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Design & Development of Partial Engine Encapsulation for Interior Noise Reduction in Commercial Vehicles

VE Commercial Vehicles Ltd-Sourabh Jadhav
VE Commercial Vehicles Ltd.-Yadhu S. Aswan
  • Technical Paper
  • 2019-01-1589
To be published on 2019-06-05 by SAE International in United States
This paper focuses on partial encapsulation technique for reducing air-borne noise from the rocker cover of a commercial vehicle diesel engine. Due to increasing awareness, customers demand for improvised NVH-Noise Vibration and Harshness performance in modern day vehicles. Better NVH performance implies better comfort for passengers as well as vehicle operator. This further increases the driver up time due to reduced driver fatigue. In order to improve NVH performance of existing vehicle and observe different noise and vibration zones, detailed noise and vibration mapping was carried out on one of our vehicle platform. It is observed that engine noise is one of the major contributors for interior noise, apart from road inputs etc. There are well established methods to reduce the inherent noise of the engine, but the same might affect other performance parameters including fuel efficiency and exhaust emissions, which are pain areas of major automotive industries due to stringent homologation norms. Engine top area partial encapsulation with barrier cover is designed considering various integration as well as heat load constraints at vehicle level.…

Optimal Pressure Relief Groove Geometry for Improved NVH Performance of Variable Displacement Oil Pumps

Ford Motor Company-Abdelkrim Zouani, vidya Marri
  • Technical Paper
  • 2019-01-1548
To be published on 2019-06-05 by SAE International in United States
Variable Displacement Oil Pump (VDOP) is becoming the design of choice for engine friction reduction and fuel economy improvement. Unfortunately, this pump creates excessive pressure ripples, at the outlet port during oil pump shaft rotation, causing oscillating forces within the lubrication system and leading to the generation of objectionable tonal noises and vibrations. In order to minimize the level of noise, different vanes spacing and porting geometries are used. This paper presents an optimization method to identify the best geometry of the oil pressure relief groove. The method integrates adaptive meshing, 3D CFD simulation, Matlab routine and Genetic Algorithm based optimization. The genetic algorithm is used to create the required design space in order to perform a multi-objective optimization using a large number of parameterized groove geometries. Results of this optimization method are discussed and a design guideline for the oil pressure relief groove is disclosed.

Towards a quiet vehicle cabin through digitalization of HVAC systems and subsystems aeroacoustics testing and design

Dassault Systemes SIMULIA-Vincent Vidal, Adrien Mann, Jonas Verriere, Minsuk Kim
Valeo Thermal Systems-Fabrice Ailloud, Manuel Henner, Olivier Cheriaux
  • Technical Paper
  • 2019-01-1476
To be published on 2019-06-05 by SAE International in United States
With the rise of electric autonomous vehicles, it has become clear that the cabin of tomorrow will drastically evolve to both improve ride experience and reduce energy consumption. In addition, autonomy will change the transportation paradigm, leading to a reinvention of the cabin seating layout which will add pressure on climate systems team to design quiet and energy efficient systems. Consequently, Heat and Ventilation Air Conditioning (HVAC) systems designers have to deliver products which performs acoustically better than before, but often with less development time. To success under such constraints, designers need access to methods providing both assessment of the system (or subsystems) acoustic performance, and identification of where the designs need to be improve to reduce noise levels. Such methods are often needed before a physical prototype is requested, and thus can only be achieved in a timely manner through digital testing. Previous studies have demonstrated the ability of a CFD/CAA approach based on the Lattice Boltzmann Method (LBM) to predict HVAC system noise including real and complex ducts, registers, mixing unit and blower…

On the Measurement and Simulation of Flow-Acoustic Sound Propagation in Turbochargers

