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New NVH Requirements for New Generation Powertrains and

Advanced Active NVH Control Technology

Takeshi Abe, Henry Ford Technical Fellow, NVHFord Motor Company (Retired)

2017 ChongQing Automotive Acoustic Summitt April 27-28,Chongqing, China

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Table of Contents1. Background2. Mega Trend3. Ford FE Strategy4. New NVH Requirements for New Generation Powertrains

• Down-sized IC Engines (3-cylinder)• Transmission NVH• Electro-magnetic-induced NVH

5. The Latest Active NVH Control Technology• Active Sound Quality Control• Active Control Engine Mount Systems

6. Summary

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1.Background: Global CO2 Regulations(~2025)

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Hydrogen ICE

FuelCell

BatteryElectric

Hybrid

GasolineEngine

SterlingEngine

SteamEngine

Diesel

1.Background: Diversified Power Units

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1.Background: Diversified Fuel OptionsAtmospheric CO2

RenewablesRenewables

Solar

Hydro

Coal

Wind

Petroleum

Nuclear

FossilHydrocarbon

FossilHydrocarbon

ElectricityElectricityCorn

Biomass

Biomass

Fusion Hybrid

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Ford's main strategy is to downsize its engines to deliver best fuel efficiency with equivalent powercompared to larger older engines being replaced (8 ->6 cyl, 6->4 cyl. 4->3 Cyl. )

2 Mega Trend (IC Engine Down-sizing)Gasoline Engine Down-sizing w/boosted DI (“GTDI”)

3.5l V6 GTDI 1 l I3 GTDI

2013 Taurus SHO 2013 Ford F150

2013 Ford Fiesta

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•Complex system integration/precise control for FE optimization (HEV)Transition NVH (Engine Start/Stop Noise/Vibration) (HEV)Power split system Gear Whine/ Gear Rattle (HEV)Power Control Unit High Frequency Switching Noise (HEV)High Frequency Motor/Generator whine (HEV/BEV)Low masking noise levels (Motor-driven) (HEV/BEV) Pedestrian Warning Sound (BEV)

2. Mega Trend: Electrification (HEV/BEV)(HEV/BEV)

Ford Fusion HEV Ford Focus BEV

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2.Mega Trend: Electrification (Fuel Cell Vehicles)FCV POWERTRAIN (Toyota MIRAI)

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Lightweight materials/structure applications.(Aluminum, HSS, CGI,Advanced Plastics)

Mega trend: Uni-body structure (car-based platform) from Body-on-frame (Trucks/SUVs) NVH challenge due to less mass/isolation/damping

-- Power train/Body NVH-- Road Noise

Weight Reduction/FEWeight Reduction/FE

Composite Panels Aluminum Structure

Structural ThermoplasticsNatural FiberReinforced Plastics

52. Mega Trend: Weight Reduction (New Material)

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Resou

rces

Development Timeline

Protot

ypes

Job#

1Upfront CAE led Design

Attribute Experts

2. Mega Trend (Process Transformation)(Front loading development process/enabler of shorter dev. process

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Cross-attribute Design Optimization

DoE SPL

P/T mount (Elastomer) CAE Model Mount Test rig

Full Vehicle Model Simulation

P/T Mount New Development Process

2. Mega Trend (Process Transformation)

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Hybrid Approach (Hardware-in-the Loop) 1st Generation(1999) Ford Spin-Torsional AWD NVH Test Facility(Virtual Engine System)

2. Mega Trend (Process Transformation)

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• Depends on the availability of the test hardware, the test specimens can be full vehicle with live engine, full vehicle without the engine, full drivetrain (transmission, driveshaft and axle) or driveline

Ford Spin-Torsional AWD NVH Facility: Test Set-up Flexibility (1999)

Virtual Engine/ Drivetrain, Driveline HIL (Hardware in the Loop)

2. Mega Trend (Process Transformation)

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2. Mega Trend (Process Transformation)

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Ford's main strategy is to downsize its engines to deliver best fuel efficiency with equivalent powercompared to larger older engines being replaced 8 ->6, 6->4, 4->3 Cyl.

