Automotive electric powertrain whistling and whining: fundamental root cause analysis to novel solutions

汽车电动动力系统啸叫和呜呜声：新颖解决方案的根本原因分析

• 批准号: EP/V053353/1
• 负责人: Stephanos Theodossiades
• 金额: $ 54.48万
• 依托单位: Loughborough University
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2021
• 资助国家: 英国
• 起止时间: 2021 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FV053353%2F1
• 关键词: Automotive; electric; powertrain; whistling; whining

The "Road to Zero" strategy is placing the UK at the forefront of designing and manufacturing zero emission vehicles, with the sale of new petrol/diesel cars and vans planned to end by 2040 (perhaps by 2030 according to recent government announcements). The strategy towards cleaner, quieter cities has accelerated the trend in the sales of Electric Vehicles (EVs). Contrary to the prevalent view though, EVs are not silent. Without the effect of masking noise from an internal combustion engine, other sounds radiating from the electric motor and the drivetrain have become more apparent (mainly at medium to high vehicle speeds). This is a major challenge for Automotive OEMs, which need to adapt their Noise, Vibration and Harshness (NVH) design methods to the "new" electric (e-) powertrain environment. Moreover, an optimum balance has to be identified between the vehicle NVH performance (and NVH package weight) and other weight increases due to heavy battery packs needed to increase the driving range.An important NVH issue in EVs is the tonal e-motor whistling noise (at harmonics of the rotor speed, depending on the number of motor poles). This is generated by the electromagnetic force, which excites the e-motor and the driveline housing. The noise is amplified by the powertrain structure, especially by the stator and its housing. Increased power and e-motor downsizing are key commercial requirements but have adverse effects on whistling noise. In addition to this, e-motor torque variation ripples and introduced misalignments in the system (between the gears, shafts and housing assembly) act as mechanical excitation on the drivetrain, leading to gear meshing oscillations and emitted noise (known as whine NVH). The issue becomes more complex considering the large range of powertrain operating conditions and increased excitation due to high-power motors, which affect the stability of the coupled electromechanical dynamics.The above e-powertrain NVH landscape requires various interrelated disciplines to be considered under the same framework (electromagnetics, component flexibility, transient dynamics and noise radiation). A coupled whistling and whining fundamental study that leads to root-cause understanding of the involved physics has not yet successfully done.The proposed research aims to identify the root causes behind the coupling of e-motor whistling and drivetrain whining NVH behaviour in e-powertrains and develop novel design solutions to reduce their severity and avoid costly and difficult remedial NVH measures later in the development process. The research will produce fundamental knowledge in e-powertrain design from the NVH perspective in the following ways: i) novel scientific knowledge will be generated for e-powertrains by analysing the root causes of the coupling between the e-motor and drivetrain transient dynamics that leads to aggressive NVH behaviour (employing 3D e-powertrain models), ii) an accurate and validated methodology for high frequency (above 10 kHz) e-powertrain NVH studies will be developed, iii) new NVH metrics will be set for use in future e-powertrain investigations and iv) novel and fast reduced-order methods will be developed based on the above NVH metrics and the parametric studies of the validated 3D e-powertrain models.New e-powertrain design methodologies for fast and accurate product development will be developed in this project with strong support of the participating industry partners. Arrival and AVL will integrate the new methods in their design processes and product portfolio (within a 5-year timescale). The project outcomes will be disseminated nationally (and internationally) so that UK automotive manufacturers can directly benefit and the UK maintains its excellence in powertrain technology.

“零排放之路”战略使英国处于设计和制造零排放汽车的前沿，计划到 2040 年（根据最近的政府公告，可能到 2030 年）停止销售新的汽油/柴油汽车和货车。建设更清洁、更安静的城市的战略加速了电动汽车 (EV) 销售的趋势。但与普遍观点相反，电动汽车并不沉默。如果没有掩盖内燃机噪音的效果，从电动机和传动系统发出的其他声音就会变得更加明显（主要是在中高车速时）。这对汽车原始设备制造商来说是一个重大挑战，他们需要调整其噪声、振动和声振粗糙度 (NVH) 设计方法以适应“新”电动 (e-) 动力总成环境。此外，必须在车辆 NVH 性能（和 NVH 套件重量）与由于增加行驶里程所需的重型电池组而导致的其他重量增加之间找到最佳平衡。电动汽车中一个重要的 NVH 问题是音调电动机啸叫噪声（在转子速度的谐波下，取决于电动机极数）。这是由电磁力产生的，电磁力激励电动机和传动系统外壳。动力系统结构（尤其是定子及其外壳）会放大噪声。增加功率和缩小电机尺寸是关键的商业要求，但会对啸叫噪声产生不利影响。除此之外，电动机扭矩变化波动和系统中（齿轮、轴和外壳组件之间）引入的不对中会对传动系统产生机械激励，导致齿轮啮合振荡和发出噪声（称为呜呜声 NVH）。考虑到大范围的动力总成运行条件以及大功率电机引起的激励增加，这会影响耦合机电动力学的稳定性，问题变得更加复杂。上述电动动力总成 NVH 景观需要在同一框架下考虑各种相互关联的学科（电磁学、组件灵活性、瞬态动力学和噪声辐射）。一项耦合啸叫和啸叫基础研究尚未成功完成，该研究有助于了解所涉及物理的根本原因。拟议的研究旨在确定电动动力系统中电机啸叫和传动系统啸叫 NVH 行为耦合背后的根本原因，并开发新颖的设计解决方案，以降低其严重性并避免在开发过程后期采取昂贵且困难的补救 NVH 措施。该研究将从 NVH 角度通过以下方式产生电动动力总成设计的基础知识：i) 通过分析导致激进 NVH 行为的电动机和传动系统瞬态动力学之间耦合的根本原因，将为电动动力总成生成新颖的科学知识（采用 3D 电动动力总成模型），ii) 准确且经过验证的高频（10 kHz 以上）方法 将开展电动动力总成 NVH 研究，iii) 新的 NVH 指标将用于未来的电动动力总成研究，iv) 将基于上述 NVH 指标和经过验证的 3D 电动动力总成模型的参数研究开发新颖且快速的降阶方法。在参与行业合作伙伴的大力支持下，本项目将开发用于快速、准确产品开发的新电动动力总成设计方法。 Arrival 和 AVL 将在其设计流程和产品组合中整合新方法（在 5 年时间内）。该项目成果将在全国（和国际）传播，以便英国汽车制造商能够直接受益，并使英国保持其在动力总成技术方面的卓越性。

项目成果

NVH of electric motors - a study on potential NVH metric

电动机的 NVH - 潜在 NVH 指标的研究

• 发表时间: 2022
• 作者: Souza MR

Analytical Multiphysics Model for NVH Prediction of a high-speed SurfacePermanent Magnet Synchronous Machine

用于高速表面永磁同步电机 NVH 预测的分析多物理场模型

• 发表时间: 2022
• 作者: Andreou P

The use of an artificial neural network for assessing tone perception in electric powertrain noise, vibration and harshness

• DOI: 10.1007/s11012-024-01753-x
• 发表时间: 2024-02
• 期刊: Meccanica
• 影响因子: 2.7
• 作者: Marcos Ricardo Souza;A. Haris;Leon Rodrigues;G. Offner;M. Sopouch;Franz Diwoky;M. Mohammadpour;S. Theodossiades