CONTACT

FEV Motorentechnik GmbH

Neuenhofstraße 181

are registred Trade Marks of FEV Motorentechnik GmbH in the States of the European Community and the United States of America.
52078 Aachen ∙ Germany
Phone +49 (0) 241 / 56 89 - 0
Fax +49 (0) 241 / 56 89 -119
E-Mail marketing@fev.com

FEV Engine Technology, Inc.

4554 Glenmeade Lane
Auburn Hills, MI 48326-1766 ∙ USA
Phone +1 (0) (248) 373 - 60 00
Fax +1 (0) (248) 373 - 80 84
E-Mail marketing@fev-et.com

FEV China Co., Ltd.

No.35 Xinda Street Qixianling
High Tech Zone ∙ 116023 Dalian ∙ China
Phone +86 (0) 411 / 84 82 - 16 88
Fax +86 (0) 411 / 84 82 - 16 00
E-Mail fev-china@fev.com

Internet http://www.fev.com

and
Acoustics and Vibration, Vehicle and Powertrain/TA/II/2007
ACOUSTICS AND VIBRATION
VEHICLE AND POWERTRAIN
 Vehicle Physics and Acoustics
FEV‘s Expertise Delivers Success

FEV has over 30 years of experience
conducting industrial and scientific NVH
projects worldwide. The Vehicle Physics and
Acoustics division employs more than 100
highly qualified NVH specialists in Germany
and the United States. We have a solid
reputation as a reliable engineering partner
to OEMs and suppliers.
We believe that today’s NVH challenges
can be solved efficiently using a full systems
approach that is in close cooperation with our
clients.
The partnership with our clients is
characterized by:

 Open partnership
 High flexibility and short response
timing
 On-site testing and resident engineers
 Full data compatibility
 Transfer of NVH expertise and methods

The high quality standard of our work is

ensured by modern testing equipment and
facilities combined with cutting-edge NVH
simulation tools and methods.

Our scope of work includes a variety of

projects such as single engine component
optimization, low noise engine development
from concept to SOP, vehicle integration and
full vehicle NVH development. We also tackle
challenges outside the automotive field, such
as NVH optimization of industrial machinery.

Our partnership with universities, such as

the Technical University of Aachen with
its internationally renowned Institute for
Internal Combustion Engines, as well as
our continuous involvement in industrial and
public research projects ensures that our
methodologies are always up to date and
thorough.

2
Vehicle Physics and Acoustics
Applications and Activities

FEV’s NVH activities cover a wide range of

automotive and industrial development tasks:

 High quality benchmarking and target  Comprehensive process noise optimization

setting of components, transmissions,  Complete product development
engines and vehicles from concept to Start of Production (SOP)
 Systematic troubleshooting  Vehicle NVH development and optimization

 CAE-based NVH development tools  NVH chassis development for premium

and methods interior sound and vibration comfort

 Sound design and acoustic refinement  Industrial, public and internal research

 Sound quality and product brand sound

development

Fields of NVH Applications

and Activities

3
 NVH Powertrain and
Vehicle Testing Facilities

The increased complexity of powertrain and FEV operates modern powertrain and vehicle
vehicle electronics requires a highly-skilled staff NVH test cells equipped with standard as well
within the assembly workshop and experienced as specific instrumentation tools and modern
test cell operators. data acquisition/analysis systems.

Vehicle NVH Dynamometer Audio Lab

Engine and Vehicle Body-In-White and

Workshop Trimmed Body Lab

Advantages created by FEV’s facilities

includes:

 All of the required state-of-the-art NVH

equipment and facilities available
 Flexible multi-shift operation

 Full project separation, utilizing all

resources
Powertrain  Integration of the client’s employees into
NVH Test Cell
the project team as required
 Certified confidentially and concealed

prototype handling

Test Track

4
NVH Tools
Commercial and FEV-Specific

FEV utilizes many industry standard CAE and

CAT tools to ensure a smooth and quick data-
transfer for our clients. The following is a list of
some of the tools that are available:

 ANSYS, NASTRAN
 Hypermesh, I-DEAS
 ADAMS Engine, ADAMS Car
 Sysnoise
 SIMPACK, DADS
 GT-Power
 Design of Experiments (DoE)
 PAK, LMS, SQLab/Artemis CVT Simulation
 MatLab/Simulink
 …

