Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept

Virtual Simuation of Engine Mounting Concept to improve Noise & Vibration Performance Part II

Le The Hung October 2007

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Content
Introduction

Vehicle Development Process Methods of Ride Comfort Analysis Engine Mount Design Conclusion

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Introduction

Optimization of engine mounting system concerning engine mount position and mount characteristics is important for the vehicle vibration and noise. Part I of the paper was focused on the virtual simulation of the engine mount system in full car model to achieve better vehicle comfort. Part II of this paper will show you how to transfer the virtual engine mounting concept into the prototype car. Due to global competition the new vehicles have to be developed in very short time frames for a growing variety of new car models, increasing customer demands on comfort, performance and quality, reducing costs . During the last ten years, the development cycles have been reduced from about five years to about three years. .

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Vehicle Development Process
The typical vehicle development process is shown in Figure 1.

Concept Development Phase Production Development Phase

Engineering Start

Styl. / Pack. Freeze

Release

Start Production

Start of Production (SOP)

Mule

Structure

Integration

Validation

Pilot

Vehicle Hardware

Initial Concept Structure integration

Validation

Virtual Vehicle Simulation

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Engine Mount System Development Figure 1

Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Vehicle Development Process
The vehicle development process consists of two major phases: the concept development phase and the product development phase. The most important milestone is at the transition from the concept phase to the production phase. In concept phase the prototype hardware is only partially available, the virtual simulation is very important for the concept decision. The development of the engine mount system has to be integrated in vehicle development process and starts in very early phase (Initial / Concept ).

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Methods of Ride Comfort-Analysis
To develop of engine mounting system related to vehicle comfort / ride comfort modern techniques and tools can be used for concept development and matching of the riding comfort (Figure 2) Virtual simulation (Part I of this paper) Bench Test in Laboratory Ride Test on Road Virtual Simulation For the conceptual development of the engine mounting system the virtual simulation using finite element method can effectively applied in early vehicle development phase. Bench Test The simulated engine mount concept has to be verified and validated in Bench Test (Figure 3). The 4 poster (cylinder) hydropuls test bench is normally used for a vibration analysis of complete vehicle. The laboratory test has a lot of advantages, such short conversion span, reproductivity of test results and the vehicle has not to be ready for driving.
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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Methods of Ride Comfort-Analysis
Engine mounting Concept Engine mount location Engine mount stiffness and damping (Conventional Mount or Hydromount) Goals: Improving Front End Shake, Idle Shake, Tip In/Tip Off

Simulation

Vehicle Test on Hydropuls Bench Test

Measurement seat acceleration Effect of different mount characteristics Transfer Path Analysis Eigenmode Analysis Ride Test on Road Measurement seat acceleration (objective evaluation) Subjective evaluation Fine tuning for Prototype Car
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Ride Test

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Figure 2: Three methods from simulation to road test

Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Methods of Ride Comfort-Analysis

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Figure 3: Test car on the 4 poster bench Source: fka, Aachen

Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Methods of Ride Comfort-Analysis
For Front End Shake Test the vehicle is harmonically excited by a signal with 2,5 mm displacement amplitude at front tires in phase or out-of-phase. The simulation results can be validated with test results for improving the simulation model. For Idle Shake Test engine is excited by engine at idle speed (700 rpm -1000 rpm). In order to identify the contribution of each engine mount to total accelleration at seat the Transfer Patch Analysis (TPA)method can be used. Figure 4 shows a typical TPA result. Ride Test ( Test on Road) A ride test on road is very important test method to get a impression of the vibration of the full car in reality environment (subjective evaluation). To improve the engine mount system measured data such as seat accelerations are needed.

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Methods of Ride Comfort-Analysis

Figure 4: Result of Transfer Path Analysis (TPA)

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Engine Mount Design
Simulation tools provide uns important information for developing the engine . Mounts. Dimension, Stiffness and Damping are physical parameters of a mount. The engine mount must satisfy following essiential but conflicting criteria: 1. First, it should be stiff and high damped for - supporting the engine - reducing large engine motions during extreme driving manoveurs for avoiding contact of the engine with body - reducing vertical motion due to road excitation for improving Front End Shake Behaviour 2. Second, it should be soft to isolate the vibration transmitted from engine mount to the body for reducting vehicle vibration in low frequency range up to 30 Hz (to improve Idle Shake behaviour) and reducing vehicle noise in higher frequency range from 80 Hz to 200 Hz (to improve Engine Boom Noise).

