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“Spotlight on Design: Insight” features an in-depth look at the latest technology breakthroughs impacting mobility. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. Extreme environment sensors require extreme environment cables that can reliably perform in temperatures up to 2300° F, withstand intense vibration, and have extraordinary strength. In the episode “Sensors: Noise Avoidance and Cable Manufacturing” (8:53), an engineer at Meggitt Sensing Systems demonstrates the intricate process of developing cable for sensors used in these situations.

The papers in this collection reflect the recent advances on the research, development and practices of Powertrain NVH treatment. The technical papers are of interest to powertrain system designers, testing specialists, NVH experts, and other individuals who evaluate and develop technologies to control powertrain NVH. The coverage includes: engine, engine subsystem and components noise and vibration; powertrain systems noise measurement and instrumentation; powertrain systems noise analysis.

Abstract This article presents a fault diagnosis approach for roller bearing by applying the autocorrelation approach to filtered vibration measured signal. An optimal Morlet wavelet filter is applied to eliminate the frequency associated with interferential vibrations; the raw measured signal is filtered with a band-pass filter based on a Morlet wavelet function whose parameters are optimized based on maximum Kurtosis. Autocorrelation enhancement is applied to the filtered signal to further reduce the residual in-band noise and highlight the periodic impulsive feature. The proposed technique is used to analyze the experimental measured signal of investigated vehicle gearbox. An artificial fault is introduced in vehicle gearbox bearing an orthogonal placed groove on the inner race with the initial width of 0.6 mm approximately. The faulted bearing is a roller bearing located on the gearbox input shaft - on the clutch side.

Abstract The high-frequency noise issue is one of the most significant noise, vibration, and harshness problems, particularly in battery electric vehicles (BEVs). The sound package treatment is one of the most important approaches toward solving this problem. Owing to the limitations imposed by manufacturing error, assembly error, and the operating conditions, there is often a big difference between the actual values and the design values of the sound package components. Therefore, the sound package parameters include greater uncertainties. In this article, an uncertainty analysis method for BEV interior noise was developed based on an interval model to investigate the effect of sound package uncertainty on the interior noise of a BEV. An interval perturbation method was formulated to compute the uncertainty of the BEV’s interior noise.

Abstract The dynamic characteristics of tires are critical in the overall vibrations of vehicles because the tire-road interface is the only medium of energy transfer between the vehicle and the road surface. Obtaining the natural frequencies and mode shapes of the tire helps in improving the comfort of the passengers. The vibrational characteristics of structures are usually obtained by performing conventional impact hammer modal testing, in which the structure is excited with an impact hammer and the response of the structure under excitation is captured using accelerometers. However, this approach only provides the response of the structure at a few discrete locations, and it is challenging to use this procedure for rotating structures. Digital Image Correlation (DIC) helps in overcoming these challenges by providing the full-field response of the structure.

NVH refinement is an important aspect of the powertrain development and vehicle integration process. The depletion of fossil-based fuels and increase in price of gasoline have prompted most vehicle manufacturers to embrace propulsion technologies with varying degrees and types of hybridization. Many different hybrid vehicle systems are either on the market, or under development, even up to all-electric vehicles. Each hybrid vehicle configuration brings unique NVH challenges that result from a variety of sources. This paper begins with an introductory discussion of hybrid propulsion technologies and associated unique vehicle NVH challenges inherent in the operation of such hybrid vehicles. Following this, the paper outlines a two-dimensional landscape of typical customer vehicle maneuvers mapped against hybrid electric vehicle (HEV) operational modes.

Piezoelectric self-sensing allows to measure frequency response functions of dynamical systems with one single piezoelectric element. This piezoceramics is used as actuator and sensor simultaneously. In this study, a model-based piezoelectric self-sensing technique is presented to obtain potential squealing frequencies of an automotive disc brake. The frequency-response function of the brake system is obtained during operation by measuring the current flowing through the piezoelectric element while the piezoelectric element is driven by a harmonic voltage signal with constant amplitude. The current flow is composed of the part which is required to drive the piezoelectric element as an actuator and a second part which is the sensor signal that is proportional to the vibration amplitude of the attached mechanical system. Typically the first part is dominant and the influence of the mechanical system is marginal.