Powertrain
Noise Simulation

FEV has also devised a number of highly reliable

FEV-specific tools to integrate cutting-edge NVH
methods into product development, such as:

 FEV-DIRA (Dynamic Impact Response Analysis)

 FEV-proprietary codes for simulation of
component dynamics (crankshaft, piston and valve train ...)
 FEV-CSL (Combustion Sound Level)

 FEV-CSL-CAL (Combustion Sound Level Calibration with DoE)

 FEV-VINS (Vehicle Interior Noise Simulation)

 FEV-V-VINS (Virtual Vehicle Interior Noise Simulation)

 FEV-VENS (Vehicle Exterior Noise Simulation)

 FEV-SME (Sound Metrics)

 FEV-C-VINS (Chassis Vehicle Interior Noise Simulation)

Driveline Simulation

5
 NVH for Production Readiness
From Concept to Start of Production (SOP)

Excellent NVH has become a vital vehicle

development target as it contributes to
product quality, driving pleasure and customer
satisfaction. Consequently, NVH optimization
of sources and transfer paths is required from
concept to SOP.

Advanced NVH experimental and simulation

tools are prerequisites for cost and time
effective development minimizing pre-produc-
tion troubleshooting effort and shortening the
time to market.

Concept and Targeting Design Prototype Development SOP

NVH Development form Concept to SOP

FEV‘s NVH activities cover the

entire cycle from the research concept
phase to the start of production:

 Concept study supported by an extensive

database and quick CAE-tools
 Development phase supported by

precise CAE-tools and methods as well as

powerful testing tools and methods
 SOP-support by experienced specialists

6
 Sound Design and Troubleshooting
Tools and Methodologies

Airborne Noise
Transfer Functions Airborne Noises

 Powertrain noise Airborne

Interior Noise
 Intake orifice noise
Excitation

Simulated Interior Noise

Airborne

 Exhaust orifice noise

 Shell noise
 Tire noise
…

Powertrain mount
Structure-Borne


vibration
Excitation

 Exhaust syst. vibr.

 Driveline vibration
… Structure-Borne
Interior Noise

Structure-Borne
Noise Transfer Functions Structure-Borne Noises FEV-VINS for Interior Noise Simulation

Key methodologies for systematic full vehicle

NVH development and optimization include:

FEV-VINS
 Vehicle Interior Noise Simulation through a

combination of individual excitations and related

transfer paths

FEV-V-VINS
 Virtual Vehicle Interior Noise Simulation is the

implementation of virtual excitations and/or transfer

functions, such as powertrain/orifice noise and/or
vibroacoustic body transfer functions

FEV-VENS
 Vehicle Exterior Noise Simulation through a
Acoustic Camera
combination of powertrain, orifice and tire noises
with corresponding airborne noise transfer functions,
Troubleshooting projects
according to the vehicle positions during pass-by tests
are supported by
acoustic camera analysis,
FEV-SME which is a very effective
 Sound Metrics (pleasentness, dynamic, knocking,...)
method for targeted noise
are available and can be applied on specific noise source identification.
phenomena
7
 Vehicle Integration
Marriage of Powertrain and Vehicle

Powertrain integration represents a primary The process is strongly supported by “virtual”

task in vehicle development and requires and hybrid methods for pre-optimization of the
systematic and continuous NVH attention. “hardware marriage” minimizing the effort
required for design changes.

Vehicle Body NVH CAE

Exhaust System Analysis

Package Analysis
Drive Off Simulation

Experimental and analytical

approaches are applied to the
refinement tasks including:
Simulation of
Powertrain Mount
 NVH benchmarking and appropriate
target setting
 Intake and exhaust system layout

and refinement
 Mount system layout and refinement

 Driveline layout and refinement

 Vehicle body refinement including

sound package development

 Continuous NVH assistance in

vehicle calibration
Virtual Intake and Exhaust
 Vehicle NVH refinement for interior/
System Development
exterior noise and vibration comfort
 Pass-by noise optimization

8
 Full NVH Responsibility
Vehicle NVH Development

FEV can manage overall vehicle NVH develop- FEV’s project managers skills coordinate ac-
ment. Such programs typically are carried out tivities between the different working groups,
in close cooperation between OEM specialists, ensuring a streamlined development process.
suppliers and FEV.

