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Technical Paper

Study of effect on structural strength of locally strengthened rotor lamination stack through virtual validation.

2024-10-17
2024-28-0006
Rotor and Stator are the key constituents of an electric motor that are made of several laminates punched from a sheet metal and stacked together. The rotor stack is inserted with magnets at the punched-out pockets and is assembled with a shaft via press fitting. Rotor assembly being the rotating part of an E-Motor is subjected to centrifugal loads due to masses of magnets, lamination stack and shaft rotating at high speeds, temperatures and assembling loads because of which rotor laminates experience failures as the high strains develop in the regions on the laminate that support magnets. Typically, these high strain locations are the sections of the magnet pockets one on the outer diameter of the laminate and the other at the sections between the magnet pockets. Traditionally, these high strains are addressed by increasing the area of these sections, but this has a detrimental effect on the electromagnetic performance.
Technical Paper

Enhancing Gear Performance: Discrete Response Optimization through OptiSLang

2024-10-17
2024-28-0040
Original equipment manufacturers have already begun to transition their vehicles from traditional internal combustion engines (ICs) to electric drives (EVs). As the industry continues to move towards electrification, the entire industry, and especially Valeo, is focusing on lean product development (LPD) with the help of numerical simulation. Optimization techniques help industry achieve the most accurate product at the lowest cost without sacrificing performance. Generally gears are mainly used for power transmission in the advanced technologies of electric vehicles. There are many factors that must be taken into account when designing a gear transmission system. Finding the most appropriate design parameters for a gear transmission system can be a challenge, and optimization parameters will help to find the best compromise between them.
Technical Paper

Modelling and Simulation Approach for Fiber-Reinforced Polymer Components in Passenger Car Engine Mounting Brackets

2024-10-17
2024-28-0016
The function of powertrain mounts is to securely anchor the engine and gearbox within a vehicle, effectively absorbing vibrations and shielding the vehicle's body from powertrain movements and road irregularities. Traditionally crafted from aluminum, sheet metal, or cast iron, there has been a notable transition towards employing fibre-reinforced polymer (FRP) as a viable alternative. This shift is motivated by the potential to reduce weight and cost, alongside enhancing noise, vibration, and harshness (NVH) characteristics. This study aims to evaluate the relative strengths of existing brackets compared to those made of FRP, with a focus on their modal response and crash resistance. Due to the absence of a standardized method for modelling orthotropic materials in powertrain mounting brackets, this paper proposes a systematic approach to address this gap.
Technical Paper

Powertrain NVH optimization of single cylinder IC engine

2024-10-17
2024-28-0001
With the increasing pursuit of comfort in mobility, NVH characteristics are becoming more important than ever. Achieving a benchmark beating NVH behavior involves optimizing source, transfer paths as well as target location mechanical characteristics. In ICE vehicles, powertrain accounts for a major source of noise and vibration. This work encompasses NVH refinement strategies for a single-cylinder compression ignition engine. The work starts with setting target values for NVH characteristics based on competitive benchmark data analysis. A complete development strategy involving extensive testing and CAE correlation is presented here. Contribution analysis in the component level for optimization of NVH behavior is carried out by employing NVH testing in an anechoic chamber supported by CAE simulations.
Technical Paper

Investigation of Mid-Frequency Interior Noise due to Tyre-Road Interaction

2024-10-17
2024-28-0005
Over the past twenty years, the automotive sector has increasingly prioritized lightweight and eco-friendly products. Specifically, in the realm of tyres, achieving reduced weight and lower rolling resistance is crucial for improving fuel efficiency. However, these goals introduce significant challenges in managing Noise, Vibration, and Harshness (NVH), particularly regarding mid-frequency noise inside the vehicle. This study focuses on analyzing the interior noise of a passenger car within the 250 to 500 Hz frequency range. It examines how tyre tread stiffness and carcass stiffness affect this noise through structural borne noise test on a rough road drum and modal analysis, employing both experimental and computational approaches. Findings reveal that mid-frequency interior noise is significantly affected by factors such as the tension in the cap ply, the stiffness of the belt, and the damping properties of the tyre sidewall.
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