Your future-proof strategy for advancing NVH vehicle ... · Body Component •Increasing testing...
Transcript of Your future-proof strategy for advancing NVH vehicle ... · Body Component •Increasing testing...
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Component-based transfer path analysis Your future-proof strategy for advancing NVH vehicle
development
Siemens Digital Industries SoftwareUnrestricted © Siemens 2020
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Unrestricted © Siemens 2020
Page 2 Siemens Digital Industries Software
Automotive OEMs have to reduce full vehicle testing to
handle wide variety of vehicles
Body Component
• Increasing testing effort
• Prototype availability?
• Impact of modification?
• …
How to ensure NVH performance while keeping development
time and cost under control?
Powertrain
Front-loading vehicle
level component
NVH testing
Virtual Vehicle Prototyping# of vehicle variantsIC
PHEV
EV
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Increasing complexity continuously challenges automotive
OEM’s and Suppliers
Increasing risk of integration
issues of components
Impact on time-to-market and possible
expensive modifications
Supplier
AOEM
No correct
excitation data
No detailed NVH
design targets
Supplier
AOEM
Independent load
description
Realistic NVH
design targets
Implication Control NVH Performance
Typical OEM-Supplier
cooperation
Improved OEM-Supplier
cooperation
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How to keep control of the NVH Performance
at any stage of the development cycle?
Can we provide a method that
addresses all these challenges?
YES, WE CAN!
Component-based TPA
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Classical Transfer Path Analysis
Source-transfer-receiver approach
a
p
X =Source (Fi,Qj) Transfer (NTF) Receiver (yk)
Engine
E-motor
HVAC
Wiper-motor
Transmission Tyres
Measure
d..
Tota
l
be_f:18:X
..
be_f:18:Y
..
be_f:18:Z
..
be_f:5018:X
..
be_f:5018:Y
..
be_f:5018:Z
..
be_r:
9:X
..
be_r:
9:Y
..
be_r:
9:Z
..
be_r:
5009:X
..
be_r:
5009:Y
..
be_r:
5009:Z
..
sh_f:30:X
..
sh_f:30:Y
..
sh_f:30:Z
..
sh_f:5030:X
..
sh_f:5030:Y
..
sh_f:5030:Z
..
sh_r:
32:X
..
sh_r:
32:Y
..
sh_r:
32:Z
..
sh_r:
5032:X
..
sh_r:
5032:Y
..
sh_r:
5032:Z
..
subf:20:X
..
subf:20:Y
..
subf:20:Z
..
subf:5020:X
..
subf:5020:Y
..
subf:5020:Z
..
10.00
60.00
dB
(A)
Pa
sh_r:32:Z
0.00 350.00Hz
RMS Sum
Spectrum: PRCM:0001:S
Spectrum: PRCM:0002:S
Spectrum: PRCM:0004:S
Spectrum: PRCM:0003:S
Spectrum: PRCM:0006:S
Spectrum: PRCM:0005:S
-40.00
50.00
dB
(A)
Pa
Contribution at path or group (case vs. rpm or frequency) A
EPS
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50020 50 100 150 200 250 300 350 400 450
Hz
20
-60
-50
-40
-30
-20
-10
0
10
dBg
180.00
-180.00
Phase
°
Harmonic Spectrum P3:T1:+Z Measured
Harmonic Spectrum P3:T1:+Z
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50020 50 100 150 200 250 300 350 400 450
Hz
30
-60
-50
-40
-30
-20
-10
0
10
20
dBg
180.00
-180.00
Phase
°
Harmonic Spectrum P3:T1:+Z Measured
Harmonic Spectrum P3:T1:+Z
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Component Based Transfer Path Analysis
Predict full system level performance
X =Step 1: Independent loads (Fbl,Q)
Step2: Virtual Assembly
(FRF, K)
Step3:
Prediction(yk)
-7.00 10.00m
65.00
75.00
dB
(A)
Pa
65.00
75.00
dB
(A)
Pa
F Left Side
F Left Side Virtual
B Right Side
B Right Side Virtual
Measure
d..
