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Technical Paper

Frequency Response Analysis of Fully Trimmed Models using Compressed Reduced Impedance Matrix Methodology

2024-06-12
2024-01-2947
As vibration and noise regulations become more stringent, numerical models need to incorporate more detailed damping treatments. Commercial frameworks, such as Nastran and Actran, allow the representation of trim components as frequency-dependent reduced impedance matrices (RIM) in frequency response analysis of fully trimmed models. The RIM is versatile enough to couple the trims to modal-based or physical components. If physical, the trim components are reduced on the physical coupling degrees of freedom (DOFs) for each connected interface. If modal, the RIMs are projected on the eigenmodes of the connected component. While a model size reduction is achieved compared to the original model, most numerical models possess an extensive number of interfaces DOFs, either modal or physical, leading to large dense RIM which triggers substantial memory and disk storage.
Technical Paper

Advanced squeak and rattle noise prediction for vehicle interior development – numerical simulation and experimental validation

2024-06-12
2024-01-2925
Squeak and rattle (SAR) noise audible inside a passenger car causes the product quality perceived by the customer to deteriorate. The consequences are high warranty costs and a loss in brand reputation for the vehicle manufacturer in the long run. Therefore, SAR noise must be prevented. This research shows the application and experimental validation of a novel method to predict SAR noise on an actual vehicle interior component. The novel method is based on non-linear theories in the frequency domain. It uses the harmonic balance method in combination with the alternating frequency/time domain method to solve the governing dynamic equations. The simulation approach is part of a process for SAR noise prediction in vehicle interior development presented herein. In the first step, a state-of-the-art linear frequency-domain simulation estimates an empirical risk index for SAR noise emission. Critical spots prone to SAR noise generation are located and ranked.
Technical Paper

On Improving CLEAN-SC Maps in The Wind Tunnel

2024-06-12
2024-01-2936
When travelling in an open-jet wind tunnel, the path of an acoustic wave is affected by the flow causing a shift of source positions in acoustical maps of phased arrays outside the flow. The well-known approach of Amiet attempts to correct for this effect by computing travel times between microphones and map points based on the assumption that the boundary layer of the flow, the so-called shear-layer, is infinitely thin and refracts the acoustical ray in a conceptually analogy to optics. However, in reality, the turbulent nature of both the not-so thin shear-layer and the acoustic emission process itself causes an additional smearing of sources in acoustic maps, which in turn causes deconvolution methods based on these maps - the most prominent example being CLEAN-SC - to produce certain ring effects, so-called halos, around sources.
Technical Paper

Evaluation of an optimal engine configuration for a SI Engine Fueled with Ethanol for Stationary Applications

2024-06-12
2024-37-0024
This work aims at investigating the optimal configuration of an internal combustion engine fueled with bio-ethanol for improving its brake power and efficiency as well as for reducing the NOx emissions, in stationary applications. A turbocharged spark ignition engine characterized by a single-point injection was preliminarily considered; subsequently, a direct injection configuration was investigated. For both cases, a 1-D numerical model was developed to compare the injection configurations under stoichiometric conditions and different spark timings. The analysis shows that the direct injection guarantees: a limited improvement of brake power and efficiency when the same spark timing is adopted, while NOx emissions increases by 20%; an increase of 6% in brake power and 2 percentage points in brake thermal efficiency by adopting the knock limited spark advance, but an almost double NOx emissions increase.
Technical Paper

Influence of Intake Charge Temperature and EGR Rate on the Combustion and Emission Characteristics of Ammonia/Diesel Dual-Fuel Engine

2024-06-12
2024-37-0025
Ammonia has emerged as a promising carbon-free alternative fuel for internal combustion engines (ICE), particularly in large-bore engine applications. However, integrating ammonia into conventional engines presents challenges, prompting the exploration of innovative combustion strategies like dual-fuel combustion. Nitrous oxide (N2O) emissions have emerged as a significant obstacle to the widespread adoption of ammonia in ICE. Various studies suggest that combining exhaust gas recirculation (EGR) with adjustments in inlet temperature and diesel injection timing can effectively mitigate nitrogen oxides (NOx) emissions across diverse operating conditions in dual-fuel diesel engines.
Technical Paper

