E-Motor: Verifizierung, Validierung, Integration Testbasierte Validierung von Komponenten und elektrifizierten Gesamtfahrzeug

Transcription

1 E-Motor: Verifizierung, Validierung, Integration Testbasierte Validierung von Komponenten und elektrifizierten Gesamtfahrzeug - Stuttgart Unrestricted

2 Simcenter Testlab Simcenter SCADAS Simcenter Test Page 2

3 Deploying the digital twin Simcenter Test for multi-attribute performance engineering Multi-attribute Optimization NVH & Acoustics Strength & Durability Vehicle Dynamics Requirements Architecture Subsystem System Vehicle performance sign-off Page 3

4 NVH of electric vehicles - Test Page 4

5 Interior noise HEV Source Considerations New noise sources Electric powertrain components Electric Motor Invertor - Current-control strategy New secondary sources Battery cooling Complex gears in HEV Less masking Windnoise Accessories Roadnoise Electric motor/gearbox noise Wind noise 30 Road noise Greg Goetchius opinion in Sound &Vibration, April 2011 Page 5

6 Vehicle NVH & Acoustic Innovation Area Electric and hybrid electric vehicles Applications Electric motor Wind Noise Road Noise Other, HVAC, battery cooling, steering systems, Warning sounds Page 6

7 Vehicle NVH & Acoustic Innovation Area Electric and hybrid electric vehicles Challenge Electric motor Sound levels may be lower but the high frequency tonal components make them quite annoying Page 7

8 ICE versus EV Motor order Resonance Motor order Resonance Tacho1 (T1) rpm db(a) Pa AutoPower mic (A) WF 126 [ rpm] Hz mic (CH1) Off-zero harmonics. Origin? ICE driven Electric driven Page 8

9 Interior noise HEV Source Considerations Permanent Magnet Motors Magnets embedded in the steel rotor Induction Motors Cylinder of steel with aluminum or copper conductors Switched Reluctance Motor Soft magnetic steel material Page 9

10 What are these High frequency Causes for the off-zero orders Electric Motor Control Switching Frequencies Electric Motor and Combustion Engine Orders Page 10

11 From DC to AC The inverter Pulse width Modulated Pulse Wave Unmodulated Pulse Wave Modulated (PWM) Sine Wave Page 11

12 DC Power Interior noise HEV Source Considerations Noise produced by the Electromechanical Control System PCU Motor voltage and current (harmonics) Motor cables Electromotor Vibrations Internal forces PWM Switching Frequency Voltage/Current control - Sinusoidal - Space vector - Hysteresis Current and voltage harmonics Permanent Magnet DC PM Synchronous Induction Motors Switched Reluctance Page 12

13 Interior noise Contribution of inverter Noise produced by the Electromechanical Control System: PWM Control IM-drive: Increasing the switching frequency -> lower vibration speeds Loudness: Sharpness: Page 13

14 What is Sound Quality? Psychoacoustics is the science of sound perception. It studies the psychological and physiological responses associated with sound Objective assessment Analyze your sound with measures that can be quantified Subjective assessment Study the perception of the sound What are the positive and negative contributors to your products sound Page 14

15 Psychoacoustics Hearing threshold Equal loudness curves Bark scale Temporal effect Masking Auditory Range L db PAIN THRESHOLD HEARING DOMAIN MUSIC SPEECH HEARING THRESHOLD 20 Hz k 2 k 5 k 10 k20 khz Binaural Recording Page 15

16 Sound Quality - Subjective Analysis - Jury Testing Gather subjective opinions Benchmark competition Consistency and statistical analysis SUBJECTIVE ANALYSIS Automated reporting Understand the expectations of your customers and design the product that exceeds them Listening tests Page 16

17 Benchmarking & Target Setting Interior noise - overall levels, sound quality metrics Page 17 Pa db(a) 10 db acum Amplitude Overall noise level A Weighted rpm Sharpness F F ICE Sharpness MICb:frri:S Sharpness MICI:frri:S EV rpm Road Speed (DT1) km/h Road Speed (DT1) km/h EV - Sound Pressure Level Hz FRRI:OUT:S (CH112) EV - Prominence Ratio Prominence Ratio FRRI:OUT:S WF 267 [ rpm] Hz FRRI:OUT:S (CH112) 48 th Order - Whine db(a) Pa 48 th Order - Whine db /Pa Pa 2 2

18 Interior noise The Source Transfer Receiver model db Pa Source (F i,q j ) X Transfer (NTF) = Receiver (y k ) Structural and acoustic Load Identification Noise source mechanisms Source modeling and engineering System concepts and layout engineering System modeling and engineering Noise transfer mechanisms TPA, Modal Analysis, FEM/BEM modeling Materials, architectures, system design engineering Assessing customer value (annoyance, quality, message) Setting targets Design engineering towards the right targets Relevant validation of targets Page 18