This paper summarizes results from the author's work on friction in dry sliding contacts in the presence of vibration. A number of idealized models of smooth and rough contacts are examined. It is shown that vibration can cause up to a 10% reduction in average friction even with continuous contact. A larger reduction in friction occurs when there is intermittent contact loss. This is found to be true for both elastic and plastic contacts, and for adhesive and plowing mechanisms of friction. The results of this work are compared and validated with measurements from experiments. The results presented are fundamental, but applicable to machine components with contacts including brake systems.

The ride dynamics of typical North-American soil compactors were investigated via analytical and experimental methods. A 12-degrees-of-freedom in-plane ride dynamic model of a single-drum compactor was formulated through integrations of the models of various components such as driver seat, cabin, roller drum and drum isolators, chassis and the tires. The analytical model was formulated for the transit mode of operation at a constant forward speed on undeformable surfaces with the roller vibrator off. Field measurements were conducted to characterize the ride vibration environments during the transit mode of operation. The measured data revealed significant magnitudes of whole-body vibration of the operator-station along the vertical, lateral, pitch and roll-axes. The model results revealed reasonably good agreements with ranges of the measured vibration data.

The Michelin Tweel tire structure has recently been developed as an innovative non-pneumatic tire which has potential for improved handling, grip, comfort, low energy loss when impacting obstacles and reduced rolling resistance when compared to a traditional pneumatic tire. One of the potential sources of vibration during rolling of a non-pneumatic tire is the buckling phenomenon and snapping back of the spokes in tension when they enter and exit the contact zone. Another source of noise was hypothesized due to a flower petal ring vibration effect due to discrete spoke interaction with the ring and contact with the ground during rolling as the spokes cycle between tension and compression. Transmission of vibration between the ground force, ring and spokes to the hub was also considered to be a significant contributor to vibration and noise characteristics of the Tweel.

The ride performance potentials of a prototype torsio-elastic axle suspension for an off-road vehicle were investigated analytically and experimentally. A forestry vehicle was fitted with the prototype suspension at its rear axle to assess its ride performance benefits. Field measurements of ride vibration along the vertical, lateral, fore-aft, roll and pitch axes were performed for the suspended and an unsuspended vehicle, while traversing a forestry terrain. The measured vibration responses of both vehicles were evaluated in terms of unweighted and frequency-weighted rms accelerations and the acceleration spectra, and compared to assess the potential performance benefits of the proposed suspension. The results revealed that the proposed suspension could yield significant reductions in the vibration magnitudes transmitted to the operator's station.

The paper presents a method for the indoor testing of road vehicle suspension systems. A suspension is positioned on a rotating drum which is located in the Laboratory for the Safety of Transport at Politecnico di Milano. Special six-axis load cells have been designed and used for measuring the forces/moments acting at each suspension-chassis joints. The forces/moments, wheel accelerations, displacements are measured up to 100 Hz. Two different types of test can be performed. The tire/wheel unbalance effect on the suspension system behavior (Vibration and Harshness, VH) has been analyzed by testing the suspension system from zero to the vehicle maximum speed on a flat surface and by monitoring the forces transmitted to the chassis. In the second kind of test, the suspension system has been excited as the wheel passes over different cleats fixed on the drum.

The advancements made in modeling and parameter identification of nonlinear isolation components in the underlying investigation confirm the importance of accurate Multibody Dynamics modeling of these components for reducing vibration and/or improving ride comfort. Considering dynamic stiffness and loss angle characteristics, the proposed nonlinear isolation component uses the Bouc/Wen hysteresis model for excitation amplitude dependency and a transfer function for excitation frequency dependency. Various combinations of Bouc/Wen hysteresis parameters result in different shapes for hysteresis loops and allows for modeling a wide range of soft and stiff isolator characteristics. The effect of the proposed isolation component on ride studies is illustrated by simulating a maneuver on a road profile using the OpenCRG road description with SimXpert Motion Workspace and Adams/Car. Tire belt dynamics are captured by adding a rigid ring part to the PAC2002 tire model [ 1 ].

