confidential and proprietary to freightliner llc. © freightliner llc. all rights reserved. 1 ev...

1Confidential and Proprietary to Freightliner LLC. © Freightliner LLC. All rights reserved.

EV ARNOLD, ERIC LEITZINGER, BRYAN UNDERWOODSUSTAINING ENG‘G & NVH

25 OCTOBER 2006

HDE 14.8 CV-DS NVH PLAN


14.8L HDE NVH TOPICS & OBJECTIVES

25 OCT 2006 NVH METHODOLOGY PRESENTATION

ENGINE COMPONENT STRUCTURAL VIBRATION Insure Structural Integrity (Durability) Define Excitation that Creates Sound

BYSTANDER SOUND LEVEL (*) Meet Regulatory Requirements Achieve Product Acoustical Performance Goals

ENGINE MOUNT VIBRATION LEVEL (*) Minimize Engine Vibration Input into Vehicle Structure

TRUCK CABIN SOUND AND VIBRATION (*) Minimize Operator Vibration Fatigue

Steering Wheel Seat

Minimize Cabin Sound Level Maximize Sound Quality

(*) ENGINE IS A MAJOR NVH EXCITATION SOURCE WITHIN THE VEHICLE


14.8L HDE COMPONENT STATIC STRUCTURAL VIBRATION ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION


ACCEPTANCE CRITERIA

No Structural Resonances below 105 Hz a) Equivalent to 3rd Order Forcing Function at 2100 RPM)

VERIFICATION (Test Procedure)

Measure Static Frequency Response Function (FRF)a) Test Set-up

Impact Hammer or Shaker Force Input Single or Multiple Accelerometer Response Points

b) Operating Condition: Static – Engine NOT running

c) Test Output Transfer Function – Identifies Resonant Frequencies, Modal

Stiffness & Damping

CORRECTIVE ACTION (If Acceptance Criterion Is Violated)a) Shift Resonant Frequency (Increase or Reduce Stiffness)

b) Reduce amplitude by increasing structural damping

c) Repeat FRF Test to Verify Effect on Vibration Behavior

VALIDATION (Test Procedure)

Conduct Component Fatigue Life Evaluationa) Shaker Input

b) Survive 10 Million Cycles (Infinite Life) @ Resonant Frequency


14.8L HDE COMPONENT OPERATING STRUCTURAL VIBRATION ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIDATION


ACCEPTANCE CRITERIA1. Vibration amplitude less than 5 mils below 105 Hz (3rd Order @ 2100 Hz) 2. No evidence of High Amplitude Resonances Within Engine Operating Conditions (*)3. No evidence of High Amplitude Order Related Vibration Within Engine Operating Conditions (*)

(*) Vibration measured in (a) peak acceleration (< 500 HZ) & (b) peak-to-peak displacement (< 250 Hz)

VERIFICATION (Test Procedures)1. Generate 2D Peak Hold Spectra

a) Test Set-up Tri-Axial Accelerometer Response Positions Same as Static FRF

b) Operating Conditions: Full Load Speed Sweep (1050 RPM to 1850 RPM) Over 90 Seconds No Load Speed Sweep (Idle to 2100 RPM) Over 90 Seconds

c) Test Output: 2D Peak Hold Spectrum (Peak Acceleration- 0 to 500 Hz) 2D Peak Hold Spectrum (Peak-to-Peak Displacement - 0 to 250 Hz)

2. Generate 3D Campbell Plotsa) Test Set-up

Same as #1 a)b) Operating Conditions:

Same as #1 b)1. Test Output:

3D Campbell Plot (Peak Acceleration- 0 to 500 Hz) 3D Campbell Plot (Peak-to-Peak Displacement - 0 to 250 Hz)

PAGE 1 OF 2


14.8L HDE COMPONENT OPERATING STRUCTURAL VIBRATION ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIDATION


CORRECTIVE ACTION (If Acceptance Criteria Are Violated)

a) Shift Resonant Frequency (Increase or Reduce Stiffness)

b) Reduce amplitude by increasing structural damping

c) Repeat FRF Test to Verify Effect on Vibration Behavior


Conduct Component Fatigue Life Evaluation

a) Shaker Input

b) Survive 10 Million Cycles (Infinite Life) @ Resonant Frequency

PAGE 2 OF 2


14.8L HDE TRUCK BYSTANDER SOUND LEVEL (Page 1 of 2) ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION


ACCEPTANCE CRITERIA1. TRUCK: Legal Compliance NAFTA

a) Pass-by: NAFTA: EPA CFR 205 {SAE J366B} = 80 dB(A) @ 15 mb) Stationary: NAFTA: EPA CFR 325 {SAE J1096} = 85 dB(A) @ 15 m

2. TRUCK / ENGINE: Trucks NAFTA Design Goala) Pass-by:

Truck = 78.3 dB(A) - Maximum Level to Insure Minimal Production Audit Engine = 75.3 dB(A) - < 51% Contribution to Total Truck Pass-by Level