19 WorldAutoSteel Reducing body structure weight by 35 percent and achieve NVH targets Pursuing seemingly contradictory objectives Enhanced NVH performance Helped achieve a 35 percent reduction in body structure weight Enabled engineers to identify and analyze specific NVH problem areas A comparison of EV- and ICE-powered class A/B car concept to enable target setting Clever body design that balances low mass and acceptable NVH performance Use Simcenter Engineering capabilities to balance multiple performance attributes in parallel Use LMS Virtual.Lab early in concept design Simcenter Engineering services carried out the NVH simulation studies on the FSV project in close collaboration with the consortium performing the crash and rigidity studies. Page 19

20 Interior noise HEV Receiver Considerations Case: WorldAutoSteel FSV concept study Benchmark Small Vehicle ICE (3-cyl.) vs. EV PWT Acceleration WOT ICE EV Low Frequency (< 200 Hz): Low orders up to np/2 Mid Frequency ( Hz): Order np quiet range Page 20

21 Interior noise HEV Receiver Considerations Case: WorldAutoSteel FSV concept study Benchmark Vehicle ICE vs. EV PWT Constant speed 120kph, drivers ear 10 db Order 4xnp Pa db(a) Articulation Index: 56% 73% Hz LF: road noise Page 21

22 Interior noise The Source Transfer Receiver model db Pa Source (F i,q j ) X Transfer (NTF) = Receiver (y k ) Structural and acoustic Load Identification Noise source mechanisms Source modeling and engineering System concepts and layout engineering System modeling and engineering Noise transfer mechanisms TPA, Modal Analysis, FEM/BEM modeling Materials, architectures, system design engineering Assessing customer value (annoyance, quality, message) Setting targets Design engineering towards the right targets Relevant validation of targets Page 22

23 Hz current1 (CH105) rpm Hz Mntl:1_06:+Z (CH3) Hz M1 (CH233) PSD current1 WF 381 [ rpm] PSD Mntl:1_06:+Z WF 381 [ rpm] PSD M1 WF 381 [ rpm] Interior noise HEV Source Considerations SRM Spectrum of current, acceleration and sound - ODS Phase current Tacho_SRM_Filt2 (T3) rpm db Pa 2 /Hz Tacho_SRM_Filt2 (T3) Tacho_SRM_Filt2 (T3) rpm db /Hz A 2 Acceleration db /Hz g 2 Sound Frequency (Hz) Page Hz: 6330 Hz: Both square and ovalization modes are excited!

24 Interior noise HEV Transfer System Engineering Experimental approach: Transfer Path Analysis Classical TPA invertor + Energetic methods: higher frequencies Time domain TPA: Transients & Auralization Structure borne Airborne charger motor batteries Page 24

25 Investigation of electrical motor noise Source-Transfer-Receiver methodology Applying TPA and ASQ methodologies on an electric vehicle Traditional TPA technology applied to electric vehicles Identification of major noise contributors up to high frequency (up to 100 th order) Electro-magnetic forces, gear whine and PWM switching as noise generating mechanisms Structure borne TPA Airborne TPA Investigation of airborne and structure borne source contributions from the powertrain to the interior by applying common TPA technologies. Traditional TPA methodologies prove well capable of investigating high frequency noise content as seen in electric vehicles if measurements and analysis are done with appropriate care. Page 25

26 Concept: Component Based TPA Allow modification prediction and virtual assembly SPLIT Body FRF + Mount Stiffness ASSEMBLE Generate the expected contact forces & contributions without physically integrating the source PREDICT NVH PERFORMANCE & MODIFICATION PREDICTION Virtual Assembly Powertrain Test Bench Source Description using in-situ TPA Road Noise, Tires, EPS Steering System, ABS, Wiper Motors, CASCADE COMPONENT DESIGN TARGETS TO SUPPLIERS Page 26

27 Daimler Truck Predict PBN levels with exhaust measured on test bench Towards virtual vehicle assembly State of the art in-room Passby noise software Quantification of subsystem contribution Calculate contribution of exhaust system, as measured on a test bench Use virtual vehicle assembly to reduce testing time Perform component tests on test bench at supplier site OEM assembles and evaluates configurations based on supplier data Daimler Trucks no longer needs to fully assemble and test every truck variant. By using this Siemens technology, Daimler Trucks can reduce the testing time by more than 50 % Page 27