3. Ford FE Strategies (Engine Down-sizing) “Eco boost” engines: Down-sizing w/turbo-charged DI (GTDI)

3.5l V6 GTDI 1 l I3 GTDI

2013 Taurus SHO 2013 Ford F150

2013 Ford Fiesta

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4. New NVH Requirements(Engine Down-sizing) Increase of Engine Torsional Excitation (AC Torque)

Torque)）

Source Path/Amplifier Response Engine A/C Torque Powerplant mounts

Powertrain torsional system RDU/Axle mounts Sub-frame system Exhaust system Suspension

Generation Mechanism of P/T Torsional NVH

Interior noise: Boom / Moan Seat track vibration Steering wheel vibration

vehicle sensitivity

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4. New NVH Requirements(Engine Down-sizing) Engine Mean Torque Engine AC Torque

Fewer cylinder engines generate higher AC torque, causing low frequency vibration, boomimg noise and gear rattle.

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4. New NVH Requirements(Increase of P/P, Susp Input)1.5th Order1st Order

Right Engine Mount Z

Right Strut Mount Z

Left and right engine mount Vertical direction are the major contribution.

Left and right strut mount in Z are the major contribution.

Left Strut Mount Z

Left Engine Mount Z

Left Engine Mount Z

Left Strut Mount Z

Seat Track Vibration (Lateral)

1l 3 Cylinder Automatic T/M Car

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4. New NVH Requirements(Increase of P/P, Susp.Input)1.5th Order1st Order

Right Engine Mount Z

Right Strut Mount Z

Left and right engine mount Vertical direction are the major contribution.

Left and right strut mount in Z are the major contribution.

Left Strut Mount Z

Left Engine Mount Z

Left Engine Mount Z

Left Strut Mount Z

Seat Track Vibration (Vertical)

1l 3 Cylinder Automaic T/M Car

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41 MPG HWY6-speed DCT (Dual Clutch Transmission

40 MPG HWY2014 Ford Fiesta

2013 Ford Focus

4. New NVH Requirements(FE Transmissions)

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Electro-Mechanical CAE for HEV/BEV Powertrain NVH

E-Drive Design Magnetic CAE Force Processing

Structure CAEVibration & Acoustic Analysis

Force Optimization

Structure OptimizationNVH as an Attribute in EM Analysis

Feedback to E-Drive Design and Analysis for NVH Improvement

Electro-Magnetic-Structural-Acoustic CAE Process

4. New NVH Requirements(Elec.-magnetic NVH)

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222nd Gear

Mesh

1st loose gear

3rd, 5th & 6thGear Mesh

6th loose gear (backside, not

shown)

Diff

Clutch

1st Gear Mesh

3rd, 2nd and 5th loose gears on output shaft

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Rattle index Shaft angular accel Countermeasures

Double-impact animation (click pic)

scissor

2GO---- Test---- CAE

-----SMF------DMF

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5. The Latest Active NVH Control Technology5-1, Active Sound Quality Technology (ANC)● History of ANC Development● Major Benefits of Active Sound Quality Control● Ford ANC System (1st Generation)● Active Sound Quality Control Strategy● Schematic of Active Sound Quality Control● Effects of Active Sound Quality Control on WOT Sound (V6 Turbo)● Lincoln Drive Control System● Lincoln Continental ANC System

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History of Automotive ANC technology implementation• The first Active Noise Cancelation Automotive Application

Nissan Bluebird (1992) 2EO Booming Noise Cancelation• Active Noise Cancelation/Active Control Engine Mount

Honda V6/I3 VDE (Variable Displacement Engines) (2004)• Gasoline HEV (Hybrid Electric Vehicle) Application(cancelation)

Toyota Crown HEV (V6 Hybrid) (2008)•The first Active Sound Quality Control car implementation(Spectrum shaping with Cancelation and Enhancement)

Lincoln MKS (V6 GTDI) : Ford (2012)

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Major benefits of Active Sound Quality Controla) An effective enabler to achieve Sound Quality/Brand DNA

targets with least constrained by hardwareb) Can eliminate or reduce heavy/bulky/expensive passive

countermeasure devices (resonators/dampers/sound pipes)c) Flexibility to adapt different requirements without changing

hardware:- Adapt to different/regional market requirements/preference- can design an arbitrary characteristics between pedal opening and sound level change

- Can realize distinctively different dynamic characteristics within a vehicle ( “Lincoln Drive Control”) by integratingmultiple active control technologies.

