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Training / Education

Critical Concepts of Tolerance Stacks 2009 3-day

2020-10-20
This course, based on the ASME Y14.5-2009 standard, provides an in-depth explanation of how to use tolerance stacks to analyze product designs and how to use geometric tolerances in stacks. You will learn the essential methods and concepts used for creating 1D part and assembly tolerance stacks.
Technical Paper

A Study on Optimization of Brake Feeling and Method for Flexible Brake with Integrated Electronic Booster

2020-10-05
2020-01-1642
Throughout the automotive industry, the application of an integrated electronic booster (IEB) system has been actively applied following with diversify powertrain types and expand autonomous vehicles. Compared to the existing vacuum boosters, the performance advantages of IEB are 1) robustness against environmental changes, 2) rapid hydraulic reactivity, etc., and the advantages of cost / university are 1) flexibility for powertrain changes 2) weight saving 3) package simplification. Although IEB has a great advantage in performance and cost, it still needs a lot of research in various fields to realize the braking feeling, which is the performance of the emotional aspect, similar to the existing system. The braking feeling of the existing system was determined by the mechanical action of the hardware connected from the input device, the brake pedal to the hydraulic line. However, IEB system has a completely different structure from the existing system.
Technical Paper

Transitioning from IC Engine to Electric Vehicle: An Optimized Wheel End Solution

2020-10-05
2020-01-1632
This paper discusses the change in vehicle parameters when moving from a conventional internal combustion engine to electric motor. It discusses the impact on the wheel end bearings. Typically these include higher GAWRs (Gross Axle Weight Rating) at lower center of gravity heights. These changes require bearings to handle higher loads. Typically, larger loads will increase the bearing size and with it the mounting interface dimensions to auxiliary components. Timken demonstrates an alternative bearing design that can handle higher vehicle GAWRs but would allow for continuity in the surrounding brake corner components – saving OEMs significant design costs and delays.
Technical Paper

A Full-System Approach to Maximise Energy Efficiency of a Wheel Bearing

2020-10-05
2020-01-1631
Environmental sustainability is morphing Automotive technical development strategies and driving the evolution of vehicles with a speed and a strength hardly foreseeable a decade ago. The entire vehicle architecture is impacted, and energy efficiency becomes one of the most important parameters to reach goals, which are now not only market demands, but also based on regulatory standards with penalty consequences. Therefore, rolling drag from all bearings in multiple rotating parts of the vehicle needs to be reduced; wheel bearings are among the biggest in size regardless of the powertrain architecture (ICE, Hybrid, BEV) and have a significant impact. The design of wheel bearings is a complex balance between features influencing durability, robustness, vehicle dynamics, and, of course, energy efficiency.
Technical Paper

Study on the Effect of Structural Parameters on the Linear Control Performance of High Speed On-Off Valve Based on Flow Field Analysis

2020-10-05
2020-01-1644
High speed on-off valve under the control of high frequency pulse width modulation (PWM) can make control linearly as proportional valve does. It is because its valve opening is adjusted linearly by duty ratio within a certain range. It is significant for high speed on-off valve to achieve precise linear control performance. In practice the performance is influenced not only by control strategy, but also the structural parameters of the valve, such as seat angle, spool diameter of valve and so on. In this paper, it is indicated that the effects of structural parameters on linear control performance of high speed on-off valve is exerted by flow force since different structural parameters bring about different valve opening-flow force characteristics. Accordingly, the relationship between the valve structural parameters and flow force is emphasized.
Technical Paper

A Generic Testbody for Low-Frequency Aeroacoustic Buffeting

2020-09-30
2020-01-1515
Raising demands towards lightweight design paired with a loss of originally predominant engine noise pose significant challenges for NVH engineers in the automotive industry. From an aeroacoustic point of view, low frequency buffeting ranks among the most frequently encountered issues. The phenomenon typically arises due to structural transmission of aerodynamic wall pressure fluctuations and/or, as indicated in this work, through rear vent excitation. A possible workflow to simulate structure-excited buffeting contains a strongly coupled vibro-acoustic model for structure and interior cavity excited by a spatial pressure distribution obtained from a CFD simulation. In the case of rear vent buffeting no validated workflow has been published yet. While approaches have been made to simulate the problem for a real-car geometry such attempts suffer from tremendous computation costs, meshing effort and lack of flexibility.
Technical Paper