28 Interior noise The Source Transfer Receiver model db Pa X = Source (F i,q j ) Transfer (NTF) Receiver (y k ) Structural and acoustic Load Identification Noise source mechanisms Source modeling and engineering System concepts and layout engineering System modeling and engineering Noise transfer mechanisms TPA, Modal Analysis, FEM/BEM modeling Materials, architectures, system design engineering Assessing customer value (annoyance, quality, message) Setting targets Design engineering towards the right targets Relevant validation of targets Page 28

29 Interior noise HEV Transfer System Engineering Can weakening NTF target gain weight? Page 29

30 Interior noise HEV Transfer System Engineering EV less low-frequency noise => gain mass in structural design by reducing steel sheet thickness and using of vibration damping steel EV high-frequency tonal components => increased HF isolation and absorption => specific sound pack design Page 30

31 Vehicle NVH & Acoustic Innovation Area Electric and hybrid electric vehicles Applications Electric motor Analyze sound quality Wind Noise Road Noise Other, HVAC, battery cooling, steering systems, Warning sounds Simulate and/or test electric motor noise from current to ear Integrate the electric powertrain into vehicle Page 31

32 Vehicle NVH & Acoustic Innovation Area Electric and hybrid electric vehicles Challenge Wind Noise Lower powertrain noise lets wind noise become apparent from lower speeds Page 32

33 Layout example of next generation aero-acoustic wind tunnel In vehicle Turntable & Traverse 4 exterior Arrays Wind tunnel control room Online and offline Analysis system Page 33

34 From Daimler wind tunnel Page 34

35 Vehicle NVH & Acoustic Innovation Area Electric and hybrid electric vehicles Applications Electric motor Analyze sound quality Wind Noise Test the right thing in an efficient way Road Noise Other, HVAC, battery cooling, steering systems, Warning sounds Simulate and/or test electric motor noise from current to ear Simulate as much as you can prior to prototypes Integrate the electric powertrain into vehicle Page 35

36 Vehicle NVH & Acoustic Innovation Area Electric and hybrid electric vehicles Challenge Road Noise Less masking and low rolling resistance tires make road noise more important Page 36

37 Road and Tire noise Types of noise resulting in exterior and interior noise TIRE NOISE = airborne Originates from tire surface vibrations and aeroacoustic events ROAD NOISE = structure borne Originates from tire patch forces wheel hub car body occupants ears/passenger compartment Page 37

38 SPL (db) Road and Tire noise Lower road noise levels by combining test & simulation Test models Body, Tire Hybrid Test/FE model (solved in NX Nastran) Minimize SPL by optimizing sub-systems and mounts FE/Test Mount description Operational Forces from Test or Simulation Original Modified Frequency (Hz) Target FE model for subframe Page 38

39 Vehicle NVH & Acoustic Innovation Area Electric and hybrid electric vehicles Applications Electric motor Analyze sound quality Simulate and/or test electric motor noise from current to ear Wind Noise Test the right thing in an efficient way Simulate as much as you can prior to prototypes Road Noise Identify the root causes and verify chassis and body modifications to increase passenger comfort Other, HVAC, battery cooling, steering systems, Warning sounds Integrate the electric powertrain into vehicle Page 39

40 Vehicle NVH & Acoustic Innovation Area Electric and hybrid electric vehicles Challenge Other New noise sources, such as HVAC, battery cooling, steering systems, wiper motors, are more noticeable and pose a complex problem to solve Page 40

41 Engine-powered accessories Power Steering System, AC compressor - Modulations Power Steering System AC Compressor Testlab Neo Roughness The Power Steering system sounds rough, because there are modulations present between 20 Hz and 300 Hz. This often happens when 2 orders are modulating each other. Modulation Maps This analysis shows how the complete frequency range is modulated. The AC compressor sound has a very audible 50 Hz modulation the harmonic cursors help to locate the problematic area. Page 41

42 Mechatronic system integration Example: Steering Systems System level integration Component Sizing Controls integration Detailed component models 1D and 3D simulation for NVH and acoustic optimization System validation Test rig or full vehicle testing Multi-domain engineering supporting all aspects of development Page 42

43 Denso Releasing products 3 times faster by using Simcenter Engineering services Quantify noise transfer paths in a shorter time Released products 3 times faster than previously possible Reduced time it took to measure TPA by 70 percent Enhanced collaboration with OEMs Page 43 Speeding the release of products Close cooperation enhances results Develop new approach in cooperation with Simcenter Engineering services Deploy LMS testing methods & tools into Denso s HVAC system development process OEMs are really satisfied with the input that we deliver using Simcenter tools. Thanks to the Simcenter solutions, we are able to release our new products three times faster than was previously the case. Tomohiro Sudo, Assistant Project Manager NVH