Interior NVH Quality:

Sound Insulation
Squeak and Rattle
HVAC Noise
Electro Servo Motor Noise
Audio and Entertainment Systems
...

Aero Acoustic: Interior Sound Quality

Body Shape
Sealing
Windows
Side Mirror
Chassis NVH: Wiper
Stiffness of Axles ...
and Subframes
Bushing Insulation
Tire Noise Powertrain induced NVH:
Steering NVH Engine and Transmission
Brake NVH Driveline
... Body NVH: Powertrain Mount
Global Stiffness Intake and Exhaust System
Stiffness of Front-End Section ...
Impedances at Interface Points
Vibro-Acoustic-Transfer Functions
Heavy Layer Distribution
...

The cooperation between OEM, FEV

and suppliers is characterized by:

 System and components level target

setting
 Experimental and analytical component high
Noise Transparency

refinement
 Development for the OEM, according to

specific processes and strategies

 Full-responsibility for NVH integration low

 NVH robustness for Production

Interior Trim Optimization

Top: Hardware Solution
Bottom: Firewall Noise Map

9
 NVH Benchmarking
From Cylinder Pressure to Driver‘s Ear

Challenging NVH targets are prerequisites

for developing excellent powertrain and Prototype
vehicle sound, along with vibration comfort. Production

DI-Diesel Engines

Sound Pressure Level [dBA]

FEV’s extensive NVH database
ranges from combustion
excitation to vehicle road and
Gasoline
wind noise: Engines

 More than 500 engines and vehicles

 More than 100 metrics 1000 2000 3000 4000 5000 6000 rpm

Extensive Powertrain NVH Database

FEV_CSL: Exterior Noise

Cylinder Pressure
Orifice Noise
Engine Structure Attenuation
P/T Noise
FEV -VINS:
P/T Mount Vibration
Structure Borne Vehicle Attenuation

Interior Vibration
Airborne Vehicle Attenuation

Road/Wind Noise
Interior Noise

10 More FEV Scatter Bands: Noise Level; Loudness; Sharpness; Tonality; Articulation Index; Comb. Noise Index; Jury Ranking; ...
Low Noise Engine and Sound Design
for Improving Powertrain NVH

Developing of a low noise engine requires

CAE-based NVH optimization from the begin- FEV’s competitive edge in low noise
ning of the concept phase. engine development:

In order to achieve a high level of refinement,
NVH CAE engineers must deliver recommen-
dations prior to the design freeze dates. Thus,
detailed NVH experience and appropriate virtual
development tools and methods are required.
Examples of FEV in-house developed tools are
FEV-DIRA and FEV-V-VINS.
FEV-DIRA reflects FEV’s philosophy for power-
train structural and dynamic NVH optimization.
 Well proven CAE Tools and methods
which fit into the development processes
of our clients
 Highly sophisticated testing tools and
methods for noise optimization
 Extensive database for NVH component
specifications
 Experiences from several powertrain
development programs

Commercial Finite Element Analysis, Multi-Bo-

dy Simulation and Boundary Element Method
software is fully compatible with that of our
clients and uses integrated specific FEV codes
such as roller bearing and damping modules.

FEV-V-VINS combines powertrain NVH simula-

tion and interior noise simulation, allowing for
vehicle-focused powertrain NVH development.

Best-In-Class
V6 Diesel Engine

11
 Transmission and
Driveline NVH

The increasing challenges for powertrain de-

velopment are also driving new transmission Driveline Simulation
technologies.

At FEV, NVH and shift quality optimization is

integrated into transmission development, FEV’s experience in quiet driveline
including design, mechanical and electronic NVH development:
development as well as integration into the
vehicle application.
 Well proven CAE tools and methods
 Highly sophisticated testing tools
Driveline NVH related tasks, such as boom,
gear whine, gear rattle, clunk, etc. are perfor- and method for noise optimization
 Extensive database for NVH component
med with the help of CAE, testing and bench-
marking. The following services are available: specifications

 Continuous design support for transmission

NVH development
 Component development

 Troubleshooting

In that context, experiences are available for

(automated) manual, (stepped) automatic and
(belt/chain) CVT transmissions.