VERIFICATION (Test Procedure)1. Measure Truck Pass-by Sound Level

a) Test Set-up Certified Pass-by Facility {Chelsea} Radar, Vehicle Telemetry & Spectral Sound Data Acquisition Microphone 15 m to the Left & Right of Vehicle Path

b) Operating Condition: J366B Mid-Gear Full Throttle Accelerationc) Test Output

Overall SPL & Spectra for Left & Right Sides of Vehicle Versus Track Position Truck Position, Truck Speed & Engine Speed Versus Track Position

2. Measure Truck Stationary Sound Levela) Test Set-up

Certified Stationary Facility {Chelsea} Engine Speed & Sound Data Acquisition Microphones 15 m from Right, Left, Front & Rear of Stationary Vehicle

1. Operating Condition: No Load Acceleration / Deceleration (Idle – Max Gov Speed – Idle)2. Test Output:

a) Peak Hold SPL & Spectra for Left, Right, Front & Rear of Vehicle


14.8L HDE TRUCK BYSTANDER SOUND LEVEL (Page 2 of 2) ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION


CORRECTIVE ACTION (If Acceptance Criteria Are Violated)

1. Conduct Pass-by or Stationary Vehicle Sound Source Evaluationa) Acoustical Mask Entire Power Train

b) Expose Each Power Train Element Separately to Identify Source Contribution

2. If Engine Is A Significant Noise Source (DDC NVH Group Responsibility)a) Apply NVH Counter Measures to One or More Engine or After Treatment Components

b) Engine Dyno Stand Tests May be Necessary to Identify & Treat Correct Engine Sources

3. If Non-Engine Sources Are Significant Sources (Portland NVH Group Responsibility)a) Intake, Exhaust, Transmission, Driveline, Drive Axle &/or Tire Acoustical Counter Measures

are Necessary

VALIDATION (Test Procedure)1. Repeat SAE J366B Pass-by Test with Power Train Noise Counter Measures

2. Repeat SAE J1096 Stationary Test with Power Train Noise Counter Measures


14.8L HDE ENGINE MOUNT VIBRATION LEVEL ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION


ACCEPTANCE CRITERIATransmissibility << 1.0 At Frequencies Greater than 1.4 X Fn Mount

a) Transmissibility = Vibration Frame Side of Mount / Vibration Engine Side of Mount


Measure Front & Rear Mount Transmissibility a) Test Set-up

Tri-Axial Accelerometers on Frame & Engine Side of Each Mount Truck on Chassis Dynamometer

b) Operating Conditions: Full Load Speed Sweep (Idle to 1850 RPM) No Load Speed Sweep (Idle to 2100 RPM) Steady State: Idle, 1200 RPM, 1800 RPM, 2100 RPM

c) Test Output Peak Acceleration & Peak-to-Peak Displacement (X, Y & Z Directions) Transmissibility (X, Y & Z Directions)

CORRECTIVE ACTION (If Acceptance Criterion Is Violated)a) Alter Mount Stiffness

b) Alter Mount Design (Shear versus Compression Mount)


Repeat Front & Rear Mount Transmissibility Measurements with Revised Mounts


14.8L HDE TRUCK CABIN VIBRATION ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION


ACCEPTANCE CRITERIA1. Meet > 8 Hour Vibration Exposure Limit for Steering Wheel Vibration (Per ISO 5349)

2. Meet > 8 Hour Vibration Exposure Limit for Seat Vibration (Per ISO 2631)


1. Test Set-upa) Tri-Axial Accelerometers on Steering Wheel Rim & Seat Base

2. Operating Conditionsa) Full Load & No Load Engine Speed Sweeps

b) Steady State Engine Operation – Idle, 1200 RPM, 1800 RPM, 2100 RPM

3. Test Outputa) RMS Acceleration Plotted Against ISO 5349 or ISO 2631 Exposure Limit Guidelines

CORRECTIVE ACTION (If Acceptance Criteria Is Violated)

1. Alter (& Correct if Necessary) Engine or Body Mounts

2. Increase Steering Column Structural Damping

3. Evaluate (& Correct if Necessary) Excessive Engine Vibration


Repeat Steering Wheel & Seat Vibration Measurements After Corrective Action


14.8L HDE TRUCK CABIN SOUND LEVEL ACCEPTANCE CRITERIA, VERIFICATION, CORRECTIVE ACTION & VALIADATION


ACCEPTANCE CRITERIA1. 68 dB(A) at Driver’s Ear at 60 MPH WOT (Freightliner Metric)2. As Good or Better than Volvo Cabin Sound Level (Industry Benchmark)

a) Sound Pressure Level (All Occupant Positions)b) Zwicker Sound Quality Metrics (All Occupant Positions)