Tota
l
be_f:18:X
..
be_f:18:Y
..
be_f:18:Z
..
be_f:5018:X
..
be_f:5018:Y
..
be_f:5018:Z
..
be_r:
9:X
..
be_r:
9:Y
..
be_r:
9:Z
..
be_r:
5009:X
..
be_r:
5009:Y
..
be_r:
5009:Z
..
sh_f:30:X
..
sh_f:30:Y
..
sh_f:30:Z
..
sh_f:5030:X
..
sh_f:5030:Y
..
sh_f:5030:Z
..
sh_r:
32:X
..
sh_r:
32:Y
..
sh_r:
32:Z
..
sh_r:
5032:X
..
sh_r:
5032:Y
..
sh_r:
5032:Z
..
subf:20:X
..
subf:20:Y
..
subf:20:Z
..
subf:5020:X
..
subf:5020:Y
..
subf:5020:Z
..
10.00
60.00
dB
(A)
Pa
sh_r:32:Z
0.00 350.00Hz
RMS Sum
Spectrum: PRCM:0001:S
Spectrum: PRCM:0002:S
Spectrum: PRCM:0004:S
Spectrum: PRCM:0003:S
Spectrum: PRCM:0006:S
Spectrum: PRCM:0005:S
-40.00
50.00
dB
(A)
Pa
Contribution at path or group (case vs. rpm or frequency) A
Contribution analysis
Sound synthesis
Pass-by Noise
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Independent
Source
characterization
Theory of method
Blocked Forces as
Independent source
description
Measurement
challenges
From theory to
measurements
Extensive mathematics
require accurate data
Component Based TPA
Application
Examples
Deal with the subsystem
specific challenges
Difference in Test benches
& methodologies
Full Vehicle NVH
Synthesis
Combining all systems
& predict full vehicle
NVH performance
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Independent
Source
characterization
Theory of method
Blocked Forces as
Independent source
description
Measurement
challenges
From theory to
measurements
Extensive mathematics
require accurate data
Component Based TPA
Application
Examples
Deal with the subsystem
specific challenges
Difference in Test benches
& methodologies
Full Vehicle NVH
Synthesis
Combining all systems
& predict full vehicle
NVH performance
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Component-based TPA
Independent load characterization
Structure-borne:
Airborne:
Blocked Forces
Volume Velocities
Free Velocities
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1. Blocked Force
Source A
12
F source
𝑭2,𝐵𝑙𝑜𝑐𝑘𝑒𝑑
2. Free Velocity
Source A
12
F source𝒂𝟐,𝑭𝒓𝒆𝒆
𝑯22𝐴 −𝟏𝒂𝟐,𝑭𝒓𝒆𝒆 = 𝑭2,𝐵𝑙𝑜𝑐𝑘𝑒𝑑
3. In-Situ TPA
𝑭2,𝐵𝑙𝑜𝑐𝑘𝑒𝑑 = 𝑯24𝐴𝐵 +𝒂𝟒
Source:Elliott, Moorhouse, Characterization of the structure borne
sound sources from measurements in-situ, 2008
Source: Mondot, Petersson, Characterization of structure-borne
sound sources: The source descriptor and the coupling function
1987
Three possible methodologies to obtain independent source description
Rigid test rig → Most times not possible Source in free free conditions ISO 9611 Any receiver is valid ISO 20270
Component-based TPA
Step1: Source characterization - Structure Borne
Source A Receiver B
12
5
4
F source
4
𝑯24𝐴𝐵
3
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Contact force vs. Blocked force
Different measurement setup for local FRF
Receiver B
3
5
4
4
𝑯34𝐵
Source A Receiver B
12
5
4
4
𝑯24𝐴𝐵31. Local FRF for
load identification
Source A Receiver B
12
5
4
F source
4
3
Source A Receiver B
12
5
4
F source
4
32. Operational
measurements
Classic TPA
Determination contact forces
Blocked Forces TPA
Determination blocked forces
𝑭3,𝑪𝒐𝒏𝒕𝒂𝒄𝒕 = 𝑯34𝐵 +𝒂𝟒 𝑭2,𝐵𝑙𝑜𝑐𝑘𝑒𝑑 = 𝑯24
𝐴𝐵 +𝒂𝟒3. Force
Identification
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Structure borne application example
Steering system integration
Source MechanismInvariant
Source Synth. ModelSub-Receiver Receiver
Steering
System
Blocked
Forces &
Impedances
Mount Pos.
