Automotive

In this Issue
Mazda Motor Corporation Operational Modal Analysis
Product News Modal Testing Solutions
Link Engineerings Model 3900 Brake Noise Dynamometer An Industry Standard
Product News Brel &Kjr Strengthens its Accelerometer Program
SAE Brazil 2004 Congratulations Svend!
ASMET Acoustic Testing of Automotive Exhaust Systems
The Brel &Kjr University Global Courses for 2005
PULSE Customer Clinic
Carcoustics The Power of Silence
Automotive NVH Seminars 2005
Mazda Motor Corporation Operational Modal Analysis
Based in Hiroshima, J apan, Mazda Motor Corporation manufactures a wide range of passen-
ger cars and commercial vehicles and in 2003, it produced more than 800000 cars and trucks
at its Hiroshima and Hofu production sites.
Long NVH Testing Relationship
Mazdas relationship with Brel &Kjr goes back over many years and, during this time,
Mazda has continually invested in its R&D NVH analysis facilities. In J uly of 2002, Mazda
placed an order for an unusual PULSE system a large 220-channel system for modal analy-
sis applications in Mazdas powertrain division. The goal to further optimise noise and vibra-
tion parameters in vehicle powertrains. Mazdas requirement was to pre- and post-validate the
data in the frequency and time domains, and to export the time data for use with the Opera-
tional Modal Analysis software.
Newsletter/February 2005/Issue 14
Welcome to this issue of Brel &Kjr Automotive its focused on your industry and is read by
automotive manufacturers and suppliers all over the world. If you would like copies of any of the earlier
editions, just send a mail to us at automotive@bksv.com and well forward them to you.
In this issue, well describe some of the interesting automotive NVH test solutions that are used by our
customers around the world. And you can find information on our series of global automotive seminars in
2005, and the recently held PULSE

Customer Clinic. Click on the blue hyperlinks to download product

data sheets, the latest copy of Brel &Kjr Magazine and our Automotive brochure. You can find further
information on all our automotive test solutions much more on our website bksv.com.
We are proud of the facilities at our headquarters in Nrum. If you would like to visit us, then please send
a mail to automotive@bksv.com you will meet some of our automotive application experts, and can try
the wide range of automotive related solutions. Well make all the arrangements and ensure that your trip
is not only worthwhile but enjoyable!
The PULSE system can measure sound and vibration up to 12.8kHz on all 220 channels
simultaneously.
The acquired data is transferred to one of the two work stations in Mazdas powertrain division
for operational modal analysis (OMA) where a detailed analysis is made. Though at the time
the order was placed, PULSE was limited to 128 channels, Mazda preferred Brel &Kjrs
solution to other potential suppliers. The decisive factors were Mazdas long-term relationship
with Brel &Kjr, its satisfaction with the existing PULSE systems, and Mazdas confidence in
the powerful algorithms and features in Operational Modal Analysis Type 7760 software.
Photos by courtesy of
Mazda Motor Corporation
Powertrain Testing
Mazdas Powertrain Division includes R&D sections that focus on the development of engines,
gearboxes, transmissions and exhaust systems. Two groups in Mazdas R&D department
decided collectively to use OMA. Additionally, a great deal of general NVH testing and evalua-
tion is carried out daily.
Mr. Yasunori Kanda is Assistant Manager, AT Testing&Research Group, Drivetrain Develop-
ment Department. He says. In our testing facilities, PULSE is a highly effective test and analy-
sis tool for optimal design and fast product development. For example, several PULSE
systems, each of 24 channels, are used for NVH bench-testing measurements. In the case of
advanced measurement techniques, such as Non-stationary STSF Software Type 7712 and
IBEM (Inverse Boundary Element Method) for advanced noise source location, our 66-channel
and 120-channel systems are effective tools for troubleshooting.
In addition, Mazda has several PULSE IDA/IDA
e
data acquisition systems, each of more than
30 channels, for operating deflection shapes (ODS) and standard experimental modal analysis.
These are strongly related to Mazdas CAE software in data communications. They also have
PULSE Sound Quality Software Type 7698. Overall, Mazda has a huge NVH testing capability.
Results
Mazda has achieved good results. By applying test data at the design stage, and by effective
troubleshooting, development times have been significantly shortened. Mr. Kanda continues,
However, high-frequency noise will be a problem in the future. Until today, this has been rather
neglected while low-frequency noise and vibration is well under control. Therefore, we made a
decision to introduce Operational Modal Analysis based on PULSE. This is a strong and flexi-
ble tool for multichannel high-frequency analysis, and enables us to take countermeasures
against high-frequency sources. It also provides the Modal Assurance Criteria (MAC) of mode
shapes for finite element analysis and operational modal analysis.
Head and Torso Simulator Type 4128C is placed on the front passenger seat, and measures
cabin noise on two channels. Several other microphones are located in other cabin and engine
compartments. The data from these sensors is simultaneously collected during 90 seconds of
run-up testing. All acquired data relates to noise path analysis, operating deflection shapes,
sound quality evaluation, and OMA. This is one of the great benefits of multichannel and multi-
analysis measurement no additional testing is required for a wide range of analysis tech-
niques.
The Right Solution
The 220-channel PULSE test bench solution for Mazda comprises:
Two very powerful PCs one PC handles the GUI the other handles the data acquisition
PULSE software including Data Recorder Type 7701, Time File Management Type 7789,
Modal Test Consultant

