New Inverter Switching Control Method to Enhance Sound Quality for Electric Vehicles

Conventional inverter control uses a fixed switching frequency, which leads to a high-pitched switching noise in electric vehicles (EVs) that does not vary with vehicle speed. Although EVs are generally much quieter than traditional internal combustion engine (ICE) vehicles, some EV owners complain about the lack of dynamic driving sound feedback. A new patented technology has been developed to enhance EV sound quality by dynamically controlling the inverter switching frequencies. This technology generates dynamic propulsion sound with new "switching order" features at multiple harmonics, with the pitch proportional to vehicle speed. A fixed pulse ratio between the switching frequency and the electric motor RPM is implemented to control the switching order. This reduces switching losses during low-speed operation and provides boosted acoustic feedback to the driver during acceleration, which enhances driving experience during sports driving. Furthermore, a special "EV shifting" sound that mimics the sound of gear shifting is generated by controlling different pulse ratios at each shifting RPM zone. High switching orders are dropped between neighboring zones to boost lower frequencies for an enhanced feeling of power. These new switching sound features have been validated through motor and electric motor dyno tests, as well as electric drive unit tests. Jury tests confirm the boosted EV sound signature with unique switching orders that are authentically generated from electric propulsion and can be tuned by controlling the switching pulse ratio. This technology has been successfully implemented in the "Watts-to-Freedom" drive mode of the Hummer EV, providing enhanced EV sound feedback and improving the driver's experience during high-acceleration events.