This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Robust Development of Electric Powertrain NVH for Compact Electric SUV
ISSN: 2641-9637, e-ISSN: 2641-9645
Published September 30, 2020 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
Event: 11th International Styrian Noise, Vibration & Harshness Congress: The European Automotive Noise Conference
Electric vehicles (EV’s) present new challenges to achieving the required noise, vibration & harshness performance (NVH) compared with conventional vehicles. Specifically, high-frequency noise and unexpected noise phenomenon, previously masked by the internal combustion engine can cause annoyance in an EV. Electric motor (E-motor) whine noise caused by electromagnetic excitation during E-motor operation is caused by torque ripple and radial excitation. Under high speed and high load operating conditions, the overall sound level may be low, however high frequency whine noise can impair the vehicle level NVH performance. An example of a previously masked unexpected noise phenomenon is a droning noise that can be caused by manufacturing quality variation of the spline coupling between the rotor shaft of the E-motor and the input shaft of the reducer. It is dominated by multiple higher orders of the E-motor rotation frequency.
In this study, the high speed and high load condition whine noise problem was reproduced through electromagnetic and structural analysis. The countermeasures (E-motor geometry refinements to reduce the excitations and mechanical system transfer path modifications to reduce the vibration response) were defined and the effects investigated. Mechanical system modification to improve NVH performance without increasing the mass is challenging. However, E-motor air-gap geometry optimization, such as slot opening modulation and rotor notch modifications achieved significant noise reduction without critical trade-off of other performance.
This paper also describes the basic improvement plan proposed through the simulation of the droning noise behavior. The main two manufacturing errors (pitch error in the spline coupling and the alignment error between the rotor and the gearbox shafts) that are responsible for the unexpected droning noise were identified. Using simulation it was shown that the droning noise can be reduced through improved quality control and tolerance design optimization of factors such as axis self-alignment and spline gear tooth quality.
- Tae-Won Ha - Hyundai Motor Company
- Jin-Wook Huh - Hyundai Motor Company
- Sang-Kyu Choi - Hyundai Motor Company
- Dong-Wook Min - Hyundai Motor Company
- Chang-Kook Chae - Hyundai Motor Company
- Annabel Abdy - Romax Technology
- Carsten Schmitt - Romax Technology
- Hanafy Mahmoud - Romax Technology
- Sharad Jain - Romax Technology
- Leon Rodrigues - Romax Technology
CitationHa, T., Huh, J., Choi, S., Min, D. et al., "Robust Development of Electric Powertrain NVH for Compact Electric SUV," SAE Int. J. Adv. & Curr. Prac. in Mobility 3(2):1038-1048, 2021, https://doi.org/10.4271/2020-01-1503.
Data Sets - Support Documents
|Unnamed Dataset 1|
|Unnamed Dataset 2|
|Unnamed Dataset 3|
|Unnamed Dataset 4|
SAE International Journal of Advances and Current Practices in Mobility
Number: V130-99EJ; Published: 2021-04-16
Number: V130-99EJ; Published: 2021-04-16
- Do , S.H. , Kim , K.B. , Park , J.B. , Hong , N.H. et al. Optimal Design of the 2nd Generation TMED Traction Motor IEEE International Electric Machines & Drives Conference (IEMDC) San Diego 2019 10.1109/IEMDC.2019.8785321
- Zheng , H. , Wei , C. , Sun , D. , Pei , R. et al. Rotor Design of Permanent Magnet Synchronous Reluctance Motors in Rail Traffic Vehicle 21st International Conference on Electrical Machines and Systems (ICEMS) Jeju, South Korea 2018 10.23919/ICEMS.2018.8549125
- Holehouse , R. , Shahaj , A. , Michon , M. , and James , B. Integrated Approach to Electro-Mechanical System NVH Analysis 10th International Styrian Noise, Vibration & Harshness Congress: The European Automotive Noise Conference Graz, Austria 2018 10.4271/2018-01-14993
- Bombardi , F.V. , Atallah , K. , Shahaj , A. , Michon , M. et al. Effects of Unbalanced Magnetic Pull on NVH Performance of an Electric Drivetrain SAE Technical Paper 2018-01-1504 2018 https://doi.org/10.4271/2018-01-1504
- Yang , S.J. Low-Noise Electrical Motors Monographs in Electrical and Electronic Engineering Oxford Science Publications 1981
- Wu , Y.C. , and Chen , Y.T. Mitigation of Cogging Torque for Brushless Interior Permanent-Magnet Motors Transaction on Mechanical Engineering, International Journal of Science & Technology 22 6 2163 2169 Dec. 2015
- Gieras , J.F. , Wang , C. , and Lai , J.C. Noise of Polyphase Electric Motors Taylor & Francis Group 2006
- Pina Ortega , A.J. Fast Design of Asymmetrical Permanent Magnet Synchronous Machines that Minimize Pulsating Torque Electromagnetic Research B 76 111 123 2017
- Hwang , M.H. , Lee , H.S. , and Cha , H.R. Analysis of Torque Ripple and Cogging Torque reduction in Electric Vehicle Traction Platform Applying Rotor Notched Design Energies 2018 10.3390/en11113053
- Platten , M. Dynamic Simulation of Transmissions and Drivelines Using Romax Designer SIA Acoustic Simulation Workshop Paris 2011
- Verma , S.P. Noise and Vibrations of Electrical Machines and Drives: Their Production and Means of Reduction Proceedings of the 1996 IEEE International Conference on Power Electronics, Drives and Energy Systems for Industrial Growth 2 1031 1037 New Delhi, India 1996