Type 7753, Operational Modal Analysis Type 7760

Eight 3560D frames each contains front-end modules which together provide 30 channels
70 Model EE 0366 001 (100 mV/g) Triaxial Accelerometers with TEDS
Two separate OMA post-processing stations
Mr. Kanda say, Using OMA, we find it easy to identify gear noise problems such as the struc-
tural resonances of gearboxes and the effect of internal gear resonances, even if there are
complicated situations due to the high orders of rotating components, and a lot of resonances
of related structures.
Mazda NVH engineers are very satisfied with the flexibility of the PULSE platform. Mazda can
use its 220-channel system for data acquisition, post-processing or real-time analysis in many
NVH applications, for example, order analysis, ODS, OMA, standard modal analysis, acoustic
holography, and source path contribution analysis all NVH data can be smoothly transferred
and easily shared by Mazdas CAE tools.
Mr. Kanda concludes, Brel &Kjr is highly competitive to other companies providing NVH
solutions. We are very pleased with our new OMA system. We have achieved significant test-
ing improvements and we can use it for many different types of tests. We are expecting even
stronger cooperation with Brel &Kjr in the future.
PULSE Hardware System Data PULSE Software System Data
Modal Testing Solutions One Stop Shop
Brel &Kjr has the worlds widest range of
modal testing solutions covering every level of
modal testing, and all your modal needs. Built
on more than 60 years of experience and
expertise, we can supply modal components
or complete modal test solutions to suit your
needs everything from impact hammers,
modal exciters, transducers and non-contact
vibrometers to our PULSE data acquisition
and analysis system, modal analysis software
and model validation and updating tools.
The Windows

-based PULSE platform pro-

vides an unrivalled degree of versatility, scala-
bility and modularity. Combined with user-
friendly analysis software, PULSE provides an optimum platform for structural dynamics test-
ing. Adding the dedicated ODS Test Consultant and/or the Modal Test Consultant

software
turns PULSE into a very powerful structural dynamics measurement platform that reduces the
very time-consuming data acquisition aspects of preparing, performing and validating measure-
ments.
Geometry-driven measurements allow you to set up your measurement points and directions
on the computers geometry, just as they are in real life. This provides almost foolproof guid-
ance during the measurement procedure.
A major user-friendly feature is seamless one-click transfer of geometry and measurement
data and activation of post-processing packages including MEscopeVES