This paper presents a methodology for simulating Fluid Structure Interaction (FSI) for a typical vehicle bonnet (hood) under a range of onset flow conditions. The hood was chosen for this study, as it is one of the panels most prone to vibration; particularly given the trend to make vehicle panels lighter. Among the worst-case scenarios for inducing vibration is a panel being subjected to turbulent flow from vehicle wakes, and the sudden peak loads caused by emerging from a vehicle wake. This last case is typical of a passing manoeuvre, with the vehicle suddenly transitioning from being immersed in the wake of the leading vehicle, to being fully exposed to the free-stream flow. The transient flowfield was simulated for a range of onset flow conditions that could potentially be experienced on the open road, which may cause substantial vibration of susceptible vehicle panels.

In response to the growing demand for fuel economy, we are developing a high-efficient variable displacement pump for hydraulic power steering systems. In order to develop a quiet variable displacement pump which generates lower noise for better vehicle interior sound quality, we have been developing a simulation tool which includes hydraulic analysis, vibration analysis, and vehicle interior noise analysis which combines simulation outputs and measured noise transfer functions of the targeted vehicle. This paper provides both validation results of the simulation tool and application examples to design improvement to conclude the effectiveness of the simulation tool developed.

Intensive R&D is currently performed worldwide on hybrid and electric vehicles. For full electric vehicles the driving range is limited by the capacity of currently available batteries. If such a vehicle shall increase its driving range some range extending backup system should be available. Such a Range Extender is a small system of combustion engine and electric generator which produces the required electricity for charging the batteries in time. Since the acoustic response of an electric motor driving the vehicle and of a combustion engine as part of a Range Extender is very different by nature an extensive acoustic tuning of the Range Extender is necessary to meet the requirements of exterior vehicle noise and passenger comfort. This paper describes the NVH (noise, vibration & harshness) development work of a range extender within the AVL approach of an electrically driven passenger car with range extender.

In the automotive industry, the use of beading is widely spread. Beads are primarily used to stiffen the floor and dash panels. The aim is to reduce vibration levels and hopefully at the same time reduce radiated noise. Beading has a positive effect close to the first panel mode's natural frequency however it can have a negative effect at all other frequencies. Typically, engineers assume a radiation efficiency of “1” (one) over the whole frequency range for simplicity or lack of available implemented formulation in their simulation tools. This assumption directs the investigation at reducing the vibration levels only. This approach can be misleading because even though radiation efficiency tends to “1” (one) above coincident frequency it is not the case below coincidence. While increasing stiffness reduces vibration levels, it also increases radiation efficiency. This can yield to higher levels of radiated noise.

For many technical applications it is necessary to avoid or to reduce vibrations. Factors benefiting from vibration reduction are for example the durability of the application, which is increased, as well as cost expenses and the level of noise, which are both decreased. Rough, bolted interfaces are common in most machines and can be used as damping devices with some effort. Perhaps in future such contact surfaces could be used as damping devices at the interfaces of an automotive engine or exhaust system. Nevertheless it is difficult to predict the effect of a change in contact interface parameters on the dynamic behavior of the entire mechanical system. Therefore a method for calculating the steady state behavior of elastic multi-body systems was developed. The basis of this method is a finite element model of each contacting unit. On each model a modal reduction is applied in order to reduce the degrees of freedom.

To uprate a 6-Cylinder In-line engine from 123 kW to 165 kW in power and upgrade the emission from Euro-2 to Euro-3 it was required to go for higher peak-firing pressures (PFP). The capability of Engine's Crankshaft to withstand the PFP was increased from 125 bar to 150 bar, maintaining the same cylinder centre distance. A crank-train model was used to achieve the required crankshaft strength for infinite fatigue life. The three aspects of crankshaft design, namely, crank strength, bearing selection, journal-pin lubrication and torsional vibration were considered during the design stage. The strength to withstand 150 bar PFP was achieved by increasing the crank web-thickness. To maintain the same cylinder centre distance, crankpin and main-journal lengths were reduced. Increased throw stiffness was achieved by increasing the crankpin diameter to improve crankshaft torsional behaviour.

To predict and minimize squeal propensity in brake systems, numerous models, which perform friction induced vibration, are available. However, today there is no model that can explain satisfactorily the dynamic behavior of brake systems. We argue that this is - among other effects - because existing models are based on decaying or constant coefficient of friction, although many investigations indicate rich dynamics of the coefficient of friction. Stability analysis of linear differential equations with periodic coefficients shows that instability regions change with rising amplitude of the periodic coefficients. If the periodic coefficient corresponds to the coefficient of friction, its periodicity can lower the stability of a minimal model.