Transcript Slide 1
HDE 14.8 CV-DS NVH PLAN
EV ARNOLD, ERIC LEITZINGER, BRYAN UNDERWOOD SUSTAINING ENG‘G & NVH 25 OCTOBER 2006
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14.8L HDE NVH TOPICS & OBJECTIVES
25 OCT 2006 NVH METHODOLOGY PRESENTATION
ENGINE COMPONENT STRUCTURAL VIBRATION
Insure Structural Integrity (Durability)
Define Excitation that Creates Sound
BYSTANDER SOUND LEVEL
(*)
Meet Regulatory Requirements Achieve Product Acoustical Performance Goals
ENGINE MOUNT VIBRATION LEVEL
(*)
Minimize Engine Vibration Input into Vehicle Structure
TRUCK CABIN SOUND AND VIBRATION
(*)
Minimize Operator Vibration Fatigue
Steering Wheel Seat
Minimize Cabin Sound Level
Maximize Sound Quality (*) ENGINE IS A MAJOR NVH EXCITATION SOURCE WITHIN THE VEHICLE
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14.8L HDE COMPONENT STATIC STRUCTURAL VIBRATION
ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION
ACCEPTANCE CRITERIA
No Structural Resonances below 105 Hz a) Equivalent to 3 rd Order Forcing Function at 2100 RPM)
VERIFICATION
(Test Procedure) Measure Static Frequency Response Function (FRF) a) b) c) Test Set-up
Impact Hammer or Shaker Force Input
Single or Multiple Accelerometer Response Points Operating Condition: Static – Engine NOT running Test Output
Transfer Function – Identifies Resonant Frequencies, Modal Stiffness & Damping
CORRECTIVE ACTION
(If Acceptance Criterion Is Violated) a) b) c) Shift Resonant Frequency (Increase or Reduce Stiffness) Reduce amplitude by increasing structural damping Repeat FRF Test to Verify Effect on Vibration Behavior
VALIDATION
(Test Procedure) Conduct Component Fatigue Life Evaluation a) b) Shaker Input Survive 10 Million Cycles (Infinite Life) @ Resonant Frequency
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14.8L HDE COMPONENT OPERATING STRUCTURAL VIBRATION ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIDATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION PAGE 1 OF 2
ACCEPTANCE CRITERIA
1.
2.
Vibration amplitude less than 5 mils below 105 Hz (3 rd Order @ 2100 Hz) No evidence of High Amplitude Resonances Within Engine Operating Conditions (*) 3.
No evidence of High Amplitude Order Related Vibration Within Engine Operating Conditions (*) (*) Vibration measured in (a) peak acceleration (< 500 HZ) & (b) peak-to-peak displacement (< 250 Hz)
VERIFICATION
(Test Procedures) 1.
2.
Generate 2D Peak Hold Spectra a) b) c) Test Set-up
Tri-Axial Accelerometer Response Positions Same as Static FRF Operating Conditions:
Full Load Speed Sweep (1050 RPM to 1850 RPM) Over 90 Seconds
No Load Speed Sweep (Idle to 2100 RPM) Over 90 Seconds Test Output:
2D Peak Hold Spectrum (Peak Acceleration- 0 to 500 Hz)
2D Peak Hold Spectrum (Peak-to-Peak Displacement - 0 to 250 Hz) Generate 3D Campbell Plots a) b) c) Test Set-up
Same as #1 a) Operating Conditions:
Same as #1 b) Test Output:
3D Campbell Plot (Peak Acceleration- 0 to 500 Hz)
3D Campbell Plot (Peak-to-Peak Displacement - 0 to 250 Hz)
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14.8L HDE COMPONENT OPERATING STRUCTURAL VIBRATION ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIDATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION
PAGE 2 OF 2
CORRECTIVE ACTION
(If Acceptance Criteria Are Violated) a) b) Shift Resonant Frequency (Increase or Reduce Stiffness) Reduce amplitude by increasing structural damping c) Repeat FRF Test to Verify Effect on Vibration Behavior
VALIDATION
(Test Procedure) Conduct Component Fatigue Life Evaluation a) b) Shaker Input Survive 10 Million Cycles (Infinite Life) @ Resonant Frequency
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14.8L HDE TRUCK BYSTANDER SOUND LEVEL
(Page 1 of 2) ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION
1.
2.
ACCEPTANCE CRITERIA
TRUCK: Legal Compliance NAFTA a) b) Pass-by: NAFTA: EPA CFR 205 {SAE J366B} = 80 dB(A) @ 15 m Stationary: NAFTA: EPA CFR 325 {SAE J1096} = 85 dB(A) @ 15 m TRUCK / ENGINE: Trucks NAFTA Design Goal a) Pass-by:
Truck = 78.3 dB(A) - Maximum Level to Insure Minimal Production Audit Engine = 75.3 dB(A) - < 51% Contribution to Total Truck Pass-by Level
VERIFICATION (Test Procedure)
1.