for classical ODS,

mobility-based modal analysis and structural dynamics modifications and Operational Modal
Analysis for performing modal parameter extraction from measured responses only. Modal data
can easily be transferred to model validation and updating tools for test-FEA integration.
No matter what your modal test application may need:
Accelerometers Charge, Integrated Electronics Piezoelectric (IEPE), Piezoresistive,
Variable Capacitance or Non-contact Vibration Transducer technologies
Smart transducers compatible with IEEEP 1451.4 standards
Mounting, positioning and orientation accessories
Excitation equipment
Data acquisition and analysis systems
A range of software for workflow, measurement, analysis and model updating
Or, whatever the size of your system:
Small 2 to 7-channel systems for troubleshooting
Medium 8 to 64-channels for lightweight and intricate structures, and for structural
dynamics component testing
Large systems of several hundred channels for complex and bisymmetrical structures
We can configure a complete modal solution to suit your specific needs a solution that pro-
vides you with consistent, high-quality, multichannel measurements and analysis data.
Modal Brochure Product Data Type 7753 Transducer Selection Guide
Link Engineerings Model 3900 Brake Noise Dynamometer Becomes an Industry Standard
Over the last decade there have been many different dynamometers developed for brake noise
testing. Early designs eliminated the hard inertia used on performance dynamometers. During
the same period there were also numerous methods for NVH data acquisition and analysis.
However, the development of the SAE J 2521 procedure has led to a standardised apparatus for
brake noise testing.
Brake NVH Test Procedure
Developed by the US Working Group on Brake NVH, SAE J 2521 was the international standard
for brake noise testing. The adoption of this standard has been so widespread that it has led to
a standard dynamometer configuration.
In the US, General Motors developed its own test procedure based on SAE J 2521. This proce-
dure was developed from General Motors experience with their NVH dynamometer and key
aspects of this dynamometer design are prescribed in the test procedure. Since the General
Motors dynamometer was designed and built by Link Engineering, the Link Engineering Model
3900 Brake Noise Dynamometer has become the standard configuration.
General Motors requires that its suppliers demonstrate their ability to correlate with General
Motors noise test results. Therefore, when General Motors suppliers need a new dynamome-
ter, the Link Model 3900 is their first preference. In fact, this dynamometer has earned such a
good reputation that it is now preferred by a wide range of vehicle manufacturers and brake
suppliers.
The Standard Brake NVH Dynamometer
Photo by courtesy of Link
Engineering
The modern brake noise test dynamometer
has become a sophisticated test platform for
identifying the propensity of a brake to gener-
ate squeal and diagnosing noise problems.
The implementation of SAE J 2521, the first
internationally recognised brake noise test
procedure, requires both drag and regular
stops.
The traditional approach to representing the
vehicle inertia is to include discs on the rotat-
ing shaft whose rotational inertia is equivalent
to the linear inertia of the vehicle. In the Link
Model 3900, state-of-the-art inertia simulation
is used to more accurately represent the iner-
tia of the vehicle. Model 3900 provides both physical inertia and inertia simulation to give the
user maximum flexibility in simulating the vehicle braking system.
Data Acquisition
Dr. J ames Thompson, Links Executive Director of NVH, Sales and Marketing says, A key part
of any noise dynamometer is the NVH data acquisition and analysis system. Brel &Kjr's
PULSE system is our preferred NVH platform and we have ordered more than 50 systems in
the last five years.
J im continues, The standard unit for our Model 3900 is a Brel &Kjr PULSE system. This
unit provides a full range of data acquisition capabilities. Typically, for brake squeal testing one
or more channels are used with sampling rates of 52kHz. The analysis capabilities of this unit
are almost endless. One can perform simple spectral analysis, coherence, coherent output
power, order tracking, and even modal analysis with this one unit. PULSE runs under the Pro-
Link software package. This operates the dynamometer, performs data acquisition, executes
data analysis, and provides complete data reporting capabilities. ProLink makes it very straight
forward for the user to configure and run a noise test. This Link and PULSE combination pro-
vides state-of-the-art capabilities in an easy to use package.
Testing Methodology
There is clear agreement that the principal brake hardware must be utilised on the dynamome-
ter to replicate squeal. To achieve maximum accuracy, the full suspension system of the vehicle
corner must be included. Previous studies have shown that it is necessary to have all the sus-
pension components, back to the connection with the vehicle structure, including the bushings,
in the system for an accurate representation of noise. The Model 3900 provides the ability to
utilise the full vehicle corner and run in a standard or inverted configuration. The inverted con-
figuration is useful when doing laser doppler or holographic imaging of the brake rotor.
The environment in which the brake is operating is also important in order to reproduce the
noise found on the vehicle. Acoustically, the environment of the vehicle operating on the road
must be reproduced. This means a free acoustical field above a reflecting plane. At the fre-
quencies of concern, the road surfaces acts much like a reflecting plane. Other brake sound
energy is free to radiate in all other directions with little attenuation. To approximate the free
acoustic field, the walls of the test enclosure are lined with an acoustically absorptive material.
To provide a sufficiently low background sound level to detect squeals, the walls of this enclo-
sure are also designed for provide high sound transmission loss. Typically these rooms provide
background sound levels below 60dB(A).
It is also necessary to accurately represent the environmental conditions under which the brake
is operating. This may include both the temperature and relative humidity conditions. Links
Model 3900 provides the ability to control these parameters. With the ability to control tempera-
ture over a range of 10 to +50

