Frontload in the Development Process: Road-to-Rig Method through Innovative Measurement Technology

Authors

Dr. D. Höfler, Dipl.-Ing. S. Maxl, tectos gmbh, Graz

Year

2020

Print Info

Fortschritt-Berichte VDI, Reihe 12, Nr. 813

Summary

Shorter product life and innovation cycles challenge the automotive industry and require more efficient development methods. Despite the popularity of electrical mobility, there is also a general trend towards frontloading, including Road-to-Rig (R2R) methods. Especially in Noise Vibration and Harshness (NVH) engineering, challenges often occur relatively late in the development process. The reasons for this are manifold and can often only be identified with great technical and financial effort. Hence, tectos constantly works on new products and methodologies to provide innovative NVH solutions for different powertrain technologies.
To successfully solve NVH challenges on test rigs and on-board vehicles, a new data-driven methodology for NVH measurement applications has been developed. The state-of-the-art R2R procedure was extended by the Cross Industry Standard Process for Data Mining (CRISP-DM). In particular, our analysis based on data sets generated with conventional NVH measurement equipment, was performed using machine learning methods and approaches. This determination of the current state from test procedures, representing the different stages in the development process, allowed for the identification of NVH optimization potentials. During this process, iteration was carried out backwards from Real Driving Emissions (RDE) test drives via a chassis dynamometer to a component test rig. Based on this holistic system understanding, a target state for NVH measurement technology could be defined.
The body of knowledge gained was used for the development of a new software tool, which together with the associated hardware form the basis of the tFender from tectos. The tFender is a newly designed NVH measurement system, with a focus on torsional and structure-borne vibrations of a vehicle’s powertrain. An integrated interface to real-time simulations additionally sets new standards in this area. In addition to the acquisition and evaluation of NVH phenomena, the use for a product, which minimizes torsional vibrations, was also identified. Hence, a concept to dampen such vibrations could be useful for NVH powertrain development. The directE module is an actively operating mechatronic system that compensates torsional vibrations in powertrains. Based on the evaluated data, the patented solution was identified to be useful in passenger vehicles and motorcycles. With the newly developed method and these two products, tectos sets the course for an innovative and secure future as an NVH supplier.