SubframeFEM/TEST
FRF
BodyFEM/TEST
FRF
STEP 1: Source Characterization STEP 2: Full Vehicle Prediction
bench
1
A
𝑎𝑖xx
x
𝐻𝑖1𝐴𝐶
𝐹𝑏𝑙𝐴
𝐹𝑏𝑙𝐴 = 𝐻𝑖1
𝐴𝐶 −1 ∗ 𝑎𝑖
𝐹𝑏𝑙𝐴
3𝑝
1 2
A
B
𝐹𝑟
𝑝 = 𝐻32𝐴𝐵 ∗ 𝐹𝑟
𝐴𝐵
Measured Coupled FRF
1. In-Situ TPA – Apply Matrix Inversion: Blocked Forces = source characterization
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Component-based TPA
Step2: Target prediction using Frequency based sub-structuring (FBS)
1. Source A:
a. Blocked Force
b. Inertance matrix
Source A
2𝑯22𝑨
𝑯22𝑨
Free-Free or
pre-load
condition
2. Receiver B:
a. Inertance matrix
b. Noise Transfer Function 𝑯𝟓𝟑𝑩
Receiver B
3 𝑯33𝐵
𝑯33𝐵
Realistic
boundary
condition
𝑭2,𝑏𝑙𝐴
3. Target prediction using blocked forces
a. Mount stiffness (not needed for rigid connections)
b. FBS
𝑲
𝑷𝟓𝑨𝑩 = 𝑯𝟓𝟑
𝑩 ∗ 𝑯𝟐𝟐𝑨 +𝑯𝟑𝟑
𝑩 +𝑲−𝟏−𝟏
∗ 𝑯𝟐𝟐𝑨 ∗ 𝑭𝟐,𝒃𝒍
𝑨
𝑭2,𝑏𝑙𝐴
Receiver B
3𝑲
Source A
12
F source
𝑭𝟐,𝒃𝒍𝑨
𝑭𝟑,𝒄𝑨𝑩
Source A
12
F source
𝑭𝟐,𝒃𝒍𝑨
5
5
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Structure borne application example
Steering system integration
Source MechanismInvariant
Source Synth. ModelSub-Receiver Receiver
Steering
System
Blocked
Forces &
Impedances
Mount Pos.
