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The increased adoption of downsized engines along with higher electrical demand is generating a challenge to the Front-End Accessory Drive (FEAD) system functioning and validation. One alternative to speed up the validation of potential design solutions is the in-vehicle experimental tests approach. Nevertheless, experimental data collection during in-vehicle FEAD evaluation imposes some challenges due to, for instance, packaging space constraints and sample rate required to capture the dynamic events during vehicle operation, among others. In order to overcome this limitation, the objective of this research is focused in the development of a customized test rig that emulates FEAD layout of an actual automobile in a simulated operating condition.

Increasingly research has been conducted lately towards reduction of both fuel consumption and gases emission in automotive vehicles propelled by Internal Combustion Engines. Among many initiatives, downsizing of those engines has been broadly adopted, arising side effects as increased vibration levels along Front-End Accessory Drive (FEAD) system. The present study focuses on the potential improvement of transmission efficiency and of vibration levels along FEAD by considering different layouts for the system. Multiple combinations of alternator pulley technologies and tensioner types are evaluated either during in-vehicle tests or in customized test rig that emulates vehicle FEAD in operating conditions. Specific transducers spred over the vehicle and at test rig assure the relevant data are captured for every layout arrangement investigated.

Currently the numerical simulations of the vibro-acoustic behavior of vehicles are built considering only major structures, such as its basic structure (body in white), doors, dashboard etc. To take into account the contribution of other components (such as trims, seats, sound insulation etc.) to the overall response of the model, the average characteristics of these materials are inserted globally in this model. However, for more correlated models is necessary to consider local characteristics of these components. This work presents the numerical procedure for simulating the effect of the structural damping of viscoelastic coatings and the acoustic absorption of the trims such that its effects can be considered in the model of the full vehicle. The operating forces applied to the model were estimated from the laboratory and road tests using the SPC/TPA technique.