Simulating and Optimizing the Dynamic Chassis Forces of the Audi e-tron

2020-09-30
2020-01-1521
With battery electric vehicles (BEV), due to the absence of the combustion process, the rolling noise comes even more into play. The BEV technology also leads to different concepts of how to mount the electric engine in the car. Commonly, also applied with the Audi e-tron, the rear engine is mounted on a subframe, which again is connected to the body structure. This concept leads to a better insulation in the high frequency range, yet it bears some problems in designing the mounts for ride comfort (up to 20Hz) or body boom (up to 70Hz). Commonly engine mounts are laid-out based on driving comfort (up to 20Hz). The current paper presents a new method to find an optimal mount design (concerning the stiffness) in order to reduce the dynamic chassis forces which are transferred to the body up to 100Hz. This directly comes along with a reduction of the sound pressure level for the ‘body boom’ phenomena.
Technical Paper

Advanced CAE Methods for NVH Development of High Speed Electric Axle

2020-09-30
2020-01-1501
The rate in the electrification of vehicles has risen in recent years. With intensified development more and more attention is paid to the noise and vibration in such vehicles especially from the EDU (Electric Drive Unit). In this paper the main NVH simulation process of a high-speed E-axle up to 30,000 rpm for premium class vehicle application is presented. The high speed, high-power density and lightweight design introduces new challenges. Benchmarking of different EDUs and vehicles leads to targets which can be used at the early stage of development as subsystem targets. This paper shows the CAE methodology which can be used to verify the design and guarantee the target achievement. Using CAE both source and structure can be optimized to improve the NVH behavior.
Technical Paper

Numerical Analysis of the Influences of Wear on the Vibrations of Power Units

2020-09-30
2020-01-1506
Numerical Analysis of the Influences of Wear on the Vibrations of Power Units Yashwant Kolluru, Rolando Doelling eBike Department Robert Bosch GmbH Kusterdingen, Germany yashwant.kolluru@de.bosch.com rolando.doelling@de.bosch.com Lars Hedrich Institute of Informatics Goethe University Frankfurt Frankfurt, Germany hedrich@em.informatik.uni-frankfurt.de The prime factor, which influences vibrations of electro-mechanical drives, is wear at the components. This paper discusses the numerical methods developed for abrasion, vibration calculations and the coupling between wear and NVH models of drive unit. Wear is a complex process and understanding it is essential for vibro-acoustics. The paper initially depicts finite element static model used for wear calculations. The special subroutines developed, aids in coupling the wear equations, various contact and friction formulations to the numerical model.
Technical Paper

Analytical Prediction of Acoustic Emissions From Turbocharger Bearings

2020-09-30
2020-01-1504
Turbochargers are progressively used in modern automotive engines to enhance engine performance and reduce energy loss and adverse emissions. Use of turbochargers along with other modern technologies has enabled development of significantly downsized internal combustion engines. However, turbochargers are major sources of acoustic emissions in modern automobiles. Their acoustics has a distinctive signature, originating from fluid-structure interactions. The bearing systems of turbochargers also constitute an important noise source. In this case, the acoustic emissions can mainly be attributed to hydrodynamic pressure fluctuations of the lubricant film. The developed analytical model determines the lubricant pressure distribution in the floating journal bearings used mainly in the modern turbocharges. This allows for an estimation of acoustic emissions.
Technical Paper

Analytical Rotordynamic Study of a High-Speed Gear Transmission System for Race Applications

2020-09-30
2020-01-1502
In motorsport power transmission systems, high-speed operation can be associated with significant rotordynamic effects. Changes in the natural frequencies of lateral (bending) vibrational modes as a function of spin speed are brought about by gyroscopic action linked to flexible shafts and mounted gear components. In the investigation of high-speed systems, it is important that these effects are included in the analysis in order to accurately predict the critical speeds encountered due to the action of the gear mesh and other sources of excitation. The rotordynamic behaviour of the system can interact with crucial physical parameters of the transmission, such as the stiffnesses of the gear mesh and rolling element-to-raceway contact in the bearings. In addition, the presence of the gear mesh acts to couple the lateral and torsional vibration modes of a dual-shaft transmission through which a torque flows.
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