CONTACTFEV Motorentechnik GmbHNeuenhofstraße 181 52078 Aachen ∙ GermanyPhone +49 (0) 241/56 89 - 0Fax +49 (0) 241/56 89 -119 E-Mail marketing@fev.com

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

FEV China Co., Ltd.No.35 Xinda Street QixianlingHigh Tech Zone ∙ 116023 Dalian ∙ ChinaPhone +86 (0) 411/84 82-16 88Fax +86 (0) 411/84 82-16 00E-Mail fev-china@fev.com

Internet http://www.fev.com

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ACOUSTICS AND VIBRATION

VEHICLE AND POWERTRAIN

2

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.

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

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 high quality standard of our work is ensured by modern testing equipment and facilities combined with cutting-edge NVH simulation tools and methods.

Vehicle Physics and AcousticsFEV‘s Expertise Delivers Success

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

3

FEV’s NVH activities cover a wide range of automotive and industrial development tasks:

High quality benchmarking and target setting of components, transmissions, engines and vehicles Systematic troubleshooting CAE-based NVH development tools and methods Sound design and acoustic refinement Sound quality and product brand sound development

Comprehensive process noise optimization Complete product development from concept to Start of Production (SOP) Vehicle NVH development and optimization NVH chassis development for premium interior sound and vibration comfort Industrial, public and internal research

Fields of NVH Applicationsand Activities

Vehicle Physics and AcousticsApplications and Activities

4

Audio Lab

Engine and VehicleWorkshop

NVH Powertrain and Vehicle Testing Facilities

The increased complexity of powertrain andvehicle electronics requires a highly-skilled staff within the assembly workshop and experienced test cell operators.

FEV operates modern powertrain and vehicle NVH test cells equipped with standard as wellas specific instrumentation tools and modern data acquisition/analysis systems.

Vehicle NVH Dynamometer

Test Track

Body-In-White and 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 Integration of the client’s employees into

the project team as required Certified confidentially and concealed

prototype handling

PowertrainNVH Test Cell

5

FEV utilizes many industry standard CAE andCAT 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 MatLab/Simulink …

FEV has also devised a number of highly reliable FEV-specific tools to integrate cutting-edge NVH methods into product development, such as:

Driveline Simulation

CVT Simulation

Powertrain Noise Simulation

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)

NVH Tools Commercial and FEV-Specific

6

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.

NVH for Production ReadinessFrom Concept to Start of Production (SOP)

NVH Development form Concept to SOP

Concept and Targeting Design Prototype Development 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

7

Sound Design and TroubleshootingTools and Methodologies

Troubleshooting projects are supported by acoustic camera analysis, which is a very effectivemethod for targeted noise source identification.

Acoustic Camera

FEV-VINS for Interior Noise Simulation

Airborne Noises

Structure-Borne Noises

Simulated Interior Noise

Structure-Borne Noise Transfer Functions

Airborne Noise Transfer Functions

Stru

ctur

e-Bo

rne

Exc

itatio

nAi

rbor

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Exci

tatio

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AirborneInterior Noise

Structure-BorneInterior Noise

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

combination of powertrain, orifice and tire noises with corresponding airborne noise transfer functions, according to the vehicle positions during pass-by tests

FEV-SME Sound Metrics (pleasentness, dynamic, knocking,...)

are available and can be applied on specific noise phenomena

Powertrain noise Intake orifice noise Exhaust orifice noise Shell noise Tire noise…

Powertrain mount vibration Exhaust syst. vibr. Driveline vibration …

8

Powertrain integration represents a primary task in vehicle development and requires systematic and continuous NVH attention.

The process is strongly supported by “virtual” and hybrid methods for pre-optimization of the “hardware marriage” minimizing the effort required for design changes.

Simulation of Powertrain Mount

Virtual Intake and Exhaust System Development

Package Analysis Drive Off Simulation

Experimental and analytical approaches are applied to the refinement tasks including:

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 Vehicle NVH refinement for interior/ exterior noise and vibration comfort Pass-by noise optimization

Exhaust System Analysis

Vehicle Body NVH CAE

Vehicle Integration Marriage of Powertrain and Vehicle

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Full NVH Responsibility Vehicle NVH Development

FEV can manage overall vehicle NVH develop-ment. Such programs typically are carried out in close cooperation between OEM specialists, suppliers and FEV.

FEV’s project managers skills coordinate ac-tivities between the different working groups, ensuring a streamlined development process.