SubframeFEM/TEST
FRF
BodyFEM/TEST
FRF
STEP 1: Source Characterization STEP 2: Full Vehicle Prediction
bench
1
A
𝑎𝑖xx
x
𝐻𝑖1𝐴𝐶
𝐹𝑏𝑙𝐴
𝐹𝑏𝑙𝐴 = 𝐻𝑖1
𝐴𝐶 −1 ∗ 𝑎𝑖
𝐹𝑏𝑙𝐴 , 𝐻11
𝐴
3𝑝
1 2
A
B
𝐹𝑟
𝐹𝑟𝐴𝐵 = 𝐻11
𝐴 + 𝐻22𝐵 + 𝐾−1 −1 ∗ 𝐻11
𝐴 ∗ 𝐹𝑏𝑙𝐴
𝑝 = 𝐻32𝐵 ∗ 𝐹𝑟
𝐴𝐵
Calculate Coupled FRF
1. In-Situ TPA – Apply Matrix Inversion: Blocked Forces = source characterization 2. Component Based TPA – Apply FBS Substructuring for load prediction
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Independent
Source
characterization
Theory of method
Blocked Forces as
Independent source
description
Measurement
challenges
From theory to
measurements
Extensive mathematics
require accurate data
Component Based TPA
Application
Examples
Deal with the subsystem
specific challenges
Difference in Test benches
& methodologies
Full Vehicle NVH
Synthesis
Combining all systems
& predict full vehicle
NVH performance
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Page 19 Siemens Digital Industries Software
• reciprocity / linearity
• directions errors / consistency
• driving point behavior
• repeatability
Use the Matrix heatmap to instantly verify
large datasets
• hard to reach location
• angle & position accuracy
• repeatability / low noise / high power
• large frequency range from 5Hz -10kHz
Dedicated FRF shaker excitation -
engineered for TPA measurement
• FRF required at exact connection
center – assuming local rigidity
• 6DOF FRF description of the
connection is required for completeness
Reduce the FRF’s to the connection center
using Virtual point transformation
Component Based TPA: required tools
‘extensive mathematics require accurate data’
Accuracy Validation Completeness
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Virtual Point Transformation (VPT)
Accurate FRFs at interface connection points
Solution:
▪ Geometrical Reduction / Virtual Point
Transformation
▪ Assumption: local rigidity in the connection
▪ Input: Geometry Information and FRFs
Challenge:
▪ Transfer functions at difficult or in most even
impossible to access positions
▪ High quality transfer functions at precise locations.
▪ Translational and rotational transfer functions (DOFs)
1000.000.00 Hz
80.00
-80.00
dBN
180.00
-180.00
Phase
°
Blocked force
at connection
Blocked force
off connection
VPT for correct blocked force estimation
VPT for correct assembly using FBS
VP
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Virtual Point Transformation (VPT)
Application examples
TransmissionVPT for
improving FBS
TRANSMISSION T/M BRACKET
Road NoiseVPT for spindle
forces/moments
and FBS
2000.0050.00 500.00 1000.00 1500.00
Hz
dB
g/N
180
-180-90
0
90
Ph
ase
°
MeasuredFBS
TIRE/WHEEL SUSPENSION
HVACForce reduction
for improved
prediction
COMPRESSOR CAR BODY
Source:” Structure-Borne Prediction on a Tire-Suspension Assembly Using Experimental Invariant Spindle Forces”, SAE 2019 DOI: 10.4271/2019-01-1541
Source:” A Frequency-Based Substructuring approach to engine mount bracket performance assessment for gear noise”, ISMA Siemens,Toyota Motor Europe 2020
https://www.researchgate.net/deref/http:/dx.doi.org/10.4271/2019-01-1541?_sg%5b0%5d=nw-DiNDxTmTL7WimDyS5ODMjR3HQnnZUysKudGFxj4xg1reAxIXG8dhranBLHdebhF_eviNSQqiuxQriR4Nv4LZgBQ.ckrKb0Q5sOGf0FQ3NXQzCTTSmF8oYjJ7sNtLJpk5XcX821sZ3vroAEgQJLu1mVr8dTFvWP1_PTHzH6i9FgpjLw
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Independent
Source
characterization
Theory of method
Blocked Forces as
Independent source
description
Measurement
challenges
From theory to
measurements
Extensive mathematics
require accurate data
Component Based TPA
Application
Examples
Deal with the subsystem
specific challenges
Difference in Test benches
& methodologies
Full Vehicle NVH
Synthesis
Combining all systems
& predict full vehicle
NVH performance
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Unrestricted © Siemens 2020
