A Modern Development Process to Bring Silence Into Interior Components

Comfort and well-being have always been connected with a flawless interior acoustic, free of any background noise or BSR, (buzz, squeak and rattle). BSR noises dominate the interior acoustic and represent one of the main sources for discomfort often causing considerable warranty costs. Traditionally BSR issues have been identified and rectified through extensive hardware testing, which by its nature intensifies toward the end of the car development process.

In the following paper the integration of a virtual BSR validation technique in a modern development process by the use of appropriate CAE methods is presented. The goal is to shift, in compliance with the front loading concept, the development activities into the early phase.

The approach is illustrated through the example of an instrument panel, from the early concept draft for single components to an assessment of the complete assembly. In a second and innovative example a combination of a virtual door slam analysis with a subsequent BSR analysis is examined. Every analysis result shown in the paper will be compared with corresponding test results.