Driveshaft Torque
Measurement

V-Vins

Tooth Stiffness
Simulation

Acoustic Test Bench

12
Combustion Process Noise
Powerful, Clean yet Silent

Combustion system development and vehicle

applications have become more complex.
This is due to advanced combustion systems,
increased flexibility of fuel injection systems, DoE-models
exhaust gas aftertreatment constraints and

5 dB
On-Board Diagnosis (OBD).

Interior Noise
FEV’s highly-qualified NVH engineers explore
Cal. 1
the full calibration of NVH potential, while
Cal. 2
achieving emissions and related fuel
consumption targets, using the in-house
developed methods, such as FEV-CSL and Time
FEV-CSL-CAL. Transient Combustion
Noise Optimization

The characteristics and advantages of FEV’s

unique NVH calibration tools:
Parameters:
 CSL: Method for engine noise breakdown,  Pilot injection
 Main injection
such that the full NVH potential of an engine
 Rail pressure
can be explored  EGR

 CSL-CAL: DOE-based method for combustion …

noise optimization Responses:

 FEV-CSL
 Interior noise
 Exterior noise
 Fuel consumption
 Emission

Engine Noise
FEV-CSL-CAL

Mechanical Noise Combustion Noise Accessory Noise

Direct Indirect
Combustion Combustion Flow Noise
Noise Noise

FEV-CSL: Engine Noise Shares

13
 Hybrid Vehicle
Balancing of Hybrid Operational Modes

In general, hybrid vehicles can possess favora-

Hybrid vehicle-specific NVH ble NVH behavior, especially during start-up
development tasks: and low speed cruising. Nevertheless, detailed
NVH refinement of HEV-specific electric com-
Smooth internal combustion engine
 ponents, powertrain mounting system and
Launch at start-up and during drive-away 
A driveline are required to achieve excellent NVH
 Moderate ICE start /stop feedback behavior.
during the vehicle stop B
 Unobtrusive ICE deactivation/activation The main NVH challenge consists in adjusting
during cruising/acceleration 
C the NVH response to the driving condition and
 Powerful, acoustically supported,
the driver’s expectation. Consequently, NVH
development focuses on the balancing of HEV
dynamic acceleration feedback D
operational modes.
 Unobtrusive NVH behavior of electrical

components, such as magnetic noise during

By using FEV-Hybrid-VINS software, vehicle
regeneration at recuperation low vehicle E operational modes can be balanced regarding
speeds vehicle interior noise, based on the HEV ope-
rational mode strategy, such as the relation of
vehicle velocity, ICE speed and speed gradient
as well as load condition.
Vehicle Velocity

D
A
D C C E B
Powertrain Noise Simulation
ICM / EM / Gen. rpm

14
Time
 Trucks and
Heavy-Duty Vehicles

Truck development is mainly driven by costs,

fuel consumption, emissions and reliability. FEV’s key elements for the optimizations are:
Nevertheless NVH comfort is becoming more
and more important.  Long term experience with trucks and
heavy-duty vehicles
To achieve an overall well balanced NVH be-  Proven CAE tools and methods
havior, the entire vehicle has to be taken into  Very efficient testing tools and methods
account. It is very important to optimize all
relevant NVH systems/components, such as:
FEV’s systematic approach allows for efficient
 Powertrain and driveline NVH development.
 Intake and exhaust system
 Chassis and mounts
 Cabin including the noise insulation

Component Optimization
Powertrain / Drivetrain

w/o NVH Optimization

5
SPL [dBA]

Combustion
w/ NVH Optimization System
Development
Displacement [l]
Pass-By Noise
Interior Noise

Benchmarking

Vehicle Integration 15
 Industrial and Off-Highway Machinery
Introduction of Virtual Development Tools

Interior Noise The development process for off-road machi-

Vibration Comfort Emission Legislation nery is influenced by multiple targets and
associated constraints. This requires well-
Production Cost Noise Legislation balanced technical and commercial targets that
focus on customer benefits.
Time to Market Durability

