Intensive development is currently performed worldwide on hybrid and electric vehicles. For full electric vehicles the driving range is today still limited by the capacity of currently available batteries. If such a vehicle shall increase its driving range some range extending backup system has to be available. The Range Extender discussed here is a small system of combustion engine and electric generator which produces the required electricity for charging the batteries in time. Since the acoustic excitation of an electric motor driving the vehicle and of a combustion engine as part of a Range Extender is very different by nature an extensive acoustic tuning of the Range Extender is necessary to meet the requirements of exterior vehicle noise and passenger comfort of an electric vehicle. This paper describes the NVH (noise, vibration & harshness) development work of the Range Extender within the AVL approach of an electrically driven passenger car. This work started with an acoustic front loading in the concept and design stage and was continued with intensive simulation and testing during combustion and engine development followed by the acoustic integration into the electric vehicle. The big challenge for good NVH of a Range Extender is the control of noise and vibration at low engine orders which result mainly in noise arising from the exhaust and intake process. With the choice of a rotary piston engine for RE application, the problem of unbalanced mass vibration as relevant for 1 and 2 cyl. engines is negligible. However, the excitation of exhaust and intake noise is high with the piston-ported rotary engine requiring extensive control measures. This includes not only strong control technologies and hardware measures, but also clever RE operation strategies for different vehicle speed ranges with a least two engine speed-load points and appropriate transitions. It may in future also include active noise cancellation technologies for extremely low vehicle interior noise requirements.
NVH development of electric vehicles with range extender
2010
14 Seiten, 12 Bilder, 3 Tabellen, 4 Quellen
Aufsatz (Konferenz)
Englisch
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