FEV Europe GmbH-Ralf Stienen
Institute for Combustion Engines, RWTH Aachen University-Hendrik Ruppert, Felix Falke, Stefan Pischinger, Marco Günther
  • Technical Paper
  • 2019-01-1488
To be published on 2019-06-05 by SAE International in United States
Internal combustion engines are increasingly being equipped with turbochargers to increase performance and reduce fuel consumption and emissions. Being part of exhaust and intake systems, the turbocharger strongly influences the orifice noise emission. Although 1D-CFD simulations are commonly used for the development of intake and exhaust systems, validated acoustic turbocharger models are not yet state-of-the-art. Consequently, the first aim of the paper is the investigation of the influence on the orifice noise and the development of an accurate 1D-CFD model. Firstly, active and passive acoustics of turbochargers are distinguished. Complex active turbocharger noise emissions were investigated on a turbocharger test rig and could be correlated with unstable rotating stall. Therefore critical acoustic operation can be identified in early engine development stages by comparison to other tested turbochargers. The passive acoustic transmission loss was measured for a wide operating range of four turbochargers, including wastegate and VTG-system variations. Low frequency attenuation is dominated by impedance discontinuities, increasing considerably with mass flow and pressure ratio. High frequencies are determined by destructive interference in the stator. A new…

New method for decoupling the Powertrain Roll mode to improve Idle Vibration

FCA US LLC-Syed F. Haider, AHMAD ABBAS, Francisco Sturla
  • Technical Paper
  • 2019-01-1588
To be published on 2019-06-05 by SAE International in United States
Modern engines have high torque outputs and have low RPM due to increased demand for fuel efficiency. Such engines have high vibration and must be mitigated for customer comfort. Decoupling the roll mode from the remaining five rigid body modes results in a vibratory response which is predominantly about the torque roll axis (TRA). Therefore, placing the mounts on the TRA early in the design phase is crucial. Best NVH performance can be obtained by optimizing the powertrain mount parameters like position, orientation and stiffness. Many times, packaging restricts the mounts to be placed about the TRA resulting in degradation in NVH performance. Assuming that the engine mounts cannot be moved, let the desired TRA be the line through the existing engine mount (body side) centers. We propose a novel method of shifting the TRA by adding mass modifying the powertrain inertia such that the new TRA is parallel to and on top of the desired TRA. This in turn will decouple the roll mode and reduce vibrations. This problem is formulated as an optimization…

Dynamics of Amphibious All-terrain Vehicle’s Chassis Having Vibration Energy Harvesting Dampers

Mega Automation inc-Dmytriy Gurevych
Nermar, Ltd.-George Nerubenko
  • Technical Paper
  • 2019-01-1510
To be published on 2019-06-05 by SAE International in United States
The rural off-road exploiting of amphibious all-terrain vehicles leads to intensive vibrations of all parts of a vehicle, and specifically of its chassis. The tested amphibian vehicle’s chassis has the lowest natural frequency of 19.34 Hz. Vibration Energy Harvesting Damper (VEHD) is used for mitigation of chassis vibrations. VEHD provides mutually interconnected results: reduction of undesired vibration levels and generating of the additional electrical power. Newly patented VEHD consists of two main components: Tuned Mass Damper and Generator of Electricity. The perspective feature of proposed VEHD is the ability of effective vibration damping in broad range of frequencies due to implementation of a control device, while that device is keeping automatically the changing natural frequency of VEHD equals to current frequency of external force. The mathematical simulation analysis based on parameters of the amphibious all-terrain vehicle chassis is developed. The experiments arranged on recently designed amphibious all-terrain vehicle illustrate the compliance with theoretical predictions, and efficiency of proposed VEHD operating mainly in low frequency interval. The analysis of dynamical performance of developed VEHD demonstrates applicability…

A Control Strategy to Reduce Torque Oscillation of the Electric Power Steering System

Duo Fu
Concordia University Montreal-Subhash Rakheja
  • Technical Paper
  • 2019-01-1516
To be published on 2019-06-05 by SAE International in United States
This paper proposes a new method of analyzing stability and design of a controller for an electric power steering (EPS) system. The main purpose of an EPS control design is to ensure that the driver will have a comfortable drivering experience, which is mostly depend on the assist torque map. However, the high level of assist gain will lead to vibration or even divergence of the steering system. Therefore, an EPS system needs to have an extra stability compensator to stabilize the system and attenuate the unpleasant vibration. In this paper, an accurate theoretical model is built and the criteria for evaluation of system quality are suggested. The bench tests and vehicle experiments are performed to verify the theoretical analysis.

