Search Results (5)

The increasing performance requirements of electric vehicle powertrains demand lightweight, efficient, and low-noise transmission systems. High-speed electric drive unit concepts offer significant potential for reducing motor size and mass by shifting torque generation to higher rotational speeds. However, this approach places increased demands on gearbox power density, efficiency, and noise, vibration, and harshness (NVH) performance. This work investigates the NVH behaviour of a compact, high-speed automotive gearbox with a focus on planetary gear stages. Although planetary stages offer high compactness, their complex kinematics can lead to pronounced NVH challenges. In particular, sequentially phased gear meshing results in characteristic sideband components whose orders can be predicted analytically, while their amplitudes remain difficult to estimate reliably during the design phase, necessitating experimental validation. Several NVH-oriented design measures, including high-contact-ratio gearing and low-NVH microgeometry, are applied to a two-stage gearbox comprising a planetary and a cylindrical gear stage. Peak-to-peak transmission error is used as a primary NVH design metric. The planetary stage is analysed in detail to assess the influence of sequential phasing on sideband components in the dynamic response and resulting vibration behaviour. The NVH-oriented gearbox is tested on a bench, with housing accelerations used to analyse planetary sidebands, providing insights into the NVH potential of compact, high-speed gearboxes and the role of sequential phasing in the vibration response. Full article

With the growing demand for hybrid and electric vehicles, the accurate prediction of NVH (Noise, Vibration, and Harshness) behavior in Permanent Magnet Synchronous Machines (PMSMs) has become a critical aspect of electric motor design. This paper presents a detailed modeling approach for electromagnetic-induced noise and vibrations in PMSMs, integrating both analytical and numerical methods. The model focuses on quantifying the contributions of radial and tangential electromagnetic forces, which are key drivers of vibro-acoustic responses. The analytical part employs curved beam theory and a simplified acoustic model, offering rapid insights during early design stages. In parallel, a detailed numerical model based on finite element analysis is developed using a physics-based approach that accounts for the actual geometry and material properties of the PMSM prototype. This allows for enhanced accuracy without relying on experimental material parameter identification. Moreover, the detailed model includes the fluid–structure interaction introduced by the channels of the cooling fluid of the electric machine, which, although poorly addressed by the existing literature, was found to play a key role in driving the vibrational behaviour of the structure. By combining analytical speed with numerical precision, the proposed approach enables consistent and physically-based NVH predictions across various design phases, ultimately supporting improved electric machine performance and reducing development time and costs. Validation against experimental data confirms the ability of the model to accurately predict both sound pressure levels and housing surface vibrations. The novelty of this work lies in its integration of fluid–structure interaction and material modeling without the need for empirical parameter tuning, offering a robust tool for NVH design in electric vehicle applications. Full article

The term honk noise describes a low-frequency brake noise from approximately 400 Hz to 500 Hz which arises at extremely low speeds and low brake pressures. Manoeuvres like slowly releasing the brake at a hill or gently braking against the drag torque of an automatic gearbox lead to honk noise. Under the same conditions, we observed creep groan at about 80 Hz. It has been shown that honk noise usually occurs after or alternates with creep groan. For this reason, it is assumed that honk noise—like creep groan—is a stick–slip-induced phenomenon and therefore shows highly nonlinear behaviour. In this paper, we present an approach for explaining the onset of honk noise under stick–slip excitation. A minimal model consisting of coupled mass oscillators excited by stick–slip is investigated. The model was able to reproduce the phenomena observed in the experiments. Thus, it is suitable for explaining the mechanisms leading to honk and estimate the influence of basic parameter variations. The lessons learned are a crucial step towards more realistic finite element or multi-body simulation methods, which have high potential for saving costs in the noise, vibration, and harshness (NVH) development process of brake systems. Full article

This paper presents a novel approach to address noise, vibration, and harshness (NVH) issues in electrically assisted bicycles (e-bikes) caused by the drive unit. By investigating and optimising the structural dynamics during early product development, NVH can decisively be improved and valuable resources can be saved, emphasising its significance for enhancing riding performance. The paper offers a comprehensive analysis of the e-bike drive unit’s mechanical interactions among relevant components, culminating—to the best of our knowledge—in the development of the first high-fidelity model of an entire e-bike drive unit. The proposed model uses the principles of elastic multi body dynamics (eMBD) to elucidate the structural dynamics in dynamic-transient calculations. Comparing power spectra between measured and simulated motion variables validates the chosen model assumptions. The measurements of physical samples utilise accelerometers, contactless laser Doppler vibrometry (LDV) and various test arrangements, which are replicated in simulations and provide accessibility to measure vibrations onto rotating shafts and stationary structures. In summary, this integrated system-level approach can serve as a viable starting point for comprehending and managing the NVH behaviour of e-bikes. Full article

This paper focuses on simulation of noise radiated by Switched Reluctance Motors for automotive powertrains. Since control for maximum efficiency leads to high torque ripple and noise radiation, optimizing the NVH behaviour is essential. The simulation approach, based on electro-magnetic and vibro-acoustic finite element models and applicable to other electric motors, is illustrated with concrete results. Full article