Interior Sound Quality

high

low

Interior Trim OptimizationTop: Hardware SolutionBottom: Firewall Noise Map

Noi

se T

rans

pare

ncy

The cooperation between OEM, FEV and suppliers is characterized by:

System and components level target setting

Experimental and analytical component refinement

Development for the OEM, according to specific processes and strategies Full-responsibility for NVH integration NVH robustness for Production

Powertrain induced NVH: Engine and Transmission Driveline Powertrain Mount Intake and Exhaust System ...

Aero Acoustic: Body Shape Sealing Windows Side MirrorWiper ...

Body NVH: Global Stiffness Stiffness of Front-End Section Impedances at Interface Points Vibro-Acoustic-Transfer Functions Heavy Layer Distribution ...

Chassis NVH: Stiffness of Axles and Subframes Bushing Insulation Tire Noise Steering NVH Brake NVH ...

Interior NVH Quality: Sound Insulation Squeak and Rattle HVAC Noise Electro Servo Motor NoiseAudio and Entertainment Systems ...

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Challenging NVH targets are prerequisites for developing excellent powertrain and vehicle sound, along with vibration comfort.

Extensive Powertrain NVH Database

Soun

d Pr

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evel

[dBA

]

1000 2000 3000 4000 5000 6000 rpm

DI-Diesel Engines

GasolineEngines

Prototype

Production

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

More than 500 engines and vehicles More than 100 metrics

More FEV Scatter Bands: Noise Level; Loudness; Sharpness; Tonality; Articulation Index; Comb. Noise Index; Jury Ranking; ...

Exterior Noise

Orifice Noise

P/T Noise

P/T Mount Vibration

Interior Vibration

Road/Wind Noise

FEV_CSL:

Cylinder Pressure

Engine Structure Attenuation

FEV -VINS:

Structure Borne Vehicle Attenuation

Airborne Vehicle Attenuation

Interior Noise

NVH Benchmarking From Cylinder Pressure to Driver‘s Ear

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Developing of a low noise engine requires CAE-based NVH optimization from the begin-ning of the concept phase.

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.

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

FEV’s competitive edge in low noise engine development:

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

Low Noise Engine and Sound Design for Improving Powertrain NVH

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Transmission and Driveline NVH

The increasing challenges for powertrain de-velopment are also driving new transmission technologies.

At FEV, NVH and shift quality optimization is integrated into transmission development, including design, mechanical and electronic development as well as integration into the vehicle application.

Driveline NVH related tasks, such as boom, gear whine, gear rattle, clunk, etc. are perfor-med with the help of CAE, testing and bench-marking. The following services are available:

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.

Driveline Simulation

Tooth Stiffness Simulation

Driveshaft TorqueMeasurement

FEV’s experience in quiet driveline NVH development:

Well proven CAE tools and methods Highly sophisticated testing tools and method for noise optimization Extensive database for NVH component

specifications

V-Vins

Acoustic Test Bench

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Combustion Process NoisePowerful, 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, exhaust gas aftertreatment constraints and On-Board Diagnosis (OBD).

FEV’s highly-qualified NVH engineers explorethe full calibration of NVH potential, while achieving emissions and related fuel consumption targets, using the in-house developed methods, such as FEV-CSL and FEV-CSL-CAL.

FEV-CSL-CAL

Parameters: Pilot injection Main injection Rail pressure EGR …

Responses: FEV-CSL Interior noise Exterior noise Fuel consumption Emission

FEV-CSL: Engine Noise Shares

Direct Combustion

NoiseFlow Noise

Indirect Combustion

Noise

Engine Noise

Mechanical Noise Accessory NoiseCombustion Noise

Transient Combustion Noise Optimization

DoE-models

Cal. 1Cal. 2

Time

Inte

rior

Noi

se

5 dB

The characteristics and advantages of FEV’s unique NVH calibration tools:

CSL: Method for engine noise breakdown, such that the full NVH potential of an engine can be explored

CSL-CAL: DOE-based method for combustion noise optimization

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In general, hybrid vehicles can possess favora-ble NVH behavior, especially during start-up and low speed cruising. Nevertheless, detailed NVH refinement of HEV-specific electric com-ponents, powertrain mounting system and driveline are required to achieve excellent NVH behavior.

The main NVH challenge consists in adjusting the NVH response to the driving condition and the driver’s expectation. Consequently, NVH development focuses on the balancing of HEV operational modes.