Use of Active Vibration Control to Improve Vehicle Refinement while Expanding the Usable Range of Cylinder Deactivation

Fiat Chrysler Automobiles-Jeff Orzechowski, Gaurav Agnihotri, Vikas Juneja
Hutchinson Antivibration-Matthew Kamps
  • Technical Paper
  • 2019-01-1571
To be published on 2019-06-05 by SAE International in United States
Cylinder deactivation has been in use at Fiat Chrysler Automobiles for several years resulting in a fuel economy advantage for V8-powered vehicles. The size of the fuel-economy benefit, compared to the full-potential possible, is often limited due to the amount of usable torque available in four-cylinder-mode being capped by Noise, Vibration, and Harshness (NVH) sensitivities of various rear-wheel-drive vehicle architectures. This paper describes the application and optimization of active vibration absorbers coupled with interior active noise control, optimized as a system, to attenuate vibration through several paths from the powertrain-driveline into the vehicle. The use of this strategy for attenuating vibration at strategic points is shown to diminish the need for reducing the powertrain source vibration amplitude. This paper describes the process by which the strategic application of these active devices is developed in order to achieve the increased usage of the most fuel-efficient cylinder-deactivation engine-operating-points.

The research on throttle influence on aerodynamic noise of gasoline engine intake system

Tianjin Univ-Ming Qin, Gao Wenzhi
  • Technical Paper
  • 2019-01-1485
To be published on 2019-06-05 by SAE International in United States
Throttle, as a significant component for the engine, could play a central role on the control of the intake flow, and would influence the fuel consumption, emission and dynamic performance of the internal combustion engine. Fluctuating the air flow and generating the aerodynamic noise, the opening and closing of the throttle valve would largely increase the intake noise. In this research, the aerodynamic noise of the intake system under steady working conditions of the engine is calculated by the co-simulation of GT-Power, Fluent and LMS Virtual.Lab. With the coupled simulation between the two programs, GT-Power and Fluent, it could simulate the gas flow inside the engine intake system, under the actual running condition of engine. The velocity at the boundary of the intake system was used as the boundary condition for CFD calculation. The LES turbulence model with a prism layer of 0.01mm thickness was applied in the flow analysis. The pressure pulsation results calculated at each time step were preserved, which were finally imported into LMS Virtual.Lab as the acoustic excitation source of aerodynamic…

Robust NVH Engineering using Experimental Methods – Source Characterization Techniques for Component Transfer Path Analysis and Virtual Acoustic Prototyping

Robert Bosch Automotive Steering LLC-Kevin Wienen, Michael Sturm
University of Salford-Andy Moorhouse, Joshua Meggitt
  • Technical Paper
  • 2019-01-1542
To be published on 2019-06-05 by SAE International in United States
A major challenge in automotive NVH engineering is to approach complex structure-borne sound and vibration problems with sufficient accuracy but reasonable experimental effort. Typical issues encountered are poor correlation between objective component performance criteria tested for during bench validation and corresponding subjective targets evaluated during system validation in the actual vehicle. Additional challenges arise from the need to impose assumptions on sophisticated physical vibration problems to reduce the complexity to a level feasible for conventional experimental test methods. This paper addresses all mentioned issues by elaborating on a system NVH engineering approach employing Virtual Acoustic Prototyping (VAP) (related to what is now often called component Transfer Path Analysis) to synthesize time domain sound and vibration responses of vibrating machinery operated in a virtual vehicle environment. One crucial step of VAP is to characterize the strength of vibrating machinery by independent quantities at the significant coupling degrees of freedom (DoF). This study puts special focus on the measurement of free velocity, suitable for machinery operated when resiliently mounted as per ISO 9611, and the in-situ measurement…