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Figure 2: Powertrain Sound Quality ANC system

Powertrain Sound Quality ANC system

Ford ANC System Configuration (1st Generation)

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SPL d

B(A)

RPM

Enha

ncem

ent

Level

dB

1000 6000rpm20

80

dB(A)Pa+ Baseline

ANC Enhanced

Order WOT Level

Sound Quality Control Strategy

ANC control strategy

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Schematic of Active Sound Quality ControlAdvanced Gasoline Power Units

Active Powertrain Sound Quality Control (Industry First: 2013 Lincoln MKS EcoBoost

ANC OffANC On

Combination of Active Noise Cancelation and Active Sound Enhancement

Need to create Powerful and Sporty Sound (Sound Quality DNA)

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Effects of Active Sound Quality Control on WOT Sound (V6 Turbo)Advanced Gasoline Power Units

Active Powertrain Sound Quality Control

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Lincoln Drive Control

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Lincoln Drive Control

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The first Ford full Active Power train Sound Quality Control product (2013 Lincoln Mks) has been developed and started production, Industry First to combine Engine Noise Cancellation and Sound Enhancement, to achieve P/T Sound Quality DNA.

Discussion and Conclusions

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This car provides a tailored engine sound experience, minimizing unwanted noises and improved perception of engine performance, providing a distinctively different "Sporty" sound under high turbo engine output, and completely new dynamic driving experience, integrating active control technologies, "Lincoln Drive Control" that is another First in Industry technology to realize "Adaptive Car" concept very successfully.

Discussion and Conclusions

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ALL-NEW LINCOLN CONTINENTAL DELIVERS QUIET LUXURY with ANC

ELEGANT, SERENE, EFFORTLESSLY POWERFUL

Innovations in managing vehicle noise and vibration, including Active Noise Control and acoustic-laminated glass, create a quiet, comfortable environment conducive to conversation or simple contemplation.

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Ford ANC Major Product LineMustang Lincoln MKC

Fusion/Lincoln MKZF150

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5-2. Active Control Mount Systems● NVH Requirements for Engine Mount System● Hardware/System Design Trend of Mount● Classification of Active Mount System● Hardware Capabilities of Active Mount

(1st Gen. Semi-Active Mounts: Sumitomo Riko)● Production History of Active Mounts

(Sumitomo Riko)● Capabilities of the Latest Active Mount Systems

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NVH Requirements for Engine Mount Systems

5

100

0 20 40 60 80 100 Vehicle Speed [ M/H ]

Freque

ncy [ H

z ]

102050

500200

Idle RideTip INCranking

Start Judder

Middle Speed Booming Noise

Engine NoiseHigh Speed

Booming Noise

Engine Movement

Low Stiffness High Damping

Background: NVH requirements for engine mounts (TRI)

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Hardware/System Design Trend of Mount

Dynamic Stiffness [ N/mm ]

100 200 300 400 500 600 700

Damping [ Ns/mm ]

5

10

Rubber Mount

ACM

Improve Idle

ECM

Trend of engine mount

(TRI)

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Semi Active

Syste

m Ma

king

Controller

Sensor

High Spec CPU Low Spec CPU

Acc. or Load Sensor N/AAlgorithm DXHS-LMS

(Adaptive Algorithm)Open Loop

FeaturesLow Cost System

Adaptive to Changesin Body Phase

Expensive System

System

Not Adaptive to Changesin Body Phase

Full Active

Classification of Active Engine Mount Systems

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Electrical Type Vacuum Type

Structure

Cancellation Force Max 100 [N] Max 30 [N]Control Frequency Max 200 [Hz] Max 50 [Hz]

Dynamic Range 60 [dB] 30 [dB]Cost (Ratio) 3 1

Hardware Capabilities of Active Mount Systems(First Generation)

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Production History

ODYSSEY (HONDA)

Sumitomo Riko is producing over 1million of ACM annually .

ES350 (LEXUS)

INSPIRE (HONDA)ACCORD (HONDA)

PATHFINDER(NISSAN)

WINDOM (TOYOTA)

CAMRY, SIENA, VENZA (TOYOTA)

99 01 03 05 07 09 11 13 15 Year

Electric Type

Vacuum TypeAVALON (TOYOTA)

ES (LEXUS)

TL, RL, RDX (ACURA)

RX (LEXUS)

Active Control Engine Mount Production

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Vacuum vs. Electric Active Control Mounts

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6. Summary1. Due to achieve CO2/FE regulations globally, powertrain has been

significantly diversified, such as IC engine down-sizing, Electrification (HEV, BEV, FCV and partial electrification).

2. Due to these significant change of Power Units, NVH requirementsalso significantly changed as well as diversified.

3. Especially 3 cyl. engines have inherently larger AC torque,causing bigger NVH challenges such as Idle NVH, booming noise, and gear rattle, and changing major vibration transfer paths as well.

4. Active Noise Control technology became matured technology, especially effective for Sound Quality control, combining activecancelation and enhancement.

5. Active Vibration Control technology(ACM) also progressed as more cost effective devices through broad application, specificallyby Japanese OEMs.