C and relative humidity from 20 to 90

%
, Model 3900 provides
highly accurate control of the test environment.
J im concludes, Noise is the number one brake related customer issue for automotive manu-
facturers throughout the world, its a critical product differentiator, and brake repairs and
replacement are hugely expensive. Noise makes a customer aware of the vehicles brakes and
affects the customers perception of the vehicle because brake noise immediately causes
safety concerns.
In the future, the best situation for vehicle manufacturers will be that brake noise will be a non-
issue. Our solutions are helping them and their suppliers to achieve this goal.
PULSE Hardware System Data PULSE Software System Data
Product News Brel & Kjr Strengthens its Accelerometer Program
We have broadened our product range of vibration sensors with the addition of 47 new types
including accelerometers, force transducers and hammers.
We now offer the most comprehensive line of high-performance, high-quality, economical, rug-
ged and lightweight uniaxial and triaxial accelerometers for almost any application, and a wide
variety of quality cables and mounting options to ensure optimum measurement integrity, ease
of setup and data reliability. This is the result of in-depth understanding of the nature of sound
and vibration combined with a very good understanding of customers needs and applications.
One of the first products to
emerge from our new
accelerometer program is
a new lightweight, triaxial,
OrthoShear

, piezoelectric
accelerometer Type 4524
An investment in brand new production facilities in
order to produce quality products quickly and accord-
ing to required specifications
Having our own facilities not only gives us the ability to react
quickly to market and customer demands for precision
instrumentation, but also gives us the opportunity to perform
exacting tests on all our new designs and fully optimise the
quality of our products.
A strengthened in-house engineering staff to continu-
ously develop new accelerometers and to provide the
ultimate support for the sound and vibration industrys
demands
Building on the many years of Brel &Kjr experience and knowledge we are continuously
strengthening our in-house engineering department giving us the capacity not only to improve
existing accelerometers, but also to develop new versions and make customer-specific variants
of existing designs.
New Miniature Triaxial Accelerometer
One of the first products to emerge from the new accelerometer program is Miniature Triaxial
DeltaTron

Accelerometer Type 4524. It is a new lightweight, triaxial, piezoelectric, OrthoS-

hear

accelerometer and addresses the needs of the automotive industry for:

Structural analysis measurements
Multichannel modal analysis measurements
Modal measurements for automotive body and powertrain applications
It is made from very few parts, making it very rugged and ensuring reliable operation and
adherence to specification over a long life time.
Type 4524 was developed using the numerical modelling technique FEM (Finite Element Mod-
elling). Type 4524B includes TEDS. Each accelerometer is individually calibrated and supplied
with a comprehensive calibration chart, using state-of-the-art, random FFT technology, provid-
ing an 800-point, high-resolution calibration (magnitude and phase), ultimately giving a unique
characterisation and securing the integrity of the vibration measurement.
Click here for further information on the new accelerometer programme.
Transducer Selection Guide Product Data Type 4524
SAE Brazil 2004 Congratulations Svend!
Svend Gade is an Associate Professor at
Brel &Kjrs University and is an application
specialist in advanced sound and vibration
measurement technologies. He has worked at
Brel &Kjr for more than twenty-five years.
Svend and his colleagues regularly present
papers at seminars and conferences all over
the world.
In November 2004, Svend presented a tech-
nical paper, Hotspot Identification Methods
for the Derivation of Acoustic Equivalent
Source Models, at the SAE Brazil Interna-
tional Transport Technology Conference and
Exhibition in Sao Paulo.
The paper focuses on methods for estimating equivalent source positions or hot spots on an
object to be modelled acoustically. This procedure is the first step in the derivation of an acous-
tic equivalent source model to be used, that is, in connection with measured acoustic transfer
paths. Methods based on Near-field Acoustic Holography as well as the Inverse Boundary Ele-
ment Method are described and compared. The use of the different methods is illustrated by
actual measurements and calculations on a real passenger car exhaust line system.
This paper, written by J akob Mrkholt, Andreas Schuhmacher, J rgen Hald and Svend Gade
won the prize for best international technical paper.
ASMET Acoustic Testing of Automotive Exhaust Systems
ASMET was founded by Andrzej Szarski in 1989. Located some 250km north-west of Warsaw,
the company has grown rapidly from its origins as an automotive spare parts supplier to
become a major European manufacturer of high quality automotive exhaust systems. ASMET
has a production capacity of up to 250000 complete exhaust systems per year and remains pri-
vately owned.
The noise performance of its exhaust systems has always been a focus area for ASMET. In
1999, the company purchased a complete Brel &Kjr solution to measure and analyse the
acoustic parameters of its products.
Exhaust System Production
Photo by courtesy of
ASMET
Exhaust systems for over 600 different
models, comprising more than 1000 dif-
ferent components, are currently in pro-
duction. All design and development is
in house, including the manufacture of
production jigs. The company is accred-
ited to ISO9001.
Miroslaw Bruski is ASMETs Managing
Director. He says, Every month we add
about ten new models to our product
range, although there is still a demand for
exhaust systems for older cars and we
keep many in stock. Others can be pro-
duced on demand with short production runs from as few as 20 pieces.
ASMET currently has about 20% of the market for replacement exhaust systems for cars and
vans in Poland more than any single competitor. Some 15% of the companys production is
exported and ASMET is keen to expand this area of its business.
R&D, Quality and Performance
Miroslaw says, To design and develop an exhaust system, we buy at least two complete units
from the original equipment manufacturer. The units are carefully measured and CAD drawings
produced. The aim is to achieve as close a shape to the original as possible. The next step is
that acoustic measurements are made in our anechoic room. The unit with the best noise
parameters is cut to reveal its construction and the interior dimensions are again measured and
CAD drawings made.
Prototypes of the new design are made and these are thoroughly tested, both for their physical
dimensions but also their acoustic properties. Subject to these being within the specified limits,
the new model is released for production.To improve the durability, heat resistance, noise level
and sound quality of its products, ASMET uses glass fibre-based Advantex