Page 23 Siemens Digital Industries Software
Development Component Based TPA methodology for NVH assessment
Hitachi AMS – Steering systems
Estimating in-vehicle noise of EPS using test bench
• More realistic design targets for
components
• Appropriate evaluation method at
component prototype phase
• Predict in-vehicle noise/vibration
using component based TPA
method
Blocked Force comparison
2000100 400 600 800 1000 1200 1400 1600Hz
Frequency
20
-80
-60-50-40-30-20-10
0
dBN
F VehicleF Bench
2000100 400 600 800 1000 1200 1400 1600Hz
Frequency
20
-80
-60-50-40-30-20-10
0
dBN
F VehicleF Bench
2000100 400 600 800 1000 1200 1400 1600Hz
Frequency
20
-80
-60-50-40-30-20-10
0
dBN
F VehicleF Bench
2000100 400 600 800 1000 1200 1400 1600Hz
Frequency
20
-80
-60-50-40-30-20-10
0
dBN
F VehicleF Bench
2000100 400 600 800 1000 1200 1400 1600Hz
Frequency
20
-80
-60-50-40-30-20-10
0
dBN
F VehicleF Bench
2000100 400 600 800 1000 1200 1400 1600Hz
Frequency
20
-80
-60-50-40-30-20-10
0
dBN
F VehicleF Bench
Test bench condition
In-vehicle Noise prediction
2000100 1000500 1500200 300 400 600 700 800 900 1100 1200 1300 1400 1600 1700 1800Hz
Frequency
60
-30
-20
-10
0
10
20
30
40
50
-25
-15
-5
5
15
25
35
45
55
dB
(A)
Pa
F Measured : In-VehicleF Noise Prediction : with Bench Blocked Force
2000100 1000500 1500200 300 400 600 700 800 900 1100 1200 1300 1400 1600 1700 1800Hz
Frequency
60
-30
-20
-10
0
10
20
30
40
50
-25
-15
-5
5
15
25
35
45
55
dB
(A)
Pa
F Measured : In-VehicleF Noise Prediction : with Bench Blocked Force
Vehicle condition
▪ Test bench identified blocked forces correlate with vehicle blocked forces
▪ Predicted cabin noise using test bench blocked forces well up to 1500Hz
Aoi Nakanome Hitachi AMS, 2019 Simcenter Conference Amsterdam
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Automotive OEM – Wiper System
Derive full vehicle structure-borne noise prediction from test rig
Identification of blocked forces
on Mockup
600.0020.00 500.00
Hz
dB
N/m
180
-180
0
Phase
°
Measured 1
Measured 2
C1/C1
C1/C2
C2/C1
C2/C2
600.0020.00 100.00 200.00 300.00 400.00 500.00
Hz
dB
g/N
180
-180
0
Phase
°Measured FRF Target / Connection 2
FBS FRF Target / Connection 2
Full vehicle assembly from
component level testing
→ Source in operation: wiper system at 35 cpm.
→ Blocked forces calculated using in-situ TPA
on dedicated test rig – matrix inversion.
Mount characterization
Substructuring
Prediction of target
response
→ Performance evaluation
→ using ISO/CD 21955 for prediction
→ Identification of path contribution
→ Input for target setting
→ What if analyses:
- Sensitivity to mount stiffness
- Receiver modification.
- …
600.0020.00 100.00 200.00 300.00 400.00 500.00
Hz
dBg
180
-180
0
Phase
°
Measured
Predicted
Wiper + Vehicle FRF
Mount stiffness
Transferability + FBS prediction
Ortega, Bianciardi, Corbeels, Ullmann, Desmet, MOUNT CHARACTERIZATION ANALYSIS IN THE CONTEXT OF FBS
FOR COMPONENT-BASED TPA ON A WIPER SYSTEM, , FA 2020, Lyon, Siemens, KULeuven, BMW
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Prediction of target response
→ Performance evaluation
→ Identification of path contribution
→ Input for target setting
25050 Hz
dB
(A)
Pa
Hz
dB
(A)
Pa
Full vehicle assembly from
component level testing
→ Independent characterization of
source and receiver
→ Virtual vehicle assembly
Identification of blocked forces
→ Invariant forces: receiver
independent
→ Transferable between receiving
structures
Hz
dBN
Vertical (Z)
Hz
dB
Nm
Automotive OEM – Road Noise
Wheel center blocked forces
▬ Measured Autopower
▬ Comp-TPA: FBS assemblyToe (Mz)
Hz
dB
(A)
Pa
Total
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Page 26 Siemens Digital Industries Software
Automotive Supplier – Tire manufacturer
Road noise – Wheel center blocked forces
Identification of blocked forces on test rig
→ Source in operation: 20 / 40 / 60 / 80 / 100 kph.