Experimental Study of Lignin Fuels for CI Engines

2024-06-12
2024-37-0022
This study explores the feasibility of using a sustainable lignin-based fuel, consisting of 44 % lignin, 50 % ethanol, and 6 % water, in conventional compression ignition (CI) marine engines. Through experimental evaluations on a modified small-bore CI engine, we identified the primary challenges associated with lignin-based fuel, including engine startup and shutdown issues due to solvent evaporation and lignin solidification inside the fuel system, and deposit formation on cylinder walls leading to piston ring seizure. To address these issues, we developed a fuel switching system transitioning from lignin-based fuel to cleaning fuel with 85 vol% of acetone, 10 vol% of water and 5 vol% of ignition improving additive, effectively preventing system clogs.
Technical Paper

A Numerical Study of the Laminar Flame Speed of Hydrogen/Ammonia Mixtures under Engine-like Conditions

2024-06-12
2024-37-0020
In the effort to achieve the goal of a climate-neutral transportation system, the use of hydrogen and other synthetic fuels plays a key role. As battery electric vehicles become more widespread, e-fuels could be used to defossilize the hard-to-electrify transportation sectors and to store energy produced from renewable and non-continuous energy sources. Among e-fuels, hydrogen and ammonia are very attractive because they are carbon-neutral and their oxidation does not lead to any CO2 emissions. Furthermore, hydrogen/ammonia mixtures overcome the issues that arise as each of the two fuels is separately used. In the automotive sector, the use of either hydrogen, ammonia or their blends require a characterization of such mixtures under engine-like conditions, that is, at high pressures and temperatures. The aim of this work is to evaluate the Laminar Flame Speed (LFS) of hydrogen/ammonia mixtures by varying the thermodynamic conditions and the molar composition of the reactants.
Technical Paper

Bushing Stiffness Optimization Method for NVH Improvement Using Blocked Force and Energy-Based Index in Suspension System

2024-06-12
2024-01-2921
Reductions in powertrain noise have led to an increased proportion of road noise, prompting various studies aimed at mitigating it. Road excitation primarily traverses through the vehicle suspension system, necessitating careful optimization of the characteristics of bushings at connection points. However, optimizing at the vehicle assembly stage is both time-consuming and costly. Therefore, it is essential to proceed with optimization at the subsystem level using appropriate objective functions. In this study, the blocked force and energy-based index derived from complex power were used to optimize the NVH performance. Calculating the complex power in each bushing enables computing the power flow, thereby providing a basis for evaluating the NVH performance. Through stiffness injection, the frequency response functions (FRF) of the system can be predicted according to arbitrary changes in the bushing stiffness.
Technical Paper

A Finite-Element-Simulation Workflow to Investigate the Aero- and Vibro-Acoustic Signature of an Enclosed Centrifugal Fan

2024-06-12
2024-01-2940
Centrifugal fans are applied in many industrial and civil applications, such as manufacturing processes and building HVAC systems. They can also be found in automotive applications. Noise-reduction mea- sures for centrifugal fans are often challenging to establish, as acous- tic performance may be considered a tertiary purchase criterion after energetic efficiency and price. Nonetheless, their versatile application raises the demand for noise control. In a low-Mach-number centrifugal fan, acoustic waves are predominantly excited by aerodynamic fluctu- ations in the flow field and transmit to the exterior via the housing and duct walls. The scientific literature documents numerous mech- anisms that cause flow-induced sound generation, even though only some are considered well-understood. Numerical simulation methods are widely used to gather spatially high-resolved insights into physical fields.
Technical Paper

The irrotational intensity: an efficient tool to understand the vibration energy propagation in complex structures using an FE Model.

