Abstract A valuable quantity for analyzing the lateral dynamics of road vehicles is the side-slip angle, that is, the angle between the vehicle’s longitudinal axis and its speed direction. A reliable real-time side-slip angle value enables several features, such as stability controls, identification of understeer and oversteer conditions, estimation of lateral forces during cornering, or tire grip and wear estimation. Since the direct measurement of this variable can only be done with complex and expensive devices, it is worth trying to estimate it through virtual sensors based on mathematical models. This article illustrates a methodology for real-time on-board estimation of the side-slip angle through a machine learning model (SSE—side-slip estimator). It exploits a recurrent neural network trained and tested via on-road experimental data acquisition. In particular, the machine learning model only uses input signals from a standard road car sensor configuration. The model

Giuliacci, Tiziano Alberto, Ballesio, Stefano, Fainello, Marco, Mair, Ulrich, King, Julian

Recurrent Neural Network Model for On-Board Estimation of the Side-Slip Angle in a Four-Wheel Drive and Steering Vehicle

15-17-01-0003-TEST-REC09/23/2023

Giuliacci, Tiziano Alberto, Ballesio, Stefano, Fainello, Marco, Mair, Ulrich, King, Julian

Characterization and Prediction of Interior Noise Quality in Electric Vehicles through Drive Unit End-of-Line Testing (EOLT)

2025-01-003905/05/2023

This paper addresses the critical aspect of interior noise quality in electric vehicles (EVs), focusing on the characterization and prediction methodologies employed during drive unit end-of-line testing. The electric drive unit plays a pivotal role in determining the overall Noise, Vibration, and Harshness (NVH) quality of the final product. This study explores the impact of drive unit assembly process variation and individual component tolerance on the NVH characteristics of electric drive units, emphasizing their direct effect on overall vehicle acoustic quality and customer comfort. The research delves into the intricate relationship between drive unit vibrational response, vehicle interior noise, and customer subjective perception, providing valuable insights into their correlation and how they collectively influence user experience and satisfaction. It aims to enhance the understanding of how electric drive unit characteristics contribute significantly to the interior noise

Arvanitis, Anastasios, Parbat, Aniket, Jadhav, Prashant, Raphael, Andrew

Application of blocked force methodology to an electrified beam axle from a medium-duty truck in vehicle and in a dynamometer test cell

2025-01-005405/05/2023

The recent shift in propulsion choice away from internal combustion engines has increased the relevance of sound and vibration from electric motors and gearboxes. Electrified beam axles require different metrics from conventional beam axles for noise and vibration because they have multiple sources of vibration energy, including an electric motor and sometimes multiple reduction gearsets. They also require different metrics from electric drive units because they have stiff suspension connections and lack significant isolation. Blocked force is a good candidate because it can completely characterize the vibration energy transmitted into a receiver and is especially useful because it is theoretically independent of the vehicle-side structure. While the blocked force methodology is not new, its application to beam axles is relatively unexplored in the literature. This paper demonstrates a case study of blocked force measurement of an electrified beam axle from a battery electric medium

Shaw, Matthew D, Grimmer, Michael J

A Theoretical and Experimental Investigation of NVH of In-Wheel Reduced Motor System

2025-01-000605/05/2023

To enhance the power density of the system and reduce production costs, the in-wheel reduced motor system (IWRMS), characterized by its integrated design and control, is poised to become the future development trend. However, the high speeds of motors and gear reducers can lead to challenges such as system stability and issues related to NVH (Noise, Vibration, and Harshness). This paper specifically addresses the NVH concerns associated with the IWRMS. Firstly, a bench test scheme was established, and vibration and noise tests were conducted under a range of conventional operating conditions. The results indicated that at the torque of 200 Nm and the speed of 5500 rpm, the noise sound pressure level reached 86.2 dB, highlighting significant vibration and noise issues within the system. Subsequently, operating deflection shapes (ODS) testing and analysis were performed on the IWRMS. Vibration responses of 48th order show that breathing mode of the motor housing bring resonance