VERIFICATION (Test Procedure)1. Test Set-up

a) Microphone 6 inches From Driver or Occupant’s Right Ear2. Operating Conditions

a) Over-the-Road & Stationary Full Throttle Acceleration (1000 RPM – 2100 RPM)b) Constant Speed Stationary (Idle,1200RPM, 1800 RPM & 2100 RPM)c) 60 MPH Constant Speed Operation with Loaded Trailer

3. Test Outputa) A-Weighted Overall Levels and One-Third Octave Spectrab) Zwicker Loudness (Sharpness, Fluctuation Strength, Roughness, Modulation)

CORRECTIVE ACTION (If Acceptance Criteria Are Violated)1. Improve Cabin Barrier & Absorption Material2. Reduce Power Train Sound Level (Engine, Transmission, Exhaust, Tires Etc)

VALIDATION (Test Procedure)Repeat Cabin Sound Level Analysis After Corrective Action


APPENDIX

CV-DS ISSUES & DELIVERABLES



DDC CV-DS NVH DELIVERABLES (page 1 of 2)9 AUGUST 2006 NVH METHODOLOGY PRESENTATION

S P8 P7 P6 P5 P4 P3 P2 P1

CONCEPT DEVELOPMENT

INITIAL PHASE

PRINCIPLE FEASIBILITY

PRODUCT DEFINITION

CONCEPT FEASIBILITY

PRODUCT CONFIGURATION

SERIES FEASIBILITY

DEVELOP MATURITY A

TEST STAND CAPABLE

DEVELOP MATURITY B

VEHICLE TEST

CAPABLE

DEVELOP MATURITY C

VEHICLE RELIAIBLITY

CAPABLE

DEVELOP MATURITY D

PRODUCTION FEASIBILITY

PRODUCTION RAMP UP

JOB NO 1

1 DEFINE NVH CRITERIA A X X X

2 CALCULATE RESONANCES & MODE SHAPES A X X X X

3 DYNAMIC FEA OF VIBRATION BEHAVIOR A X X X X

4 BOUNDARY ELEMENT MODEL OF SPL A X X X X

5 TORSIONAL VIBRATION ANALYSIS A X X X X

6 SAE J1074 SPL T X X X X X X

7 DIN SPEC SOUND PRESSURE T X X X X X X

8 SOUND QUALITY METRICS T X X X X X X

9 CROSS-SPECTRAL INT & SND PWR T X X X X X X

10 FRF & MODAL ANALYSIS T X X X X X

11 INDUCTION NOISE MEASUREMENT T X X X X X X

12 INTERNAL ENGINE NOISE SOURCE ANALYSIS T X X X

CONCEPT DEVELOPMENT PRODUCT DEVELOPMENT PRODUCTION

NVH DELIVERABLES FOR CV-DS PAGE 1 OF 2

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QUALITY GATE


DDC CV-DS NVH DELIVERABLES (page 2 of 2)9 AUGUST 2006 NVH METHODOLOGY PRESENTATION

S P8 P7 P6 P5 P4 P3 P2 P1

CONCEPT DEVELOPMENT

INITIAL PHASE

PRINCIPLE FEASIBILITY

PRODUCT DEFINITION

CONCEPT FEASIBILITY

PRODUCT CONFIGURATION

SERIES FEASIBILITY

DEVELOP MATURITY A

TEST STAND CAPABLE

DEVELOP MATURITY B

VEHICLE TEST

CAPABLE

DEVELOP MATURITY C

VEHICLE RELIAIBLITY

CAPABLE

DEVELOP MATURITY D

PRODUCTION FEASIBILITY

PRODUCTION RAMP UP

JOB NO 1

13 TRANSFER PATH ANALYSIS T X X X

14 ENGINE SURFACE SOURCE RANKING T X X X

15 ENGINE MOUNT VIBRATION TRANSMISSIBILITY T X X X X X

16 TORSIONAL VIBRATION MEASUREMENT T X X X X X

17 EXHAUST NOISE MEASUREMENT T X X X X X

18 SAE J366 TRUCK PASS-BY T X X X X

19 AUSTRALIAN TRUCK ADR PASS-BY T X X X X

20 SAE J1096 STATIONARY VEHICLE SPL T X X X X

21 PASS-BY POWER TRAIN SOURCING T X X

22 DRIVER'S RIGHT EAR SPL T X X X X

23 ISO 5349 HAND VIBRATION T X X X X

24 ISO 2631 WHOLE BODY VIBRATION T X X X X

PRODUCT DEVELOPMENT PRODUCTION

NVH DELIVERABLES FOR CV-DS PAGE 2 OF 2

DE

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NVH DELIVERABLE

AN

AL

YT

ICA

L (

A)

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QUALITY GATE

CONCEPT DEVELOPMENT

confidential and proprietary to freightliner llc. © freightliner llc. all rights reserved. 1 ev...

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