A Modular Method for Certified Virtual Validation of NVH Performance in Automotive Platforms

This work presents a modular engineering methodology (DigPhBalance - Digital Physical Balance) for the virtual validation of Noise, Vibration, and Harshness (NVH) performance in automotive development. The approach addresses the inefficiency of repeated physical testing across vehicle variants by introducing a structured two-phase process—Launcher and Reskin—centered on quantitative performance indicators with formal acceptance thresholds. In the Launcher phase, a digital replica of the base vehicle is built and iteratively correlated with physical test data. Validation is governed by objective indicators of confidence, conformity, and correlation, each evaluated against predefined thresholds. Once validated, the model becomes a certified reference, enabling its reuse across derivative configurations in the Reskin phase. Physical testing is only required if indicators fall below threshold, with a final gate test on pre-series vehicles ensuring industrial robustness. DigPhBalance formalizes the decision to replace physical testing with simulation, introducing automation, traceability, and repeatability into the validation workflow. The method is scalable across platforms and adaptable to other technical domains such as durability, thermal, and safety. The strategic ambition is clear: to enable up to 100% elimination of redundant NVH testing on vehicle variants. Early applications demonstrate significant reductions in development time and cost, while enhancing confidence in simulation-based decisions. DigPhBalance bridges the gap between digital simulation and industrial validation, offering a new standard for virtual engineering in the automotive sector.