→ Blocked forces calculated using in-situ TPA: matrix inversion
using multiple integral shakers for FRF a
→ Blocked forces measured on rigid test rig using force cell (usable
only up to 300 Hz)
On board validation of target response on
test rig
→ On-board validation
→ Identification of path contribution
→ Input for realistc target setting & prediction
→ Independent
Hz
dBN X
Hz
dBN Y
Hz
dBN Z
Hz
dB
Nm MZ
Hz
dB
Nm MX
Blo
cked
Fo
rces a
nd
Mo
men
ts
Hz
dBg
Measured
Predicted
Hz
dB g
AutoPower RIG:TARGET_1:+Z
AutoPower RIG:TARGET_1:+Z
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▪ Performance evaluation
▪ Identification of path contribution
▪ Input for target setting
▪ Independent characterization of
source and receiver
▪ Virtual vehicle assembly
▪ Invariant forces: receiver independent
▪ Transferable between receiving
structures
▪ High frequency up to 4.5kHz
Order60, X-direction
Component-based TPA
Electromotor blocked forces – Assembly vibration prediction
Order80, Y-directionFBS vs Measured ▬ Measured Order
▬ Comp-TPA: FBS assembly
Identification of blocked
forces
System assembly from
component level testingPrediction of target response
Bianciardi, Corbeels, Choukri, HIGH FREQUENCY SOURCE CHARACTERIZATION OF AN E-MOTOR USING
COMPONENT BASED TPA, SIA 2020, Siemens
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Independent
Source
characterization
Theory of method
Blocked Forces as
Independent source
description
Measurement
challenges
From theory to
measurements
Extensive mathematics
require accurate data
Component Based TPA
Application
Examples
Deal with the subsystem
specific challenges
Difference in Test benches
& methodologies
Full Vehicle NVH
Synthesis
Combining all systems
& predict full vehicle
NVH performance
-
Unrestricted © Siemens 2020
Page 29 Siemens Digital Industries Software
Component based TPA for full vehicle NVH assessment
Model Based Development for NVH – Concept
NVH
synthesis
Solver
Digital Twin
Model
Methods
Scenarios
-7.00 10.00m
65.00
75.00
dB
(A)
Pa
65.00
75.00
dB
(A)
Pa
F Left Side
F Left Side Virtual
B Right Side
B Right Side Virtual
Compare Contribution Analysis
Sound Synthesis Result
Pass-by Noise Synthesis
NVH Driving Simulator Evaluation
Combining
Test & Simulation
data
Vehicle
Architectures
Stiffness
FRF
Forces
Component
Library
Target
Requirements
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Page 30 Siemens Digital Industries Software
Simcenter Testlab NVH Synthesis
Model Based Development for NVH
Define the vehicle
architecture
Create Validated
Components
Populate Assemblies /
Configurations
Perform Calculation
Contribution Analysis &
Audio Replay & Reporting
Supported by Model (Lifecycle) Data Management
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Page 31 Siemens Digital Industries Software
How can Simcenter help you ?
Implementation roadmap for component-based TPA
Engineering and Consulting• Worldwide technology
deployment & technology transfer services
• Dedicated approach for each application
Testing Solutions• Integrated solution for transfer path
analysis with shakers, sensors, hardware and software
• The reference solution for airborne and structureborne source characterization, substructuring and NVH Synthesis.
• Embedded in test-based NVH engineering solution covering TPA, structural dynamics, acoustics and rotating machinery
Simcenter Solution• Single source provider for test
and simulation models that can be used in a NVH Synthesis context
• Process implementation to predict NVH performance during the entire development process –concept, detailed engineering, full-vehicle
Technology
transfer
End-to-end
test system
Combining test
and simulation
-
Thank you
Siemens Digital Industries SoftwareUnrestricted © Siemens 2020