With the trend towards electrification, as well as the reduced cycles of design, engineers are faced with many new challenges. Tonal noise such as motor whine and gear whine is more prominent for an electric drive (e-drive) powertrain in Hybrid Electric Vehicles (HEV) or Electric Vehicles (EV). This is because the ICE is not there anymore to mask this tonal noise. The source of the motor whine is the motor electromagnetic forces, whereas the gear whine originates mainly from the variation of stiffness during the meshing cycle, which is defined by the gear geometry and by the contact behaviour between gear teeth. Structural response of the powertrain to these excitations can result in excessive noise which can negatively affect customer satisfaction. Addressing motor whine and gear whine requires a deep understanding of both the electrical and mechanical system. Properly capturing relevant effects requires many detailed information such as the stiffness of the assembly, EM excitation, gear micro geometry, stiffness of light weighted gears, bearing clearances, bearing preload, etc. This requires a robust developed system level NVH approach, which is not yet well established for e-drive modules compared to ICE engines. A typical NVH performance development process for an e-drive ranges from system simulation in early design phase to 3D simulation and test validation in the detailed design phase. This presentation will introduce the overall development process for NVH performance of an e-drive based on an industrial use case. Focus will go to detailed mechanical simulation, where loads from a CAD based EM simulation will be included in a system level multibody simulation of the complete e-drive. Multibody simulation allows the engineer to consider both loading conditions as system compliances (from the bearing, flexible shafts, housing, etc.) onto the gear contact detection. Moreover, using high fidelity methods for the gear contact, the engineer can investigate the influence of microgeometry modifications and custom gear blank designs on the NVH performance. Finally, the loads from the multibody simulation will be used to perform a vibro-acoustic simulation to understand the radiated acoustic power from the e-drive. Special attention will go to the structural analysis, testing, model updating and correlation process of the housing assembly. A validated housing assembly gives further confidence in interpreting results from downstream multibody and vibroacoustic simulations. Finally, a quantitively comparison will be made between simulation and test for the NVH response of the e-drive for a run-down condition. Test based validation allows to confirm the customer requirements and establish predictive simulation methods.
Reference | NWC23-0236-presentation |
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Authors | Verhoogen. J Kucukcoskun. K |
Language | English |
Type | Presentation |
Date | 16th May 2023 |
Organisation | Siemens Digital Industries Software |
Region | Global |
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