By using FEV-Hybrid-VINS software, vehicle operational modes can be balanced regarding 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.

Powertrain Noise Simulation

Hybrid vehicle-specific NVH development tasks:

Smooth internal combustion engine Launch at start-up and during drive-away Moderate ICE start /stop feedback during the vehicle stop Unobtrusive ICE deactivation/activation during cruising/acceleration Powerful, acoustically supported, dynamic acceleration feedback Unobtrusive NVH behavior of electrical components, such as magnetic noise during regeneration at recuperation low vehicle speeds

AD C C

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. rpm

A

B

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Hybrid Vehicle Balancing of Hybrid Operational Modes

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Trucks and Heavy-Duty Vehicles

Truck development is mainly driven by costs, fuel consumption, emissions and reliability. Nevertheless NVH comfort is becoming more and more important.

To achieve an overall well balanced NVH be-havior, the entire vehicle has to be taken into account. It is very important to optimize all relevant NVH systems/components, such as:

Powertrain and driveline Intake and exhaust system Chassis and mounts Cabin including the noise insulation

FEV’s key elements for the optimizations are:

Long term experience with trucks and heavy-duty vehicles

Proven CAE tools and methods Very efficient testing tools and methods

FEV’s systematic approach allows for efficient NVH development.

Powertrain/Drivetrain

Combustion System Development

Vehicle Integration

Component Optimization

w/o NVH Optimization

w/ NVH Optimization

Displacement [l]

SPL

[dBA

]

5

Pass-By NoiseInterior Noise

Benchmarking

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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-sive optimization process are CAE and hybrid methods including:

Combined FEA and MBS for structural optimization with respect to NVH and

stress analysis 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 Combined MBS and CFD simulation for 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.

The development process for off-road machi-nery is influenced by multiple targets and associated constraints. This requires well-balanced technical and commercial targets that focus on customer benefits.

Development Targets forOff-Highway Machinery

Structure-borne: Comb. engine Hydraulic pumps Hydraulic motor Hydraulic tubes Gearbox Transfer box Axle differentials …

Airborne: Comb. engine Exhaust Intake Fan/air flow …

Flexibility and Effort for Troubleshootingduring the Development Process

Flexibility forProblem Solving

Effort forTroubleshooting

Planning Development Production

Des

ign

Flex

ibili

ty /

Cost

Typical Interior Noise Share Distribution for Off-Highway Machinery

Package/Visibility

Design

Vibration Comfort

Interior Noise

Fuel Consumption

Noise Legislation

Machine Performance

Durability

Off-Road Use

Thermal Balance

Production Cost

Maintenance

Time to Market

Assembly Line

After-Sales

Emission Legislation

Industrial and Off-Highway Machinery Introduction of Virtual Development Tools

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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 CameraOptimized Vibration Isolation for Stable Pictures During the Race

Heavy-Duty Industry: Power Station

Exhaust System Orifice Noise Optimization

Appliances (White Goods):

Heating System BoilerOptimization of Noise

Emission and Flame Stability

Recreational Devices: Power Tower

Noise Source Identification and Optimization -

Compressed Air Lift System

Diverse Applications Non-Conventional NVH Projects

Formula 1 Sound

Race Car Sound Design

Compressor Noises

Coal Mill Noise

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Melody of DrivingEngine Sound and Music

Engineers studying mechanical acoustics 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).

Machinery sound is characterized by non-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.

Sound Design by Engine Order

Composition: 5-Cylinder Engine

4.5th EO

3.5th EO 4th EO

3rd EO

Features of Natural Tone and Engine Noise

Harmonics

Tonic

Noises

Engine Orders Resonance

Base Dissonant Consonant

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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.

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.

Road Traffic Noise as a Focus of Public Discussion

(Source LfU 2004)

AirTraffic

RoadTraffic

RailTraffic

Neighbor-hood

RecreationalIndustry

35%

30%

25%

20%

15%

10%

5%

0%

1999

2004

1999

2004

1999

2004

1999

2004

1999

2004

1999

2004

Annoyance

Mean

Intense

Test Set up Controller Assessment

Aside from public NVH interest, FEV invests in many internal research projects to be prepared for future technological challenges, including the following:

„Virtual” powertrain and vehicle development Technology NVH road maps Sound quality

Piezo Patch

Shaker

Signal Processing

Piezo Control

NVH Research Activities Prepared for Future Challenges