Predicting Electric Vehicle Interior Noise Quality from Drive Unit End-of-Line Vibration Testing

The Noise, Vibration, and Harshness (NVH) quality of electric vehicles (EVs) is heavily influenced by the performance of the electric drive unit. As a critical step in production, End-of-Line (EOL) testing of drive units is used to assess and control component-level NVH before vehicle assembly. However, the correlation between EOL test results and final vehicle interior noise quality, which directly impacts customer satisfaction, is not always fully understood. This paper presents a methodology for characterizing and predicting vehicle interior noise quality based on data from drive unit EOL vibration testing. Our study investigates the intricate relationship between drive unit assembly variations, component tolerances, and the resulting vibrational response. We establish a robust correlation between these drive unit characteristics and both objective vehicle interior noise levels and subjective customer perception. The findings provide a framework for using EOL data to proactively identify critical manufacturing risks and optimize processes. This approach not only facilitates the delivery of a superior, noise-concern-free product but also contributes to reducing manufacturing costs by minimizing scrap and rework. This research advances NVH quality assessment for EVs and provides manufacturers with a vital tool to enhance customer experience and satisfaction in a competitive market.