44 Battery Cooling NVH Validate modifications w/o need for full vehicle validation Modification at unit projected to in-vehicle SOURCE Inlet & outlet ducts located in cabin interior Transfer Measured FRF s between sources and cabin microphones RECEIVER Cabin sound pressure level Solution: In vehicle near field sound pressure levels accurately calculated and correlated from unit level source measurement using Airborne Source Quantification Method Predict the likely effect on cabin sound pressure levels due to modifications of the battery cooling unit ducts without in-vehicle testing Page 44

45 Vehicle NVH & Acoustic Innovation Area Electric and hybrid electric vehicles Applications Electric motor Wind Noise Road Noise Other Warning sounds Analyze sound quality Simulate and/or test electric motor noise from current to ear Integrate the electric powertrain into vehicle Test the right thing in an efficient way Simulate as much as you can prior to prototypes Identify the root causes and verify chassis and body modifications to increase passenger comfort Take control of the variety of new noise sources, such as HVAC, battery cooling, steering systems, wiper motors, that would have gone unnoticed in the past Page 45

46 Vehicle NVH & Acoustic Innovation Area Electric and hybrid electric vehicles Challenge Warning sounds Legislation is either already in place or is at least soon to come in many regions to protect vulnerable road users from not noticing electric vehicles Low Risk Pedestrian Detected High Risk Pedestrian Detected Page 46

47 Warning sounds Pass the minimum pass-by noise threshold Key messages: Minimum noise test procedure supported Required for homologation Test can be done both in-room or exterior Stopped condition Microphones at 2m Unestricted Frequency Siemens shift AG 2018 Page 47 Slow speed cruise

48 Vehicle NVH & Acoustic Innovation Area Electric and hybrid electric vehicles Applications Electric motor Wind Noise Road Noise Other Warning sounds Analyze sound quality Simulate and/or test electric motor noise from current to ear Integrate the electric powertrain into vehicle Test the right thing in an efficient way Simulate as much as you can prior to prototypes Identify the root causes and verify chassis and body modifications to increase passenger comfort Take control of the variety of new noise sources, such as HVAC, battery cooling, steering systems, wiper motors, that would have gone unnoticed in the past Simulate the noise generated by warning systems that are designed to protect pedestrians without creating noise pollution Page 48

49 Model Based System Testing Page 49

50 New challenges in NVH engineering Reduce dependency on late-stage prototype testing Reduce dependency full vehicle prototype validation Virtual Testing Conventional bench testing Virtual Testing Virtual Testing Virtual Testing + early stage validation + no expensive prototyping - guaranteed accuracy - full-vehicle assessment + sub-system validation + accuracy - prototype cost and lead time - full-vehicle assessment Eliminate late stage modifications Avoid program delays Reduce cost and time for prototype testing Conventional bench testing Field testing Virtual Testing Virtual Testing + full-vehicle validation + accuracy - prototype cost and lead time - risk for late-stage issue Page 50

51 Simcenter Testlab Model Based System Testing Combining the speed of simulation and the accuracy of testing Virtual Testing Virtual Testing Virtual Testing Component, subsystem and control unit testing in near-real conditions Conventional bench testing Virtual Testing Virtual Testing Virtual Testing Full-system testing during all development phases: virtual - hybrid - physical Conventional bench testing Field testing Virtual Testing Virtual Testing Model Based System Testing Virtual Testing Virtual Testing Single Testing toolset from virtual testing to field testing Faster validation without compromising on accuracy Page 51

52 Simcenter Testlab Model Based System Testing Delivering a hybrid toolset for test & simulation engineers Simcenter Amesim 3. the model sketch opens. Click on component 2. browse to the Amesim model Simcenter TestLab Analyze simulation data analytics with Test components and methods Easily compare test and simulation results for model validation Apply simulation for quick troubleshooting of test results 1. simulate the model to generate the simulation results 4. component variables are listed 5. post-process and display simulation variables A unified toolset for analytics of test and simulation results Page 52

53 Simcenter Testlab Model Based System Testing Delivering a hybrid toolset for test & simulation engineers Extra insight during testing with model-based virtual channels & sensors Visualization for documentation of FMU - model Component model parameter updating during Testing Measurement validation during testing based on component simulation Testlab Process Designer connects methods and processing function in automated chain Model using the FMI - Functional Mockup Interface 2.0 Co-simulation Adding virtual channels and sensors to physical testing Page 53

54 Mehr Interesse? Kontakt: Oder besuchen Sie unser kommendes Akustik-Test-Seminar Danke für die Aufmerksamkeit Page 54