2024-06-12
2024-01-2942
Although structural intensity was introduced in the 80's, this concept never found practical applications, neither for numerical nor experimental approaches. Quickly, it has been pointed out that only the irrotational component of the intensity offers an easy interpretation of the dynamic behavior of structures by visualizing the vibration energy flow. This is especially valuable at mid and high frequency where the structure response understanding can be challenging. A new methodolodgy is proposed in order to extract this irrotational intensity field from the Finite Element Model of assembled structures such as Bodies In White. This methodology is hybrid in the sense that it employs two distinct solvers: a dynamic solver to compute the structural dynamic response and a thermal solver to address a diffusion equation analogous to the thermal conduction built from the previous dynamic response.
Technical Paper

Assessment of Equivalent Properties for Flat Multilayered Panels

2024-06-12
2024-01-2943
The use of lightweight complex heterogeneous structures increased during the last years principally in the transportation sector (i.e., aviation and trains). This sector's technology enhancement pursues reducing long-term CO2 emissions and increasing efficiency. Lightweight structures may have poor vibro-acoustic behavior and in designs with complex shapes and material heterogeneities, its vibro-acoustic modeling brings new challenges in terms of accuracy and computational cost. Techniques such as model order reduction, homogenization, mesh and meshless methods (with and without periodicity conditions) and energy methods are typically employed to tackle this problem. Within homogenization techniques, an equivalent properties strategy can be utilized to equivalently represent complex structures into more simple ones (for example, a single layer panel).
Technical Paper

Advance simulation method for aero-acoustic vehicle design

2024-06-12
2024-01-2938
With the electrification of powertrains, the noise level inside vehicles reach high levels of silence. The dominant engine noise found in traditional vehicles is now replaced by other sources of noise such as rolling noise and aeroacoustic noise. These noises are encountered during driving on roads and highways and can cause significant fatigue during long journeys. Regarding aeroacoustic phenomena, the noise transmitted into the cabin is the result of both turbulent pressure and acoustic pressure created by the airflow. Even though it is lower in level, the acoustic pressure induces most of the noise perceived by the occupants. Its wavelength is closer to the characteristic vibration wavelengths of the glass, making its propagation more efficient through the vehicle's windows. The accurate modeling of these phenomena requires the coupling of high-frequency computational fluid dynamics (CFD) simulations and vibro-acoustic simulations.
Technical Paper

Guided Port Injection of Hydrogen as An Approach for Reducing Cylinder-To-Cylinder Deviations in Spark-Ignited H2 Engines – A Numerical Investigation

2024-06-12
2024-37-0008
The reduction of anthropogenic greenhouse gas emissions and ever stricter regulations on pollutant emissions in the transport sector require research and development of new, climate-friendly propulsion concepts. The use of renewable hydrogen as a fuel for internal combustion engines promises to provide a good solution especially for commercial vehicles. For optimum efficiency of the combustion process, hydrogen-specific engine components are required, which need to be tested on the test bench and analysed in simulation studies. This paper deals with the simulation-based investigation and optimisation of fuel injection in a 6-cylinder PFI commercial vehicle engine, which has been modified for hydrogen operation starting from a natural gas engine concept.
Technical Paper

Harmonizing Safety Regulations and Perception: A Simulation Methodology for AVAS System Design

2024-06-12
2024-01-2915
The development of an effective Acoustic Vehicle Alert System (AVAS) is not solely about adhering to safety regulations; it also involves crafting an auditory experience that aligns with the expectations of vulnerable road users. To achieve this, a deep understanding of the acoustic transfer function is essential, as it defines the relationship between the sound emitter (the speaker inside the vehicle) and the receiver (the vulnerable road user). Maintaining the constancy of this acoustic transfer function is paramount, as it ensures that the sound emitted by the vehicle aligns with the intended safety cues and brand identity that is defined by the car manufacturer. In this research paper, three distinct methodologies for calculating the acoustic transfer function are presented: the classical Boundary Element method, the H-Matrix BEM accelerated method, and the Ray tracing method.
Technical Paper

Model-Based Algorithm for Water Management Diagnosis and Control for PEMFC Systems for Motive Applications

2024-06-12
2024-37-0004
Water management in PEMFC power generation systems is a key point to guarantee optimal performances and durability. It is known that a poor water management has a direct impact on PEMFC voltage, both in drying and flooding conditions: furthermore, water management entails phenomena from micro-scale, i.e., formation and water transport within membrane, to meso-scale, i.e., water capillary transport inside the GDL, up to the macro-scale, i.e., water droplet formation and removal from the GFC. Water transport mechanisms through the membrane are well known in literature, but typically a high computational burden is requested for their proper simulation. To deal with this issue, the authors have developed an analytical model for the water membrane content simulation as function of stack temperature and current density, for fast on-board monitoring and control purposes, with good fit with literature data.
Technical Paper