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Engine Mount Design
The conflict between the high damping required for reducing engine mount motion . and the low damping for dealing with noise had led to the development of the hydromount. Figure 5 shows a schematic of this type of mount. A fluid is pumped from one chamber into the another chamber through a long spiral tube. This result is an increase damping in the mount. A hydromount also contains a decoupler , which is a plate that for small motion allows the fluid to go around the plate and avoid going through the tube. Thus, for rough road shake, the mount adds considerable damping while for idle shake the mount reacts like a conventional rubber mount ( small damping at low frequeny).

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Engine Mount Design
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Mount Stiffness and damping (loss angle)

___Simulation -----Test for 1 mm excitation dispalcement ___ Simulation ------Test for 0.1 mm excitation dispalcement 14.10.2007

Figure 5: Hydromount and mount characteristics

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Engine Mount Design
B . efore getting started on design an engine mounting sytem, following basic questions have to be answered: 1. What engines are to be mounted ? Engine Volume :1.0 Liter,1.2 Liter,1.4 Liter, 1.6 Liter,1.8 Liter,2.0 Liter ? Petrol engine or Diesel engine ? 4 cylinder engine or 6 cylinder engine ? Gear boxes ? 2. Is there a carry over location system? 3. Are there carry over mount designs? 4. Limit on cost of the mounting system. Can you use hydromounts, hydrobushings or need to stay with rubber mounts? (convetional rubber mounts are cheaper than hydrolmounts). 5. For each engine you need : - Engine loads , idle speed, idle and full load, maximum engine moment (torque) - Mass, Inertia, Engine Location ( Center of Gravity in Engine Compartment) - Potential location of mounts (location and space for location)
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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Engine Mount Design

Var. A

Var. B

Engine Mount right

Var. C Var. D

Strut Mount Front

Engine Mount left

Strut Mount Rear

Figure 6: Engine Mounting System with different mount designs for diffrent engines
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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Engine Mount Design
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Criteria

Concept A Concept B Concept C

Cost Mount Design NVH Performance Crash Performance

0 0 0 0

0 0 +

+ + + +
0 not good/ not bad - bad - good /acceptable

Figure 7: Decision Matrice

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Engine Mount Design

Kriterien der Lagerentwicklung Requirement

Function Durability Thermal reability Resistance to corosion Easy of fitting Cost Weight
Figure 8: Component development
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Constraints
Mount position Space

Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Engine Mount Design

Figure 9: Engine Mounts in different designs and dimensions

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Engine Mount Design

Engine mount brackets V6 Engine

Box retainer

Mount Box Diesel Throttlemembrane Petrol Throttleplate Basic plat

Fluid
Figure 10: Hydromount Design
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Balance membrane Clamping ring 19

Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Engine Mount Design

Screw

Fluid

Mount Box

Mount Body Elastomere

Engine Mount Bracket Version B

Engine mount bracket Version A 14.10.2007

Figure 11: Hydromount Design

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Engine Mount Design Matreial used for weight reduction Gewichtsanteil [%]
Al 53%

DP600 6%

Fluid 3% Elastomer 10% St 28%

Figure 12: Engine Mount Brackets

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept Conclusion
Application of virtual simulation of engine mount system to improve vehicle comfort was discussed Simulation results provided import information for defining a suitable engine mounting system Validated simualtion model car help to get more understanding of physical system behaviour and to solve problems encounted during testing Engine mounting system with Torque roll axis has a lot of advantages for improving vehicle comfort Hydromount helps to solve conflict problems of vibration and noise

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Computer Simulation in Automobile Industry Vehicle Comfort Engine Mounting Concept References
[1] G. Ddlbacher: Rechnerische Ermittlung des Schwingungsverhaltens des elastisch gelagerten Motors. Automobil-Industrie Nr. 1, S. 57-61 (1982) [2] H. Demant, J. Roos und D.F. Wolko: Schwingungstechnische Anforderung an Triebwerklagerungssysteme. ATZ Automobiltechnische Zeitschrift 92 S. 116-118 (1990) [3] H. Le the, E. Dornauf: Auslegung von Motorlagerungssystemen, Seminar im Haus der Technik,Essen (1993) [4] R., Singh: Linear analysis of an automotive hydro-mechanical mount with emphasis on decoupler characteristics., J. Sound Vibr. 158, 219-243 (1992) [5] M., Hofmann: Antivibrationssysteme: Grundlagen, Ausfhrungen, Anwendungen, in der Reihe von Bibiliothek der Technik (2001)

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