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A Diagnostic Technology of Powertrain Parts that Cause Abnormal Noises using Artificial Intelligence

Hyundai Motor Company-Insoo Jung, Dongchul Lee, Dongkyu Yoo, Kibeen Lim
Hanyang University-Kyoungjin Noh, Joon-Hyuk Chang
  • Technical Paper
  • 2020-01-1565
To be published on 2020-06-03 by SAE International in United States
In general, when a problem occurs in a component, various phenomena appear, and abnormal noise is one of them. The service technicians diagnose the noise through the analysis using hearing and equipment. Depending on their experiences, the analysis time and diagnosis accuracy vary widely. The newly developed AI-based diagnostic technology diagnoses parts that cause abnormal noises within seconds when a noise is input to the equipment. To create a learning model for diagnosis, we collected as many abnormal noises as possible from various parts, and selected good and bad data. This process is very important in the development of diagnostic techniques. Artificial intelligence was learned by deep learning with selected good data. This paper is about the technology that can diagnose the abnormal noises generated from the engine, transmission, drivetrain and PE (Power Electric) parts of the eco-friendly vehicle through the diagnosis model composed of various methods of deep learning.
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Development, System Integration and Experimental Investigation of an Active HVAC Noise Control System for a Passenger Car

Hyundai Motor Company-Joong-Kwan Kim, Jinmo Lee, ChiSung Oh, Kang-Duck Ih
Fraunhofer Institute LBF-Jonathan Millitzer, Valentin Mees, Christopher Ranisch
  • Technical Paper
  • 2020-01-1538
To be published on 2020-06-03 by SAE International in United States
Current developments in the automotive industry such as electrification and consistent lightweight construction increasingly enable the application of active control systems for the further reduction of noise in vehicles. As different stochastic noise sources such as rolling and wind noise as well as noise radiated by the ventilation system are becoming more noticeable and as passive measures for NVH optimization tend to be heavy and construction space intensive, current research activities focus on the active reduction of noise caused by the latter mentioned sources. This paper illustrates the development, implementation and experimental investigation of an active noise control system integrated into the ventilation duct system of a passenger car. Making use of a model-based design process, the development is based upon a holistic numerical simulation model integrating a reduced order acoustic model derived from finite element simulations as well as simplified loudspeaker and microphone characteristics. The numerical simulation assists the selection of a suitable loudspeaker microphone configuration, taking into account the available installation space and the integration of low-cost loudspeakers and MEMS microphones. The ventilation…
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Robust Development of Electric Powertrain NVH for Compact Electric SUV

Hyundai Motor Company-Tae-Won Ha, Jin-Wook Huh, Sang-Kyu Choi, Dong-Wook Min, Chang-Kook Chae
Romax Technology-Annabel Abdy, Carsten Schmitt, Hanafy Mahmoud, Sharad Jain, Leon Rodrigues
  • Technical Paper
  • 2020-01-1503
To be published on 2020-06-03 by SAE International in United States
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 abnormal noise, previously masked by the internal combustion engine can also 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 stator local excitation. Under high speed and high load operating conditions, the sound level is low, however high frequency whine noise is a factor that can impair the vehicle level NVH performance. An example of a previously masked abnormal noise 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, and the countermeasure (E-motor geometry refinements to reduce the excitations and mechanical system transfer path…
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Reinforcement of Low-Frequency Sound by Using a Panel Speaker Attached to the Roof Panel of a Passenger Car

Hyundai Motor Company-Munhwan Cho
Korea Advanced Inst of Science & Tech-Ki-Ho Lee, Jeong-Guon Ih
  • Technical Paper
  • 2020-01-1570
To be published on 2020-06-03 by SAE International in United States
The woofer in a car should be large to cover the low frequencies, so it is heavy and needs an ample space to be installed in a passenger car. The geometry of the woofer should conform to the limited available space and layout in general. In many cases, the passengers feel that the low-frequency contents are not satisfactory although the speaker specification covers the low frequencies. In this work, a thin panel is installed between the roof liner and the roof panel, and it is used as the woofer. The vibration field is controlled by many small actuators to create the speaker and baffle zones to avoid the sound distortion due to the modal interaction. The generation of speaker and baffle zones follows the inverse vibro-acoustic rendering technique. In the actual implementation, a thin acrylic plate of 0.53ⅹ0.2 m2 is used as the radiator panel, and the control actuator array is composed of 16 moving-coil actuators. The shape of the desired speaker zone is an ellipse, and the required amplitude of this piston source is…
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Concept Study on Windshield Actuation for Active Control of Wind Noise in a Passenger Car

Hyundai Motor Company-Joong-Kwan Kim, Jinmo Lee, ChiSung Oh, Kang-Duck Ih
Fraunhofer Institute LBF-Thorsten Koch, Jonathan Millitzer, William Kaal PhD, Georg Stoll, Matthias Schmidt
  • Technical Paper
  • 2020-01-1535
To be published on 2020-06-03 by SAE International in United States
The windshield is an integral part of almost every modern passenger car. Combined with current developments in the automotive industry such as electrification and the integration of lightweight material systems, the reduction of interior noise caused by stochastic and transient wind excitation is deemed to be an increasing challenge for future NVH measures. Active control systems have proven to be a viable alternative compared to traditional passive NVH measures in different areas. However, for windshield actuation there are neither comparative studies nor actually established actuation concepts available to the automotive industry. Based upon a numerical simulation of an installed windshield of a medium-sized car, this paper illustrates a conceptual study of both the evaluation of optimal positioning as well as a consideration of different electromechanical activation measures. A simulation model of the installed windshield is gained from an experimental modal analysis of both the windshield in free-free condition as well as in its installed configuration. The experimental data serves the frequency domain model update process of a finite element model of the installed windshield. A…
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Appropriate Damping Loss Factor of Vehicle Interior Cavity For Valid Application of Statistical Energy Analysis

