NVH Development of a High Torque SUV with new vibration isolation technology using passive and active vibration isolation system (Active Torque Rod)

Paper #:
  • 2018-01-0685

Published:
  • 2018-04-03
Abstract:
During the last decade, fuel economy mandates (CAFE regulations) have driven engine downsizing and down-speeding trends. More recently, downsized turbos are percolating down to heavier SUVs and trucks. Larger/heavier vehicles require high torque engines to provide attractive dynamic performance. While higher torque requirements can be satisfied with new innovations like the variable compression engine, larger and more upscale vehicles also need to deliver higher quietness requirements. For this, the vibration control system for combustion induced forces with high torque engines becomes very important. To address both dynamic performance and quietness, active engine mounts have been previously adopted, however challenges for light-weighting, downsizing, and costs have persisted. A new vibration isolation technology using passive and active vibration isolation system (Active Torque Rod) was studied for application to a new vehicle to realize quietness targets with a smaller, lighter, and less expensive engine mount system. The basic concept of the active torque rod is to set it’s resonance below 200 Hz so as not to degrade the acceleration noise due to down-sizing by utilizing the passive vibration-isolation region. However, the engine primary order (2nd order) booming noise degrades due the torque rod resonance below 200 Hz. Therefore, the resonance amplitude is suppressed by utilizing an inertia mass actuator in the torque rod and inputting an out-of-phase control force corresponding to the engine 2nd order input. This paper demonstrates the benefits of applying an active torque rod to a premium C-segment SUV under development with a new inline 4-cylinder turbocharged engine. In order to achieve the acceleration noise targets, an active upper torque rod was applied to counter the large roll reaction force input. Acceleration noise levels were reduced about 10 dB (250-800 Hz) compared to conventional torque rod system. Both acceleration noise and booming noise achieved class leading levels. The proposed mounting system is approximately 8 kg lighter than the existing active control engine mount system.
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