Muffler Roving,
For some applications, polyethylene bags filled with continuous filament fibre glass wool are
used.
Acoustic Performance
Miroslaw explains, We have always regarded the acoustic performance of our products as a
critical factor. Our goal is to make our exhaust systems highly durable but also quieter than the
original component. The measured spectra of our products must be equal or better than those
of the original part. Exhaust noise is becoming an ever-increasing issue in Poland and the
acoustic performance of our exhaust systems is a key market differentiator. We always aim for
the best possible noise performance. Of course many people, especially younger drivers, want
their cars to sound right. So although we aim to manufacture exhaust systems with the lowest
noise level, we also pay attention to the overall quality of the sound.
Test System
Brel &Kjr has, in my opinion, always had a reputation as the world market leader in the field
of noise and vibration, says Miroslaw.
Analysis of the noise parameters of complete exhaust systems are made in ASMETs purpose-
built laboratory. White noise produced by Noise Generator Type 1405 is amplified by Power
Amplifier Type 2706 connected to a loudspeaker contained in a specially developed enclosure.
A sound pressure level of 128dB is applied at the inlet of the exhaust system. The noise at both
the input and output is measured using two 1/2 microphones connected to Real-time Fre-
quency Analyzer Type 2143. The difference between the input and output levels enables the
degree of attenuation to be calculated. Measurements are made in the frequency range from
63Hz to 5kHz using 1/3-octave CPB analysis. Linear and A-weighted levels are also meas-
ured.
Although tests for R&D are made in the anechoic room, for troubleshooting, the exhaust sys-
tem is installed on the relevant vehicle and the engine run at a predetermined steady state.
Microphones are positioned at the input and output of the exhaust system and in the cabin.
Measurements are also made at full throttle.
A Successful Partnership The Future
Owner of ASMET and President, Mr. Andrzej Szarski explains, When I decided to invest in a
complete noise measurement facility, we didnt know much about noise. Our products either
passed the relevant standard, or failed. I based my decision to buy from Brel &Kjr on a
number of factors. Firstly, Brel &Kjr was recommended to us by other users in the automo-
tive industry and secondly, then, as now, the company had an excellent brand name and repu-
tation.
Mr. Andrzej Szarski concludes, Our Brel &Kjr system does exactly what we intended. It is
totally reliable and has enabled us to ensure that the acoustic properties of our products are
optimised. But just leaving the system alone is going backwards and we must ensure that we
always use the latest state-of-the-art technology. The time has now come to upgrade our NVH
solution to PULSE.
The Brel & Kjr University Global Courses
Throughout 2005, we will be running an extensive series of courses and training covering all
aspects of sound and vibration. Click here to see the global courses schedule for 2005.
PULSE Customer Clinic A Huge Success
Chris Waltenberry of
International Truck,
Indiana, in deep discussion
with Alun Crewe, PULSE
Marketing Manager
In early February, Brel &Kjrs University
facility at Nrum was host to the first PULSE
Customer Clinic. We invited seven PULSE
user experts from automotive, aerospace
and industrial companies from J apan, USA
and Europe to attend this three day event.
Alun Crewe, Brel &Kjrs PULSE Market-
ing Manager says, Its vital for us to get con-
tinuous feedback from our customers to
ensure that we fully understand their requir-
ments. In the past, we travelled around the
world and made demos of functionality we
were developing, but it was very time con-
suming to visit a large number of customers
and we could only spend limited time with each of them. Its important to have enough time to
discuss the next PULSE release.
A further important aspect is that our developers in R&D meet the users and, as a result, have
a much better idea of what is important to our customers.
Alun concludes, I think this first PULSE Customer Clinic was very successful. It confirmed
what we thought, and has helped us to prioritise some new features in future releases. We aim
to hold a second event in J une of this year and to increase its scope.