Measure Truck Pass-by Sound Level a) b) c) Test Set-up
Certified Pass-by Facility {Chelsea}
Radar, Vehicle Telemetry & Spectral Sound Data Acquisition
Microphone 15 m to the Left & Right of Vehicle Path Operating Condition: J366B Mid-Gear Full Throttle Acceleration Test Output
Overall SPL & Spectra for Left & Right Sides of Vehicle Versus Track Position
Truck Position, Truck Speed & Engine Speed Versus Track Position 2.
Measure Truck Stationary Sound Level a) b) c) Test Set-up
Certified Stationary Facility {Chelsea}
Engine Speed & Sound Data Acquisition
Microphones 15 m from Right, Left, Front & Rear of Stationary Vehicle Operating Condition: No Load Acceleration / Deceleration (Idle – Max Gov Speed – Idle) Test Output:
Peak Hold SPL & Spectra for Left, Right, Front & Rear of Vehicle
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14.8L HDE TRUCK BYSTANDER SOUND LEVEL
(Page 2 of 2) ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION
CORRECTIVE ACTION
(If Acceptance Criteria Are Violated) 1.
2.
3.
Conduct Pass-by or Stationary Vehicle Sound Source Evaluation a) b) Acoustical Mask Entire Power Train Expose Each Power Train Element Separately to Identify Source Contribution If Engine Is A Significant Noise Source (DDC NVH Group Responsibility) a) b) Apply NVH Counter Measures to One or More Engine or After Treatment Components Engine Dyno Stand Tests May be Necessary to Identify & Treat Correct Engine Sources If Non-Engine Sources Are Significant Sources (Portland NVH Group Responsibility) a) Intake, Exhaust, Transmission, Driveline, Drive Axle &/or Tire Acoustical Counter Measures are Necessary
VALIDATION (Test Procedure)
1.
Repeat SAE J366B Pass-by Test with Power Train Noise Counter Measures 2.
Repeat SAE J1096 Stationary Test with Power Train Noise Counter Measures
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14.8L HDE ENGINE MOUNT VIBRATION LEVEL
ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION
ACCEPTANCE CRITERIA
Transmissibility << 1.0 At Frequencies Greater than 1.4 X F n Mount a) Transmissibility = Vibration Frame Side of Mount / Vibration Engine Side of Mount
VERIFICATION
(Test Procedure) Measure Front & Rear Mount Transmissibility a) b) c) Test Set-up
Tri-Axial Accelerometers on Frame & Engine Side of Each Mount
Truck on Chassis Dynamometer Operating Conditions:
Full Load Speed Sweep (Idle to 1850 RPM)
No Load Speed Sweep (Idle to 2100 RPM) Steady State: Idle, 1200 RPM, 1800 RPM, 2100 RPM Test Output
Peak Acceleration & Peak-to-Peak Displacement (X, Y & Z Directions)
Transmissibility (X, Y & Z Directions)
CORRECTIVE ACTION
(If Acceptance Criterion Is Violated) a) b) Alter Mount Stiffness Alter Mount Design (Shear versus Compression Mount)
VALIDATION
(Test Procedure) Repeat Front & Rear Mount Transmissibility Measurements with Revised Mounts
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14.8L HDE TRUCK CABIN VIBRATION
ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION
ACCEPTANCE CRITERIA
1.
2.
Meet > 8 Hour Vibration Exposure Limit for Steering Wheel Vibration (Per ISO 5349) Meet > 8 Hour Vibration Exposure Limit for Seat Vibration (Per ISO 2631)
VERIFICATION
(Test Procedure) 1.
Test Set-up a) Tri-Axial Accelerometers on Steering Wheel Rim & Seat Base 2.
3.
Operating Conditions a) b) Full Load & No Load Engine Speed Sweeps Steady State Engine Operation – Idle, 1200 RPM, 1800 RPM, 2100 RPM Test Output a) RMS Acceleration Plotted Against ISO 5349 or ISO 2631 Exposure Limit Guidelines
CORRECTIVE ACTION
(If Acceptance Criteria Is Violated) 1.
2.
3.
Alter (& Correct if Necessary) Engine or Body Mounts Increase Steering Column Structural Damping Evaluate (& Correct if Necessary) Excessive Engine Vibration
VALIDATION
(Test Procedure) Repeat Steering Wheel & Seat Vibration Measurements After Corrective Action
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14.8L HDE TRUCK CABIN SOUND LEVEL
ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION 25 OCT 2006 NVH METHODOLOGY PRESENTATION
ACCEPTANCE CRITERIA
1.
68 dB(A) at Driver’s Ear at 60 MPH WOT (Freightliner Metric) 2.
