Systematic troubleshooting CAE-based NVH development tools and methods Sound design and acoustic refinement Sound quality and product brand sound development
Comprehensive process noise optimization Complete product development from concept to Start of Production (SOP) Vehicle NVH development and optimization NVH chassis development for premium interior sound and vibration comfort Industrial, public and internal research
Fields of NVH Applicationsand Activities
Vehicle Physics and AcousticsApplications and Activities
4
Audio Lab
Engine and VehicleWorkshop
NVH Powertrain and Vehicle Testing Facilities
The increased complexity of powertrain andvehicle electronics requires a highly-skilled staff within the assembly workshop and experienced test cell operators.
FEV operates modern powertrain and vehicle NVH test cells equipped with standard as wellas specific instrumentation tools and modern data acquisition/analysis systems.
Vehicle NVH Dynamometer
Test Track
Body-In-White and Trimmed Body Lab
Advantages created by FEV’s facilities includes:
All of the required state-of-the-art NVH equipment and facilities available
Flexible multi-shift operation Full project separation, utilizing all
resources Integration of the client’s employees into
the project team as required Certified confidentially and concealed
prototype handling
PowertrainNVH Test Cell
5
FEV utilizes many industry standard CAE andCAT tools to ensure a smooth and quick data-transfer for our clients. The following is a list of some of the tools that are available:
ANSYS, NASTRAN Hypermesh, I-DEAS ADAMS Engine, ADAMS Car Sysnoise SIMPACK, DADS GT-Power Design of Experiments (DoE) PAK, LMS, SQLab/Artemis MatLab/Simulink …
FEV has also devised a number of highly reliable FEV-specific tools to integrate cutting-edge NVH methods into product development, such as:
Driveline Simulation
CVT Simulation
Powertrain Noise Simulation
FEV-DIRA (Dynamic Impact Response Analysis) FEV-proprietary codes for simulation of component dynamics (crankshaft, piston and valve train ...) FEV-CSL (Combustion Sound Level) FEV-CSL-CAL (Combustion Sound Level Calibration with DoE) FEV-VINS (Vehicle Interior Noise Simulation) FEV-V-VINS (Virtual Vehicle Interior Noise Simulation) FEV-VENS (Vehicle Exterior Noise Simulation) FEV-SME (Sound Metrics) FEV-C-VINS (Chassis Vehicle Interior Noise Simulation)
NVH Tools Commercial and FEV-Specific
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Excellent NVH has become a vital vehicle development target as it contributes to product quality, driving pleasure and customer satisfaction. Consequently, NVH optimization of sources and transfer paths is required from concept to SOP.
Advanced NVH experimental and simulation tools are prerequisites for cost and time effective development minimizing pre-produc-tion troubleshooting effort and shortening the time to market.
NVH for Production ReadinessFrom Concept to Start of Production (SOP)
NVH Development form Concept to SOP
Concept and Targeting Design Prototype Development SOP
FEV‘s NVH activities cover the entire cycle from the research concept phase to the start of production:
Concept study supported by an extensive database and quick CAE-tools Development phase supported by precise CAE-tools and methods as well as powerful testing tools and methods SOP-support by experienced specialists
7
Sound Design and TroubleshootingTools and Methodologies
Troubleshooting projects are supported by acoustic camera analysis, which is a very effectivemethod for targeted noise source identification.
Acoustic Camera
FEV-VINS for Interior Noise Simulation
Airborne Noises
Structure-Borne Noises
Simulated Interior Noise
Structure-Borne Noise Transfer Functions
Airborne Noise Transfer Functions
Stru
ctur
e-Bo
rne
Exc
itatio
nAi
rbor
ne
Exci
tatio
n
AirborneInterior Noise
Structure-BorneInterior Noise
Key methodologies for systematic full vehicle NVH development and optimization include:
FEV-VINS Vehicle Interior Noise Simulation through a
combination of individual excitations and related transfer paths
FEV-V-VINS Virtual Vehicle Interior Noise Simulation is the
implementation of virtual excitations and/or transfer functions, such as powertrain/orifice noise and/or vibroacoustic body transfer functions
FEV-VENS Vehicle Exterior Noise Simulation through a
combination of powertrain, orifice and tire noises with corresponding airborne noise transfer functions, according to the vehicle positions during pass-by tests
FEV-SME Sound Metrics (pleasentness, dynamic, knocking,...)
are available and can be applied on specific noise phenomena
Powertrain noise Intake orifice noise Exhaust orifice noise Shell noise Tire noise…
Powertrain mount vibration Exhaust syst. vibr. Driveline vibration …
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Powertrain integration represents a primary task in vehicle development and requires systematic and continuous NVH attention.