Hyundai Motor Company-Ki-Sang Chae, Byung Young Oh
  • Technical Paper
  • 2020-01-1524
To be published on 2020-06-03 by SAE International in United States
By using a method of a previous study (SAE 2014-01-2081), sound transmission loss (STL) of vehicle panel structure could be calculated with an FEM model. The FEM model is consisting of the body in white, a hemispehere-shaped exterior cavity, and the interior cavity. The exterior cavity is excited and Statistical Energy Analysis (SEA) principle is applied for the calculation of STL of vehicle panel structure. It is known that SEA is a rapid and simple methodology for analyzing the complex vibroacoustic system. However, SEA principle is not always valid and one has to be careful about the physical conditions at which SEA principle is acceptable. In this study, the appropriate damping loss factor of the vehicle interior cavity is studied in the viewpoint of the modal overlap factor of the cavity and the decay per mean free path (DMFP) of the cavity. It is found that DMFP is appropriate between 0.5 ~ 1 dB for applying SEA principle. DMFPs of several vehicles' interior compartments are observed between 1 dB ~2.5 dB, and which means that…
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A Performance Measurement and Analysis Method for Infotainment System

Hyundai Motor Company-Peace Lee
  • Technical Paper
  • 2020-01-1347
To be published on 2020-04-14 by SAE International in United States
The car infotainment system provides various functions such as navigation, DMB, and external device interworking. In the future, complex new technologies such as remote diagnosis and control, V2X communication, integrated display, and autonomous driving interworking should be reflected. Also, even after mass production, such as smartphones, software must be constantly updated to apply bug fixes and new functions. However, as the internal software modules work together in a complicated way, system performance problems tend to occur due to changes in the software, and if they are not managed from the development stage, more costs must be paid for improvement over time. Moreover, after mass production, the scope of improvement will be limited. Therefore, software must be verified and optimized from time to time to ensure system performance quality from the minimum development process. Generally, various tools are used to verify software performance. Currently, top, perf, strace, gdb, DLT, and bootchart are mainly used on Linux-based platforms. In addition, there is a lack of intuitive statistical information to analyze and judge the overall performance of the…
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A Study on the Design and Development of an Integrated 48V Motor with Motorized Internal Combustion Engine

Hyundai Motor Company-Jongwon Lee, Kyoung-Pyo Ha, Kihoon Nam
Korea Electronics Technology Institute-Jeongjong Lee
  • Technical Paper
  • 2020-01-0446
To be published on 2020-04-14 by SAE International in United States
The electrification of the internal combustion engine is an important item of future automotive technology. By using a motorized internal combustion engine, it is possible to recover waste energy by regeneration technology and to reduce various losses that reduce the efficiency of the internal combustion Engine. This paper summarizes the results of the development of an engine-integrated motor that can be applied to a 48V mild hybrid system for motorization of an internal combustion engine. Like the 48V MHSG-mounted mild hybrid system designed to replace the generator, the motorized internal combustion engine is designed with the scalability as the top priority to minimize the additional space for the vehicle and to mount the same engine in various models. The addition of an integrated motor to the crankshaft instead of the motor of a belt-driven mild hybrid system that replaces the generator will allow the removal of components with redundant functions, starters, etc. and the accessory belt system. The motor mounted on the crankshaft also helps to effectively overcome the disadvantages of the engine, which was…
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A study on optimization of the cross-section of door impact beam for weight reduction

Hyundai Motor Company-Heejin Im
  • Technical Paper
  • 2020-01-0631
To be published on 2020-04-14 by SAE International in United States
This paper focuses on the optimization of the cross section of a member type impact door beam. The cross section of the beam was parameterized by using a geometry morphing tool FCM(Fast Concept Modeler) which plug in CATIA, and the metamodel of FE analysis results was created and optimized by LS-OPT. The ANOVA analysis of results was performed to find the factor of weight reduction. And then a new cross section concept was proposed to overcome the limitation of old structure. The proposed cross section was optimized to obtain the final cross section which has a weight reduction of 10% or more.
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Development of an Air support system for long-distance drive comfort

Hyundai Motor Company-Dongwoo Jeong, Seon Chae Na, Sangdo Park, Sangho Kim, Seungyoung Lee
Hyundai Transys-Inho Lee, Sunghoon Kim
  • Technical Paper
  • 2020-01-0868
To be published on 2020-04-14 by SAE International in United States
Passenger fatigue during long distance driving is greatly influenced by the comfort performance of the seat and is one of the important performance of the seat. In order to satisfy this performance, it is determined by the appropriate contour of the seat and the appropriate pad with sufficient thickness and the frame supporting the pad and coverings. Recently, however, more parts such as ventilation seats and passenger detection sensors have taken up the pad In addition, The height of the vehicle have been lowered to enhance car styling, and battery for electric vehicle applied to the underbody of the vehicle, reducing the package space of seats in the vehicle. These external factors eventually lead to a reduced pad thickness of the seat cushion and exacerbate the most important cushioning in the seat cushion compartments, creating an uncomfortable cushioning problem when driving long distances. To improve the cushion composition of the seat within a limited package, air bladders are applied to the underside of the cushion pad. In addition, the function to support the buttocks using…