And our expert users also enjoyed the event and found it very useful.
Chris Waltenberry from International Truck in the US says, I enjoyed the time I spent at the
Brel &Kjr Customer Clinic. I appreciated the opportunity to help provide direction and sug-
gestions to the developers on the upcoming version of PULSE. It was also great to have direct
access to the programmers to ask questions about the current PULSE software. I am excited to
see how PULSE will improve as a result of direct customer feedback.
Holger Schmidt from Continental AG, Germany, adds, Many thanks for the warm acceptance
and the interesting presentations of the new PULSE functionalities. From the direct discussions
with the developers and those responsible for PULSE, I have seen how meticulous and exten-
sive the development work is. By the direct contact between development and users, many
improvements can be initiated. I especially like to contribute to the new functionality for RPM
determination and triggering of measurements and Im sure that these improvements can sim-
plify the measurements on vehicles and tyres. For me, for many years, the name Brel&Kjr
stands for precision, reliability and long life.
Lionel Duvermy from Vibratec, France comments, I found it very useful. We work as noise and
vibration consultants both in France and around the world, and use 6 PULSE platforms. It gave
me an opportunity to see some of the interesting future PULSE developments but also to dis-
cuss our opinions on a wide variety of NVH testing issues new PULSE applications, the user
interface, and functionality of the platform.
Carcoustics The Power of Silence
Originally founded over 50 years ago, today Carcoustics International GmbH has 18 facilities in
12 countries, and is a global leader in the design, development and manufacture of total vehicle
acoustics and heat management solutions for the automotive industry. Focusing on the mid- to
high-range passenger car market, Carcoustics customers include many of the worlds leading
automotive manufacturing companies.
Carcoustics Tech Center is located at the companys head quarters at Leverkusen, 25km
north-east of Cologne, Germany. It has impressive test and measurement facilities including
semi-anechoic rooms, a transmission loss suite, material testing equipment, test tracks and an
a large two-axle dynamometer test cell. Independent of wind and weather, this test facility ena-
bles the acoustic characteristics of a complete vehicle to be analysed under simulated driving
conditions.
Carcoustics is globally accredited to ISO14001 and ISO16949 (the automotive quality stand-
ard).
Acoustic Simulation
Photo and illustration by
courtesy of Carcoustics
Carcoustics products range from large blow-
moulded panels, components using foam
composites, through to moulded carpets
specially developed for the automotive
industry. The company is building a huge
database of complete cars and components,
and the effects of damping, insulating and
absorbing materials. This database provides
an initial specification for the design of com-
ponents, specification of materials, and ena-
bles an accurate prediction of the acoustic
parameters of the vehicle to be predicted.
Ralph Bungenberg, an acoustics expert, has worked at Carcoustics Tech Center for nine years
and was responsible for the design of many of the companys test facilities. Ralph says, The
demands for quieter, more comfortable vehicles constantly increase. Our customers are our
partners and together our goal is to develop innovative, cost-effective solutions to reduce air-
borne noise. We are frequently involved in the design of acoustic solutions for a vehicle at the
very earliest stages of its design and we extensively use mathematical models to simulate the
acoustic parameters of a new vehicle. This substantially reduces the number of prototypes and
tests, and shortens the time to market.
Acoustic Measurements
Spatial Transformation of
Sound Fields (STSF)
Software Type 7688. A
digital picture of the test
object (a complete vehicle
dashboard) has been
superimposed on the
contour plot. Areas of
special interest have been
mapped and named, and
are defined by the green
and red rectangles. The
averaged sound power of
each area is displayed. In
the graph of sound power
vs. frequency, the black
curve shows the integrated
sound power of the whole
test area. The green and
red curves denote the
partial sound power
contribution of their defined
areas
Carcoustics relationship with