The process is strongly supported by “virtual” and hybrid methods for pre-optimization of the “hardware marriage” minimizing the effort required for design changes.
Simulation of Powertrain Mount
Virtual Intake and Exhaust System Development
Package Analysis Drive Off Simulation
Experimental and analytical approaches are applied to the refinement tasks including:
NVH benchmarking and appropriate target setting Intake and exhaust system layout and refinement Mount system layout and refinement Driveline layout and refinement Vehicle body refinement including sound package development Continuous NVH assistance in vehicle calibration Vehicle NVH refinement for interior/ exterior noise and vibration comfort Pass-by noise optimization
Exhaust System Analysis
Vehicle Body NVH CAE
Vehicle Integration Marriage of Powertrain and Vehicle
9
Full NVH Responsibility Vehicle NVH Development
FEV can manage overall vehicle NVH develop-ment. Such programs typically are carried out in close cooperation between OEM specialists, suppliers and FEV.
FEV’s project managers skills coordinate ac-tivities between the different working groups, ensuring a streamlined development process.
Interior Sound Quality
high
low
Interior Trim OptimizationTop: Hardware SolutionBottom: Firewall Noise Map
Noi
se T
rans
pare
ncy
The cooperation between OEM, FEV and suppliers is characterized by:
System and components level target setting
Experimental and analytical component refinement
Development for the OEM, according to specific processes and strategies Full-responsibility for NVH integration NVH robustness for Production
Powertrain induced NVH: Engine and Transmission Driveline Powertrain Mount Intake and Exhaust System ...
Aero Acoustic: Body Shape Sealing Windows Side MirrorWiper ...
Body NVH: Global Stiffness Stiffness of Front-End Section Impedances at Interface Points Vibro-Acoustic-Transfer Functions Heavy Layer Distribution ...
Chassis NVH: Stiffness of Axles and Subframes Bushing Insulation Tire Noise Steering NVH Brake NVH ...
Interior NVH Quality: Sound Insulation Squeak and Rattle HVAC Noise Electro Servo Motor NoiseAudio and Entertainment Systems ...
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Challenging NVH targets are prerequisites for developing excellent powertrain and vehicle sound, along with vibration comfort.
Extensive Powertrain NVH Database
Soun
d Pr
essu
re L
evel
[dBA
]
1000 2000 3000 4000 5000 6000 rpm
DI-Diesel Engines
GasolineEngines
Prototype
Production
FEV’s extensive NVH database ranges from combustion excitation to vehicle road and wind noise:
More than 500 engines and vehicles More than 100 metrics
More FEV Scatter Bands: Noise Level; Loudness; Sharpness; Tonality; Articulation Index; Comb. Noise Index; Jury Ranking; ...
Exterior Noise
Orifice Noise
P/T Noise
P/T Mount Vibration
Interior Vibration
Road/Wind Noise
FEV_CSL:
Cylinder Pressure
Engine Structure Attenuation
FEV -VINS:
Structure Borne Vehicle Attenuation
Airborne Vehicle Attenuation
Interior Noise
NVH Benchmarking From Cylinder Pressure to Driver‘s Ear
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Developing of a low noise engine requires CAE-based NVH optimization from the begin-ning of the concept phase.
In order to achieve a high level of refinement, NVH CAE engineers must deliver recommen-dations prior to the design freeze dates. Thus, detailed NVH experience and appropriate virtual development tools and methods are required. Examples of FEV in-house developed tools are FEV-DIRA and FEV-V-VINS.
FEV-DIRA reflects FEV’s philosophy for power- train structural and dynamic NVH optimization.
Commercial Finite Element Analysis, Multi-Bo-dy Simulation and Boundary Element Method software is fully compatible with that of our clients and uses integrated specific FEV codes such as roller bearing and damping modules.
FEV-V-VINS combines powertrain NVH simula-tion and interior noise simulation, allowing for vehicle-focused powertrain NVH development.
Best-In-Class V6 Diesel Engine
FEV’s competitive edge in low noise engine development:
Well proven CAE Tools and methods which fit into the development processes of our clients Highly sophisticated testing tools and
methods for noise optimization Extensive database for NVH component
specifications Experiences from several powertrain development programs
Low Noise Engine and Sound Design for Improving Powertrain NVH
12
Transmission and Driveline NVH
The increasing challenges for powertrain de-velopment are also driving new transmission technologies.
