NVH Design, Analysis and Optimization of Chevrolet Bolt Battery Electric Vehicle

Paper #:
  • 2018-01-0994

Published:
  • 2018-04-03
Author(s):
Affiliated:
Abstract:
A multi-stage system level NVH design, analysis and optimization method is used to optimize and improve motor NVH performance of the propulsion system design of General Motors’ Chevrolet Bolt battery electric vehicle (BEV) incorporating a permanent magnet synchronous motor. First, the rotor EM design optimizes magnet placement between adjacent poles asymmetrically, along with a pair of small slots stamped near the rotor outer surface to lower torque ripple and radial force. The size and placement of stator slot openings under each pole are optimized to lower torque ripple and radial force. Next, motor stator level Finite Element (FE) analysis and modal test correlation are performed to benchmark the orthotropic stator material properties and accurately predict modal results within 7% error below 2 kHz. Furthermore, EM tangential and radial forces are applied on motor-in-fixture subsystem FE model, which predicts surface vibration and pseudo sound power on the motor housing. Analysis results are used to benchmark motor NVH source (EM NVH design and structural coupling with stator mechanical design) and identify key motor orders and rpm for optimization study. Lastly, optimized EM and mechanical designs are modeled in the drive unit for transmission level NVH analysis. The multi-stage system level model is used to study key design parameters like EM force coupling with structural modes, motor mounting, drive unit ribbing and stiffness optimization on Bolt motor NVH performance. Key design concepts and parameters that have most influence on radiation sound power from drive unit are identified, and subsequently optimized for improved noise performance of Bolt EV.
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