Brel &Kjr goes back more than 20
years. A 24-channel PULSE data
acquisition and analysis system was
purchased in 2002. Ralph explains,
The use of simulation tools reduces
the development time, and puts
emphasis on the need for practical
testing to validate the acoustic per-
formance. With large modules such
as vehicle front-ends with dash panel
isolation, floor pans or doors in our
transmission loss test setups, we use
PULSE, Sound Intensity Probe Kit
Type 3599, Rotating Microphone
Boom Type 3923, a positioning robot
and noise source mapping software to determine the acoustic properties of the complete com-
ponent.
He comments, PULSE is a very good standard platform for NVH testing from basic sound
level measurements to advanced structural and acoustic holography applications and it ena-
bles us to make instant reports in our own templates.
The first step is to test the component without any noise damping material. The Carcoustics
solution is then added. Depending on the component or assembly, between five and thirty
measurements may be made and the test data compared during post-process analysis. White
noise from the built-in PULSE generator, via Power Amplifier Type 2706, drives a OmniPower
Sound Source Type 4296. Up to 3200 measurement points can be made to build a contour plot
of the test object over a frequency range from 200Hz to 10kHz.
STSF
Ralph continues, We are expanding our use of PULSE and acoustical holography using Spa-
tial Transformation of Sound Fields (STSF) Software Type 7688 and it is our intention to use
STSF for this type of application in the future. This will gives us several benefits. Firstly, it will
considerably reduce the measurement time. STSF will give us direct pictures and it is easy to
superimpose a digital picture of the test object onto the contour plot. This is very useful in
reporting results and discussions with customers. But perhaps the most interesting benefit is
that it enables us to easily investigate damping at a local point. We can then change the mate-
rial, for instance by making a complete one piece foam-based component thicker or thinner in
one specific place. This means we can target our solution and offer our customers the most
cost-effective and efficient noise reduction.
Carcoustics Tech Center in the USA also has PULSE. Using our intranet, it's very easy and
convenient to share test data with our colleagues, and when required, we can exchange com-
plete PULSE projects, says Ralph.
Expanding Competence and Markets
Carcoustics is constantly expanding its competence in total vehicle acoustics. For example, the
company recently acquired a facility in the UK that manufactures automotive carpet materials,
and a state-of-the-art carpet moulding machine has been installed at the Tech Center GmbH in
Leverkusen.
Carcoustics continues to serve its customers, by providing innovative and effective acoustic
and thermal management solutions, but it is bringing these solutions to new market areas,
including commercial vehicles and heavy trucks, and entry into the Asian market.
Product Data Type 3599 Product Data Type 7688 Product Data Type 4296
Automotive NVH Seminars
Once again, in 2005 we will be host-
ing our popular series of automotive
NVH seminars around the world.
These free-of-charge events are
aimed at those involved in research,
development and testing of vehicles,
their systems and components.
Seminar Programme
The seminars will focus on how to
make better quality measurements
from transducers and data acquisition to final documentation and reporting, with special
emphasis on automotive NVH. We will also tell you about some exciting new testing applica-
tions. And, over coffee or lunch, theres time to make new friends, and to discuss news and the
latest trends with your colleagues from the automotive industry.
Why Not Join Us in 2005?
In the first half of 2005, we are planning a series of events in the following countries:
Korea 21st and 22nd April, and 4th to 8th J uly
United Kingdom 10th and 11th May
Italy 9th to 13th May
Germany 6th to 10th J une
China 13th to 24th J une
J apan J une (final dates will be fixed soon)
For further information, please contact your local Brel &Kjr office, or send us an e-mail at
automotive@bksv.com, and we will pass on your request.
You can find further details of the dates and venues for other countries in the next issue of this
newsletter. You will be very welcome and we are looking forward to seeing you.