At FEV, NVH and shift quality optimization is integrated into transmission development, including design, mechanical and electronic development as well as integration into the vehicle application.
Driveline NVH related tasks, such as boom, gear whine, gear rattle, clunk, etc. are perfor-med with the help of CAE, testing and bench-marking. The following services are available:
Continuous design support for transmission NVH development Component development Troubleshooting
In that context, experiences are available for (automated) manual, (stepped) automatic and (belt/chain) CVT transmissions.
Driveline Simulation
Tooth Stiffness Simulation
Driveshaft TorqueMeasurement
FEV’s experience in quiet driveline NVH development:
Well proven CAE tools and methods Highly sophisticated testing tools and method for noise optimization Extensive database for NVH component
specifications
V-Vins
Acoustic Test Bench
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Combustion Process NoisePowerful, Clean yet Silent
Combustion system development and vehicle applications have become more complex. This is due to advanced combustion systems, increased flexibility of fuel injection systems, exhaust gas aftertreatment constraints and On-Board Diagnosis (OBD).
FEV’s highly-qualified NVH engineers explorethe full calibration of NVH potential, while achieving emissions and related fuel consumption targets, using the in-house developed methods, such as FEV-CSL and FEV-CSL-CAL.
FEV-CSL-CAL
Parameters: Pilot injection Main injection Rail pressure EGR …
Responses: FEV-CSL Interior noise Exterior noise Fuel consumption Emission
FEV-CSL: Engine Noise Shares
Direct Combustion
NoiseFlow Noise
Indirect Combustion
Noise
Engine Noise
Mechanical Noise Accessory NoiseCombustion Noise
Transient Combustion Noise Optimization
DoE-models
Cal. 1Cal. 2
Time
Inte
rior
Noi
se
5 dB
The characteristics and advantages of FEV’s unique NVH calibration tools:
CSL: Method for engine noise breakdown, such that the full NVH potential of an engine can be explored
CSL-CAL: DOE-based method for combustion noise optimization
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In general, hybrid vehicles can possess favora-ble NVH behavior, especially during start-up and low speed cruising. Nevertheless, detailed NVH refinement of HEV-specific electric com-ponents, powertrain mounting system and driveline are required to achieve excellent NVH behavior.
The main NVH challenge consists in adjusting the NVH response to the driving condition and the driver’s expectation. Consequently, NVH development focuses on the balancing of HEV operational modes.
By using FEV-Hybrid-VINS software, vehicle operational modes can be balanced regarding vehicle interior noise, based on the HEV ope-rational mode strategy, such as the relation of vehicle velocity, ICE speed and speed gradient as well as load condition.
Powertrain Noise Simulation
Hybrid vehicle-specific NVH development tasks:
Smooth internal combustion engine Launch at start-up and during drive-away Moderate ICE start /stop feedback during the vehicle stop Unobtrusive ICE deactivation/activation during cruising/acceleration Powerful, acoustically supported, dynamic acceleration feedback Unobtrusive NVH behavior of electrical components, such as magnetic noise during regeneration at recuperation low vehicle speeds
AD C C
D
E B
Time
Vehi
cle
Velo
city
ICM
/ E
M /
Gen
. rpm
A
B
C
D
E
Hybrid Vehicle Balancing of Hybrid Operational Modes
15
Trucks and Heavy-Duty Vehicles
Truck development is mainly driven by costs, fuel consumption, emissions and reliability. Nevertheless NVH comfort is becoming more and more important.
To achieve an overall well balanced NVH be-havior, the entire vehicle has to be taken into account. It is very important to optimize all relevant NVH systems/components, such as:
Powertrain and driveline Intake and exhaust system Chassis and mounts Cabin including the noise insulation
FEV’s key elements for the optimizations are:
Long term experience with trucks and heavy-duty vehicles
Proven CAE tools and methods Very efficient testing tools and methods
FEV’s systematic approach allows for efficient NVH development.
