Experimental Design for Characterization of Force Transmissibility through Bearings in Electric Machines and Transmissions

Abstract

With the increasing stringent emissions legislation on ICEs, alongside requirements for enhanced fuel efficiency as key driving factors for many OEMs, there are many research activities supported by the automotive industry that focus on the development of hybrid and pure EVs. This change in direction from engine downsizing to the use of electric motors presents many new challenges concerning NVH performance, durability and component life. This paper presents the development of experimental methodology into the measurement of NVH characteristics in these new powertrains, thus characterizing the structure borne noise transmissibility through the shaft and the bearing to the housing. A feasibility study and design of a new system level test rig have been conducted to allow for sinusoidal radial loading of the shaft, which is synchronized with the shaft's rotary frequency under high-speed transient conditions in order to evaluate the phenomena in the system. The present work introduces a new component level test rig that can predict the response of new EV and hybrid systems using different types of rolling element bearings such as deep groove ball bearings, angular contact roller bearings, tapered roller bearings and the cylindrical roller bearings. Moreover, it is possible to investigate the influence of factors such as bearing clearance and the amount of axial bearing preload which will be used to further explore the capability of bearing CAE tools. The test rig has multiple novel elements compared to those previously developed. In particular, the rotational speed of the shaft, which significantly exceeds that of previously reported rigs, and the excitation frequency ramp up at the same rate as the frequency of the shaft enabling the phenomena found in Hybrid and EVs. The sinusoidal radial load is supplied using a loading device featuring a single load point to minimize undesired excitation effects. With respect to structure borne noise the system response is captured through the vibrational displacement of the shaft and bearing housing.

Tribo-dynamic analysis of high-speed roller bearings for electrified vehicle powertrains

“…The displacement of the bearing centre governs the conditions at the contact and was found experimentally using a high-speed bearing test rig, originally reported by Walker et al [23]. A 5 kW AC synchronous motor, capable of reaching up to 32 000 rpm was coupled to a steel shaft that is supported by two bearing brackets.…”