As Good or Better than Volvo Cabin Sound Level (Industry Benchmark) a) b) Sound Pressure Level (All Occupant Positions) Zwicker Sound Quality Metrics (All Occupant Positions)
VERIFICATION
(Test Procedure) 1.
2.
3.
Test Set-up a) Microphone 6 inches From Driver or Occupant’s Right Ear Operating Conditions a) Over-the-Road & Stationary Full Throttle Acceleration (1000 RPM – 2100 RPM) b) c) Constant Speed Stationary (Idle,1200RPM, 1800 RPM & 2100 RPM) 60 MPH Constant Speed Operation with Loaded Trailer Test Output a) b) A-Weighted Overall Levels and One-Third Octave Spectra Zwicker Loudness (Sharpness, Fluctuation Strength, Roughness, Modulation)
CORRECTIVE ACTION
(If Acceptance Criteria Are Violated) 1.
2.
Improve Cabin Barrier & Absorption Material Reduce Power Train Sound Level (Engine, Transmission, Exhaust, Tires Etc)
VALIDATION
(Test Procedure) Repeat Cabin Sound Level Analysis After Corrective Action
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25 OCT 2006 NVH METHODOLOGY PRESENTATION
APPENDIX CV-DS ISSUES & DELIVERABLES
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DDC CV-DS NVH DELIVERABLES (page 1 of 2)
9 AUGUST 2006 NVH METHODOLOGY PRESENTATION NVH DELIVERABLES FOR CV-DS PAGE 1 OF 2 NVH DELIVERABLE S P8 P7 P6 QUALITY GATE P5 P4 P3 P2 P1 CONCEPT DEVELOPMENT PRINCIPLE FEASIBILITY CONCEPT FEASIBILITY SERIES FEASIBILITY TEST STAND CAPABLE VEHICLE TEST CAPABLE VEHICLE RELIAIBLITY CAPABLE PRODUCTION FEASIBILITY JOB NO 1 INITIAL PHASE PRODUCT DEFINITION PRODUCT CONFIGURATION DEVELOP MATURITY A DEVELOP MATURITY B DEVELOP MATURITY C DEVELOP MATURITY D PRODUCTION RAMP UP PRODUCT DEVELOPMENT PRODUCTION 1 2 3 4 5 6 DEFINE NVH CRITERIA CALCULATE RESONANCES & MODE SHAPES DYNAMIC FEA OF VIBRATION BEHAVIOR BOUNDARY ELEMENT MODEL OF SPL TORSIONAL VIBRATION ANALYSIS SAE J1074 SPL 9 10 7 8 DIN SPEC SOUND PRESSURE SOUND QUALITY METRICS CROSS-SPECTRAL INT & SND PWR FRF & MODAL ANALYSIS 11 INDUCTION NOISE MEASUREMENT 12 INTERNAL ENGINE NOISE SOURCE ANALYSIS A A A A T T A T T T T T CONCEPT DEVELOPMENT X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
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DDC CV-DS NVH DELIVERABLES (page 2 of 2)
9 AUGUST 2006 NVH METHODOLOGY PRESENTATION NVH DELIVERABLES FOR CV-DS PAGE 2 OF 2 NVH DELIVERABLE S P8 P7 P6 QUALITY GATE P5 P4 P3 P2 P1 CONCEPT DEVELOPMENT PRINCIPLE FEASIBILITY INITIAL PHASE PRODUCT DEFINITION CONCEPT FEASIBILITY SERIES FEASIBILITY PRODUCT CONFIGURATION DEVELOP MATURITY A TEST STAND CAPABLE DEVELOP MATURITY B VEHICLE TEST CAPABLE DEVELOP MATURITY C VEHICLE RELIAIBLITY CAPABLE PRODUCTION FEASIBILITY DEVELOP MATURITY D PRODUCTION RAMP UP JOB NO 1 13 TRANSFER PATH ANALYSIS 14 ENGINE SURFACE SOURCE RANKING 15 ENGINE MOUNT VIBRATION TRANSMISSIBILITY 16 TORSIONAL VIBRATION MEASUREMENT 17 EXHAUST NOISE MEASUREMENT 18 SAE J366 TRUCK PASS-BY 19 AUSTRALIAN TRUCK ADR PASS-BY 20 SAE J1096 STATIONARY VEHICLE SPL 21 PASS-BY POWER TRAIN SOURCING 22 DRIVER'S RIGHT EAR SPL 23 ISO 5349 HAND VIBRATION 24 ISO 2631 WHOLE BODY VIBRATION T T T T T T T T T T T T CONCEPT DEVELOPMENT PRODUCT DEVELOPMENT X X X X X X X X X X X X X X X X X X X X X X X X X X X X X PRODUCTION X X X X X X X X X X X X X X X X X X
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