Powertrain/Drivetrain
Combustion System Development
Vehicle Integration
Component Optimization
w/o NVH Optimization
w/ NVH Optimization
Displacement [l]
SPL
[dBA
]
5
Pass-By NoiseInterior Noise
Benchmarking
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NVH optimization of industrial and off-highway machines is characterized by multiple airborne and structure-borne noise sources and related transfer paths. Key elements for a comprehen-sive optimization process are CAE and hybrid methods including:
Combined FEA and MBS for structural optimization with respect to NVH and
stress analysis Interior noise simulation 1-D CFD for intake and exhaust system optimization 1-D and 3-D CFD simulation for the air cooling system layout MBS simulation of vehicle dynamics Combined MBS and CFD simulation for the hydraulic systems layout
The systems approach allows for a reduction in prototype/pre-production testing, minimizing technical risks, improving product quality and reducing the time to market.
The development process for off-road machi-nery is influenced by multiple targets and associated constraints. This requires well-balanced technical and commercial targets that focus on customer benefits.
Development Targets forOff-Highway Machinery
Structure-borne: Comb. engine Hydraulic pumps Hydraulic motor Hydraulic tubes Gearbox Transfer box Axle differentials …
Airborne: Comb. engine Exhaust Intake Fan/air flow …
Flexibility and Effort for Troubleshootingduring the Development Process
Flexibility forProblem Solving
Effort forTroubleshooting
Planning Development Production
Des
ign
Flex
ibili
ty /
Cost
Typical Interior Noise Share Distribution for Off-Highway Machinery
Package/Visibility
Design
Vibration Comfort
Interior Noise
Fuel Consumption
Noise Legislation
Machine Performance
Durability
Off-Road Use
Thermal Balance
Production Cost
Maintenance
Time to Market
Assembly Line
After-Sales
Emission Legislation
Industrial and Off-Highway Machinery Introduction of Virtual Development Tools
17
FEV’s NVH specialists are also tasked with sup-porting non-conventional NVH projects that deal with NVH topics that present a wide range of challenges.
Motorsports: Onboard CameraOptimized Vibration Isolation for Stable Pictures During the Race
Heavy-Duty Industry: Power Station
Exhaust System Orifice Noise Optimization
Appliances (White Goods):
Heating System BoilerOptimization of Noise
Emission and Flame Stability
Recreational Devices: Power Tower
Noise Source Identification and Optimization -
Compressed Air Lift System
Diverse Applications Non-Conventional NVH Projects
Formula 1 Sound
Race Car Sound Design
Compressor Noises
Coal Mill Noise
18
Melody of DrivingEngine Sound and Music
Engineers studying mechanical acoustics can learn a great deal from music. Objective insights were gained from an internal research project, where melodic and harmonic sound pattern features of music were transferred to engine noise characteristics.
Music consists of sequences of natural tones and harmonies (tonic plus a series of its harmonics). The tone sequence is characterized by intervals, including the frequency ratio of every two consecutive notes where the interval is perceived as consonant (pleasant) or dissonant (disturbing).
Machinery sound is characterized by non-periodic noises, unpleasant noise components with some harmonics (engine orders) in a low frequency range, impacts and consecutively fading natural oscillations.
The rules of musical harmonic theory were introduced in FEV’s engine and vehicle sound design development processes as key elements to create a perfect composition for a melody of driving.
Sound Design by Engine Order
Composition: 5-Cylinder Engine
4.5th EO
3.5th EO 4th EO
3rd EO
Features of Natural Tone and Engine Noise
Harmonics
Tonic
Noises
Engine Orders Resonance
Base Dissonant Consonant
19
The perception of noise ranges from being an annoyance to something that is harmful to our health. Therefore, the European Community will significantly increase activities in programs to reduce road, rail and aircraft traffic noise.
FEV accepts this tremendous challenge for a clean and quiet environment, in close coope-ration with universities and public research centers.
One example of FEV’s cooperation in EU-sponsored projects is InMAR (Intelligent Ma-terials for Active Noise Reduction). The task is to apply actuators and foils based upon piezo technology to reduce powertrain induced noise and vibration using active control.
Road Traffic Noise as a Focus of Public Discussion
(Source LfU 2004)
AirTraffic
RoadTraffic
RailTraffic
Neighbor-hood
RecreationalIndustry
35%
30%
25%
20%
15%
10%
5%
0%
1999
2004
1999
2004
1999
2004
1999
2004
1999
2004
1999
2004
Annoyance
Mean
Intense
Test Set up Controller Assessment
Aside from public NVH interest, FEV invests in many internal research projects to be prepared for future technological challenges, including the following:
„Virtual” powertrain and vehicle development Technology NVH road maps Sound quality
Piezo Patch
Shaker
Signal Processing
Piezo Control
NVH Research Activities Prepared for Future Challenges