Making modal analysis easy and more reliable – Reference points identification by experimental prestudy

2024-06-12
2024-01-2931
Though modal analysis is a common tool to evaluate the dynamic properties of a structure, there are still many individual decisions to be made during the process which are often based on experience and make it difficult for occasional users to gain reliable and correct results. One of those experience-based choices is the correct number and placement of reference points. This decision is especially important, because it must be made right in the beginning of the process and a wrong choice is only noticeable in the very end of the process. Picking the wrong reference points could result in incomplete modal analysis outcomes, as it might make certain modes undetectable, compounded by the user's lack of awareness about these missing modes. In the paper an innovative approach will be presented to choose the minimal number of mandatory reference points and their placement.
Technical Paper

Analysis of the Mechanism by Which Spline Pitch Errors Affect Powertrain Vibration

2024-06-12
2024-01-2910
As environmental concerns have taken the spotlight, electrified powertrains are rapidly being integrated into vehicles across various brands, boosting their market share. With the increasing adoption of electric vehicles, market demands are growing, and competition is intensifying. This trend has led to stricter standards for noise and vibration as well. To meet these requirements, it is necessary to not only address the inherent noise and vibration sources in electric powertrains, primarily from motors and gearboxes, but also to analyze the impact of the spline power transmission structure on system vibration and noise. Especially crucial is the consideration of manufacturing discrepancies, such as pitch errors in splines, which various studies have highlighted as contributors to noise and vibration in electric powertrains. This paper focuses on comparing and analyzing the influence of spline pitch errors on two layout configurations of motor and gearbox spline coupling structures.
Technical Paper

Metrics based design of electromechanical coupled reduced order model of an electric powertrain for NVH assessment

2024-06-12
2024-01-2913
Electric vehicles offer cleaner transportation with lower emissions, thus their increased popularity. Although, electric powertrains contribute to quieter vehicles, the shift from internal combustion engines to electric powertrains presents new Noise, Vibration, and Harshness challenges. Unlike traditional engines, electric powertrains produce distinctive tonal noise, notably from motor whistles and gear whine. These tonal components have frequency content, sometimes above 10 kHz. Furthermore, the housing of the powertrain is the interface between the excitation from the driveline via the bearings and the radiated noise (NVH). Acoustic features of the radiated noise can be predicted by utilising the transmitted forces from the bearings. Due to tonal components at higher frequencies and dense modal content, full flexible multibody dynamics simulations are computationally expensive.
Technical Paper

A Study on RANC Technique for Server-based Control Filter Optimization

2024-06-12
2024-01-2960
Broadband active noise control algorithms require high-performance so multi-channel control to ensure high performance, which results in very high computational power and expensive DSP. When the control filter update part need a huge computational power of the algorithm is separated and calculated by the server, it is possible to reduce cost by using a low-cost DSP in a local vehicle, and a performance improvement algorithm requiring a high computational power can be applied to the server. In order to achieve the above goal, this study analyzed the maximum delay time when communication speed is low and studied response measures to ensure data integrity at the receiving location considering situations where communication speed delay and data errors occur.
Technical Paper

AI-Based Optimization Method of Motor Design Parameters for Enhanced NVH Performance in Electric Vehicles

2024-06-12
2024-01-2927
The high-frequency whining noise produced by motors in modern electric vehicles causes a significant issue, leading to annoyance among passengers. This noise becomes even more noticeable due to the quiet nature of electric vehicles, which lack other noises to mask the high-frequency whining noise. To improve the noise caused by motors, it is essential to optimize various motor design parameters. However, this task requires expert knowledge and a considerable time investment. In this study, we explored the application of artificial intelligence to optimize the NVH performance of motors during the design phase. Firstly, we selected and modeled three benchmark motor types using Motor-CAD. Machine learning models were trained using Design of Experiment methods to simulate batch runs of Motor-CAD inputs and outputs.
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