Huang, Chao, Xiong, Lu, Meng, Dejian, gong, Yu, Guo, Han, Zhang, Mengyuan

High-Fidelity NVH Model Development for Electric Motors using Deep learning and Machine Learning Algorithms

2025-01-012305/05/2023

Electric motor whine is a significant source of noise in electric vehicles (EVs). To improve the noise, vibration, and harshness (NVH) performance of electric propulsion systems, it is essential to develop a physics-based, high-fidelity stator model. In this study, a machine learning (ML) model is developed using an artificial neural network (ANN) method to accurately characterize the material properties of the copper winding, varnish, and orthotropic stator laminate structure. A design of experiments (DOE) approach using Latin hypercube sampling of parameters is implemented after evaluating alternative surrogate models. A finite element (FE) model is constructed using the nominal stator design parameters to train the ANN model using 121 DOE variables and 72,000 data points. The ML-trained ANN model is then verified to predict the driving point frequency response function (FRF) spectrum with reasonable accuracy. Subsequently, modal tests are conducted on the electric stator, and the

Rao, Bhyri Rajeswara, GSJ, Gautam, He, Song

NVH Analysis and Optimization of Electric Drive System in Over Modulation and Six-Step Regions

2025-01-008205/05/2023

Pulse width modulation (PWM) and the corresponding modulation index (MI) value are of critical importance to the performance of electric drive systems for electric vehicle applications. For interior permanent magnet (IPM) machines, operating in overmodulation (OVM) and six-step modes increases the voltage output beyond the linear region, allowing the motor to achieve higher torque and power with reduced inverter loss. However, the resulting distorted current waveforms and higher current ripple harmonics lead to a notable increase in the motor noise. A multi-disciplinary approach has been developed to analyze the NVH performance of a three-phase 8-pole IPM motor when it operates in the OVM and six-step regions at high speed. The PWM current ripple harmonics induced by voltage-source inverters are predicted using different MIs and subsequently validated through experiments. The current ripple data are used for the prediction of electric motor efficiency, including an analysis of copper

He, Song, Chang, Le, Gong, Cheng, Zhang, Peng, GSJ, Gautam

Asymmetric Gear Blank Optimization to Reduce Gear Noise for Electric Drive Units

2025-01-007905/05/2023

Gear whine has emerged as a significant challenge for electric vehicles (EVs) in the absence of engine masking noise. The demand from customers for premium EVs with high speed and high torque density introduces additional NVH risks. Conventional gear design strategies to reduce the pitch-line velocity and increase contact ratio may impact EV torque capacitor or its efficiency. Furthermore, microgeometry optimization has limited design space to reduce gear noise over a wide range of torque loads. This paper presents a comprehensive investigation into the optimization of transfer gear blanks in a single-speed two-stage FDW electric drive unit (EDU) with the objective of reducing both mass and noise. A detailed multi-body dynamics (MBD) model is constructed for the entire EDU system using a finite-element-based time-domain solver. This investigation focuses on the analysis and optimization of asymmetric gear blank design features with three-slot patterns. A DOE methodology is employed to

He, Song, Bahk, Cheonjae, Li, Bo, Du, Isaac, Patruni, Pavan Kumar, Baladhandapani, Dhanasekar

Methodology for Radiated Noise Refinement of Electrified Drivetrain Systems

2025-01-009805/05/2023

Electric drive units (EDU) of battery electric vehicles and electric drivetrain components of hybrid vehicles require significant development effort and planning to ensure that a refined NVH sound quality is achieved. New tools and methods are required to understand the NVH performance throughout the development process and to ensure that NVH risks can be quickly identified and mitigated within the correct EDU subsystems. This paper discusses the development of a methodology (EDSL – Electric Drive Sound Level) aimed at addressing this need. It also outlines how the EDSL tool can be used to address radiated noise issues and understand the NVH performance of the various subsystems within an electrified drivetrain component. The first use of the EDSL methodology is to characterize component-level radiated noise test results and compare the different mechanical and electrical noise sources to targets. The results from this are used to guide EDU development in the appropriate areas