After-Sales Thermal Balance

Flexibility for Effort for

Design Flexibility / Cost

Off-Road Use Problem Solving Troubleshooting
Assembly Line

Maintenance Machine Performance

Design Fuel Consumption

Package/Visibility
Planning Development Production

Development Targets for Flexibility and Effort for Troubleshooting

Off-Highway Machinery during the Development Process

NVH optimization of industrial and off-highway

machines is characterized by multiple airborne
and structure-borne noise sources and related
transfer paths. Key elements for a comprehen- Airborne:
Structure-borne:
sive optimization process are CAE and hybrid  Comb. engine
 Comb. engine
 Exhaust
methods including:  Hydraulic pumps
 Intake
 Hydraulic motor
 Fan/air flow
 Hydraulic tubes
 Combined FEA and MBS for structural  Gearbox
…

optimization with respect to NVH and  Transfer box

stress analysis  Axle differentials

…
 Interior noise simulation

 1-D CFD for intake and exhaust

system optimization
 1-D and 3-D CFD simulation for the air

cooling system layout

 MBS simulation of vehicle dynamics
Typical Interior Noise Share Distribution
 Combined MBS and CFD simulation for
for Off-Highway Machinery
the hydraulic systems layout

The systems approach allows for a reduction in

prototype/pre-production testing, minimizing
technical risks, improving product quality and
reducing the time to market.
16
Diverse Applications
Non-Conventional NVH Projects

FEV’s NVH specialists are also tasked with sup-

porting non-conventional NVH projects that deal
with NVH topics that present a wide range of
challenges.

Motorsports:
Onboard Camera
Optimized Vibration
Isolation for Stable Formula 1 Sound
Pictures During
the Race

Race Car Sound Design

Appliances
(White Goods):
Heating System Boiler
Optimization of Noise
Emission and
Flame Stability

Compressor Noises

Heavy-Duty Industry: Recreational Devices:

Power Station Power Tower
Exhaust System Orifice Noise Source Identification
Noise Optimization and Optimization -
Compressed Air Lift System

Coal Mill Noise

17
 Melody of Driving
Engine Sound and Music

Harmonics
Noises

Tonic
Engine Orders Resonance

Features of Natural Tone and Engine Noise

Engineers studying mechanical acoustics Machinery sound is characterized by non-

can learn a great deal from music. Objective
insights were gained from an internal research
project, where melodic and harmonic sound
pattern features of music were transferred to
engine noise characteristics.
Music consists of sequences of natural tones
and harmonies (tonic plus a series of its
harmonics). The tone sequence is characterized
by intervals, including the frequency ratio of
every two consecutive notes where the interval
is perceived as consonant (pleasant) or
dissonant (disturbing).
periodic noises, unpleasant noise components
with some harmonics (engine orders) in a low
frequency range, impacts and consecutively
fading natural oscillations.
The rules of musical harmonic theory were
introduced in FEV’s engine and vehicle sound
design development processes as key elements
to create a perfect composition for a melody of
driving.

EO
th
4.5 EO
O
E 4th
3.5th
EO
3rd

Base Dissonant Consonant

Sound Design by Engine Order

Composition: 5-Cylinder Engine

18
 NVH Research Activities
Prepared for Future Challenges

The perception of noise ranges from being an
annoyance to something that is harmful to our
health. Therefore, the European Community
will significantly increase activities in programs
to reduce road, rail and aircraft traffic noise.
35%
FEV accepts this tremendous challenge for a
clean and quiet environment, in close coope-
ration with universities and public research
centers.
One example of FEV’s cooperation in EU-
sponsored projects is InMAR (Intelligent Ma-
terials for Active Noise Reduction). The task is
to apply actuators and foils based upon piezo
technology to reduce powertrain induced noise
and vibration using active control.

30%

25% Annoyance
Mean
20% Intense
Aside from public NVH interest,
FEV invests in many internal
15%

10% research projects to be prepared

5% for future technological
challenges, including the
0%
following:
1999
2004

1999
2004

1999
2004

1999
2004

1999
2004

1999
2004

Road
Traffic
Air
Traffic
Neighbor-
hood
Rail
Traffic
Industry Recreational  „Virtual” powertrain and
(Source LfU 2004)
vehicle development
Road Traffic Noise  Technology NVH road maps
as a Focus of Public Discussion
 Sound quality

Piezo Patch

Shaker

Signal Processing

Piezo Control

Test Set up Controller

Assessment

19