Newest Trends and Technologies for Aero- Acoustic Windtunnel testing Gert Sablon, Director Business Development, STS TEST

Transcription

1 Newest Trends and Technologies for Aero- Acoustic Windtunnel testing Gert Sablon, Director Business Development, STS TEST Realize innovation.

2 Shift towards increased effort to reduce wind noise Shift in NVH development effort from powertrain towards road noise and aero-acoustic noise reduction Powertrain noise 10% ICE vehicle 10% Road noise Wind Noise Ancillary system noise 15% Electric Vehicle 10% 15% 50% Other noise and vibration phenomenon 30% 30% 40% Source: Leading the Charge The Future of Electric Vehicle Noise Control, Greg Goetchius, Sound & Vibration, April 2011 Page 2

3 This results in new investments in Aero-acoustic testing Wind noise can only be effectively tested in wind tunnels, but these tests are expensive Many completely new wind tunnels are constructed across the globe BUT mainly the next generation wind tunnel test complies more advanced testing technology Goal: Increase further the return out of each test Get more work done in the wind tunnel Reduce the number of iterations and modifications made to the vehicle Page 3

4 Evolution towards the next generation aero-acoustic testing Exterior Wind tunnel Testing First generation Second generation Third Generation NOW High Low Cost Return of investment Page 4

5 Overview Aero-acoustic testing technologies Combining all into one integrated solution image Get maximum out of your test campaign Beyond Testing Page 5

6 Overview Aero-acoustic testing technologies Combining all into one integrated solution Get maximum out of your test campaign Beyond Testing Page 6

7 Overview of the different aero-acoustic testing technologies Interior wind noise measurements Direct interior measurements Interior Sound Source Localization S C A L A B L E Exterior source identification Direct Exterior Measurements Surface Pressure Measurements Cfr. GRAS surface microphones Additional sensors in Robots or underbody Why? E.g. to validate aero-dynamic simulation Acoustic Arrays for Source estimation Page 7

8 Direct interior Noise Acquisition Microphones mounted on head rest Analog binaural heads (GRAS, B&K, ) Digital binaural heads (HEAD HMS) LMS SCADAS Mobile VS8-E: support Voltage, ICP & digital head Support equalization for binaural All required post-processing such as 1/3 octave bands, spectrums, loudness, articulation index, Fully realistic replay (incl. equalization for replay) Support of all possible interior noise sensors, including equalization filters for binaural heads. Support of digital binaural heads to reduce risks of mistakes in set-up Page 8

9 Noise source localization and leak detection inside the vehicle LMS 3D Acoustic Camera Geometry scanning Locate and propagate sources on the correct location 400 Hz Efficient batch processing & comparison of datasets, e.g. different frequencies, yaw angle, wind speed, Solid sphere with 54 microphones Provides best-in-class results with supreme directivity & dynamic range Additional postprocessing with ESM & Bayesian Focalization for low frequency Accurate results over wide frequency range Page 9

10 Direct Exterior pressure measurements Use of special microphones for in-flow acquisition R&D Inhouse Wind tunnel For Aero-Acoustic Microphones Surface Microphones (1/4 ) Flush mounted (1/4 ) Quality G.R.A.S Microphone HALT Testing Highly Accelerated Live Testing 5 year warranty Nose cones superior inflow noise rejection Surface microphones with Turbulence screen attenuate hydrodynamic pressure Page 10

11 Exterior source localization by means of acoustic arrays Standard & customized arrays best array performance for your wind tunnel Efficient data comparison with only few clicks EASY comparisons between results during test Identification of pressure distribution around the vehicle by means of combination of multiple arrays Wind speed & Yaw angle automatically taken into account No Risks to make mistakes later Page 11

12 Exterior source localization by means of acoustic arrays Original Coherence with left ear Propagation on plane surface or full 3D Increased accuracy by localizing sources on real location Evolution calculation speeds Additional postprocessing Increased performance & wide frequencies Coherence analysis with interior, e.g. drivers ear but also 3D Camera Focus on what is important Ultra fast calculations Allows to view fully processed results continuously during testing Page 12

13 Overview Aero-acoustic testing technologies Getting maximum out of all used methods by having access to best technology Combining all into one integrated solution Get maximum out of your test campaign Beyond Testing Page 13

14 Overview Aero-acoustic testing technologies Combining all into one integrated solution Get maximum out of your test campaign Beyond Testing Page 14

15 Overview of the different aero-acoustic testing technologies Interior wind noise measurements Direct interior measurements Interior Sound Source Localization S C A L A B L E INTEGRATED SOLUTION Exterior source identification Direct Exterior Measurements Surface Pressure Measurements Cfr. GRAS surface microphones Additional sensors in Robots or underbody Why? E.g. to validate aero-dynamic simulation Acoustic Arrays for Source estimation Page 15

16 Integrated Means it is all measured together, fully synchronized 3DCam, Binaural Heads Left Acoustic arrays Top Right SCADAS.Mobile inside vehicle Integration with wind tunnel controller SCADAS.Lab SCADAS.Mobile underneath turn table Master control integrated with wind tunnel control system Online and offline Analysis system Data Storage & Management Additional microphones Wind Tunnel control room Page 16

17 Why an integrated solution is important for next generation aeroacoustic testing solution? What is the value of an integrated solution? Only one system to learn and operate Integration with wind tunnel controller only needs to be done once Page 17 More efficient to set up BUT there is much more = 3 Annotate and save vehicle attributes, wind speed & Yaw angle automatically for all acquired data

