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MAHLE cuts NVH characterization time by 80% for e-bike drivetrain and ensures end-of-line product quality

MAHLE uses Simcenter testing solutions to streamline e-bike drivetrain NVH analysis and for end-of-line testing: Read the full article

As more people seek eco-friendly and efficient means of commuting, the demand for e-bikes has been steadily increasing. Recognizing this trend, MAHLE, a company with a long-standing history of developing automotive components, has ventured into the e-bike sector. With a focus on integrated systems, minimal noise, and enhanced performance, MAHLE is shaping the future of mobility in the e-bike industry.

Bicyclists riding MAHLE e-bikes

Diversification and market demand

MAHLE’s decision to invest in the e-bike sector marks a strategic shift in their business approach. They have identified the rising market demand for e-bikes, especially among cyclists seeking lower carbon footprint alternatives. By diversifying their offerings, MAHLE demonstrates their ability to stay ahead of emerging trends in mobility and cater to the evolving needs of consumers.

Integrating design and performance

One of the key factors influencing e-bike purchasing decisions is motor noise. Customers expect premium brands to deliver advanced features while ensuring minimal sound generated by the drive system. MAHLE understands this demand and focuses on developing small integrated drivetrains and smart connectivity. These integrated solutions not only provide a sleek appearance but also give users greater control over their riding experience by allowing them to fine-tune their bikes to meet their preferences and needs.

A MAHLE e-bike powertrain

Testing for NVH performance

To ensure their e-bike systems meet the highest standards of quality and performance, MAHLE relies on Simcenter SCADAS XS hardware and Simcenter Testlab Neo software for NVH characterization and testing. The interaction of mechanical and structural components in an e-bike can produce a wide range of noise and vibration patterns, making testing a complex process. However, with Simcenter testing solutions, MAHLE can pinpoint the sources of noise and vibration and make design adjustments to improve acoustic performance and enhance durability.

Precise data capture

MAHLE’s engineers use Simcenter SCADAS XS to capture time signals from various sensors, analyze the drivetrain’s rotating components, and evaluate noise from the rider’s perspective using binaural headsets. Federico Lopez, a MAHLE NVH engineer, explains that he uses many of the Simcenter SCADAS XS features to capture the required data.

Simcenter SCADAS XS is easy to set up and the measurements are precise, which helps us to understand the loudness, articulation index and roughness to better describe the subjective feeling of the noise rather than simply measuring the decibels.”

Federico Lopez
MAHLE NVH engineer

Simcenter SCADAS XS mobile unit used for NVH characterization and testing

Full NVH characterization and analysis

Simcenter Testlab Neo complements these efforts by providing rich processing capabilities and automated reporting. The use of these tools significantly reduces testing time, allowing MAHLE to characterize a complete drivetrain in just one hour, compared to five hours with other tools.

“I have different templates defined for different objectives in Simcenter Testlab Neo, making it quick to set up,” Lopez says. “Combined with automated reporting, this saves us considerable time in the testing process. Characterizing a complete drivetrain now takes just one hour while with other tools it could take as much as five hours.” This represents a time savings of 80 percent.

NVH analysis results performed using Simcenter Testlab Neo and Simcenter Testlab SCADAS XS

Meeting high quality standards with Simcenter Anovis

MAHLE uses the Simcenter Anovis™ system for end-of-line testing purposes. This system is employed to inspect drive units and establish criteria for determining whether they pass or fail the test. “Simcenter Anovis allows us to specify the conditions for identifying NVH patterns,” says Lopez. “Whenever components are changed to reduce NVH, we update the pass boundaries in Simcenter Anovis to reflect this.”

It’s a great solution for identifying issues and discarding units that don’t meet our high standards.”

Federico Lopez
MAHLE NVH engineer

Collaboration and future innovations

MAHLE’s collaboration with Siemens has been instrumental in their success. Looking ahead, MAHLE aims to incorporate simulation solutions into their development process to further speed up the process and reduce costs. Additionally, they are exploring the potential of using artificial intelligence (AI) to process large amounts of testing data and gain new insights for future designs.

To learn more about how MAHLE characterizes a complete drivetrain in just one hour: Read the full article


Elif Altuntop Kavas

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This article first appeared on the Siemens Digital Industries Software blog at https://blogs.sw.siemens.com/simcenter/mahle-cuts-e-bike-nvh-characterization-time/