Pruetz, Jeffrey E., Steffens, Christoph, Fu, Tongfang, Govindswamy, Kiran

Electric compressor integration noise influence in Battery Electric Vehicles

2025-01-007505/05/2023

Within the automotive industry’s shift to Battery Electric Vehicles, in order to meet the global zero emission target, thermal management systems are key aspects to address. For instance, vehicle cooling requirements are reinforced to take into account the cabin comfort as well as battery management performances. Consequently to the increased cooling requirements, the critical component that is the Electric Drive Compressor, must operate at higher speeds and refrigerant pressures to achieve these targets. This trend results in increased noise levels which might occur inside the car cabin and outside. In this paper, noise investigations were performed on different Battery Electric Vehicles to assess the behavior of the electric compressor within a temperature controlled environment. Then, the electric compressors alone were investigated on specific test benches with compressor load units. The vehicle level assessment highlighted significant noise differences between vehicles. Further

Bennouna, Saad, Yamayoshi, Itsukyo, Del Valle, Edward

Crash Performance Improvement: The Impact of Engine Mount Crash Plates on Achieving a 5-Star Safety Rating

2025-01-008505/05/2023

Electric vehicles (EVs) differ from internal combustion engine (ICE) vehicles in that they lack a conventional engine and feature an electric drive unit, leading to distinct dynamic behaviours in the powertrain. Additionally, the arrangement of auxiliary components in EVs often differs from that in traditional ICE vehicles, which can sometimes significantly impact safety ratings. This paper examines a case study of a critical failure during a crash test, where displacement of an engine mount arm caused substantial structural intrusion and reduced the vehicle's safety rating. To address this issue and enhance crashworthiness, a "crash plate" was designed and integrated into the mount system. This solution effectively constrained the mount arm's movement during impact, preventing the intrusion observed in previous tests. The paper provides a detailed analysis of the crash plate's dimensions and its relationship to the engine mount, demonstrating its potential for broader application in

Hazra, Sandip, Khan, Arkadip, Mohare, Gourishkumar

Immersion Cooling for Power Electronics

2022-28-044611/09/2022

The ability to precisely control electrical voltages on a large scale has made possible many efficient, powerful innovations, from high-speed electric trains to wind turbines to electric drive motors for everything from heavy earthmoving equipment to personal electric vehicles (EVs). But the equipment that manages this process — including power inverters, thyristors and variable-speed drives — requires high-performance power electronics cooling. As temperatures rise, the efficiency, reliability, and life spans of these devices drop, and the power electronics inside HEVs and EVs are no exception. Advancements in power electronic thermal management technologies will enable next generation automotive to fulfill increasingly demanding mission objectives. DC-DC converter and inverter systems slated for higher performances, reliable and sustainable applications. Even with very high efficiencies, the components of these systems produce kilowatts of power loss in the form of heat. The current

Sahoo, Pranati

Study and Application of Gear Micro Modification of Electric Drive System

15-16-01-0001

09/15/2022

Abstract The gear whine in the electric drive system of an electric vehicle is important and remains a challenge in developing novel electric vehicles. A gearbox dynamic model is established, and the effects of modification parameters on the sound pressure level, transmission error, and contact stress of the gear pair are introduced to reduce the gear whine. A multi-objective optimization study of four modification variables under multiple torque conditions is carried out by using transmission error and maximum contact stress as the objective functions. The eclectic programming method is imported to solve the convergence problem of multi-objective optimization. The influence of modification variables on objective functions is studied by establishing an approximate model of the optimal Latin hypercube design. Results show that the application of the multi-objective optimization method combined with the eclectic planning method for the micro modification of the gear can reduce the

Chen, Chen, Zhu, Linpei, Liu, Jing, Wei, Dan, Yu, Hao