18 Value of fully integrated solution Example 1 Link binaural head with exterior array by viewing together Which exterior sources lead to high loudness? LOUDNESS Configuration A- B Time Varying Loudness Vehicle1_Inter_FR:S Blocked 95% 95% perc percentile: 15.5 sone Time Varying Loudness Vehicle2_Inter_FR:S Free 95% 95% perc percentile: 13.9 sone Viewing and comparing results from different techniques together on one screen gives additional insight sone Amplitude s Time Configuration blocked underbody Configuration free underbody Page 18

19 Value of fully integrated solution Example 2 Link binaural head with exterior array by coherence analysis Which external source is important for driver s left ear? Top Array Result Top Array Result correlated to driver s right ear Coherence analysis allows to focus on sources for interior noise FKFS conference 2015, The new Daimler Automotive Wind tunnel, Acoustic properties and measurement system, R. Buckisch, Daimler AG Page 19

20 Value of fully integrated solution Example 3 Link 3D Cam with exterior array by coherence analysis Energy flow analysis - Where does an external source leak into the vehicle? Exterior Arrays Top Array Result 3D Camera Overall 3DCam results 3DCam results related to source selected outside Coherence analysis between interior and exterior array allow energy flow analysis Remark: above schematic just to explain principle Page 20

21 Overview Aero-acoustic testing technologies Getting maximum out of each used methods by having access to best technology Combining all into one integrated solution Getting new insights from combining technologies Increasing efficiency by having only one system Get maximum out of your test campaign Beyond Testing Page 21

22 Amount of information Efficiency Effectiveness ROI Overview Aero-acoustic testing technologies Combining all into one integrated solution Get maximum out of your test campaign Beyond Testing Page 22

23 How in practice does an aero-acoustic testing campaign look like? Test modification of a vehicle Analyze What could cause problems? Yaw Angle Speed [km/h] [degrees] In total often many modifications tested Apply modifications: change mirrors, tape seals, Page 23

24 How to drastically increase testing efficiency? Make tests run automatically & real-time visualization of results Test version/modification of vehicle Allow to view fully processed data in a minute In total often many modifications tested Allow easy selection of what to process & process in batch Allow easy comparison between processed datasets with only few clicks By doing all this, Help drastically reducing number of iterations Thanks to better analysis, apply effective modifications Page 24

25 How to drastically increase testing efficiency? Make tests run automatically & real-time visualization of results STEP 1: Definition Test Schedule Testing configuration Which wind speeds to test, e.g. 100, 120, 160 kph Which Yaw Angles to test, e.g. -10, -5, 0, 5, 10 degrees Step 2: Fully automatic test 1. Bring wind tunnel in requested condition (wind speed, yaw angle) 2. Automatically start test 3. Real-time visualization of all results on separate screens Sound quality Left Right Top Interior 1. Bring wind tunnel Page 25

26 How to drastically increase testing efficiency? Process and view array results in few seconds Drastic reduction in calculation time thanks to persistent optimizations and move of calculations towards GPU First CPU algorithm optimizations Move calculations towards GPU GPU algorithm optimizations Data handling optimization Reference: 4000 grid points (full vehicle with 5 cm resolution) 480 frequency lines ( Hz) 10 sec time data 2012 Dell precision workstation with quad core Xeon CPU 7 nvidia K5000 GPU Page 26

27 How to drastically increase testing efficiency? Process and view array results in few seconds 10 seconds versus 5 minutes So What? Calculation times build up exponentially! Total Calculation time (hours) 22 A wind tunnel test easily consists of 100s of measurement in the end Processing ,2 Optimized processing running on GPU Page 27

28 How to drastically increase testing efficiency? Allow easy and fast processing and viewing Easy selection of processing to be done: configuration, wind speed, yaw angle, frequency range, method, Easy selection of data to be viewed with only few clicks & Easy comparison of results Calculations running automatically in batch View & compare ANY result Allows to decide what modifications to test next drastically remove total test time or make test more effective Page 28

29 Overview Aero-acoustic testing technologies Getting maximum out of each used methods by having access to best technology Combining all into one integrated solution Getting new insights from combining technologies Increasing efficiency by having only one system Get maximum out of your test campaign Use all functionality at ALL the time Be able to use results during test campaign & reduce the number of tested modifications Beyond Testing Page 29

30 Overview Aero-acoustic testing technologies Combining all into one integrated solution Get maximum out of your test campaign Beyond Testing Page 30

31 Simcenter TM 3D Exterior aeroacoustics and interior aero-vibro-acoustic wind noise simulations using aerodynamic or acoustic loads on the flexible structures Exterior noise Internoise NXNastran Interior noise Interior noise Internoise SAE Page 31

32 Research activities with Universities & industrial partners KEY TOPICS of research: Further enhance both testing AND simulation New source localization algorithms Underbody localization techniques Transfer of sources towards interior (also with simulation) New sensors and arrays (e.g. for underbody) e.g. of special sphere Partners in research: MicrodB (SSL) & G.R.A.S (microphones) Von Karman Institute Mutiple universities, e.g. KUL, ECL Page 32

33 Overview Aero-acoustic testing technologies Getting maximum out of each used methods by having access to best technology Combining all into one integrated solution Getting new insights from combining technologies Increasing efficiency by having only one system Get maximum out of your test campaign Use all functionality at ALL the time Be able to use results during test campaign & reduce the number of tested modification Beyond Testing Full portfolio including simulation through Simcenter Continued innovation & research Page 33

34 Conclusion Exterior Wind tunnel Testing First generation Second generation Third Generation NOW High Low Cost Return of investment Technology Integrated solution Efficiency Trusted partner Page 34

35 Thank you. Restricted Siemens AG 2017