Electric Motor Noise Variation Study Due to Air Gap Effect in Electric Vehicles

Motor whine is a crucial factor in the design of electric motors for electric vehicles (EVs). Predicting noise in a virtual environment is challenging due to the many possible variations during sample testing. The air gap between the stator and rotor in each sample is a significant contributor to radiated noise variation in the electric drive unit (DU). A baseline is first established for radiated noise prediction, assuming a nominal uniform airgap distribution, using the front electric DU in General Motors' Hummer EV. This study explains how the sensitivity of critical motor orders changes with static offset direction when the stiffness of DU is non-uniform and varies with radial direction. It also predicts the range of motor airborne noise variation due to offset orientation. Next, the effect of tilt direction on motor noise variation is studied at different torque conditions and motor speeds. Motor noise is found to be sensitive to tilt direction and angle as the DU stiffness changes axially. Additionally, rotor dynamic offset is investigated, which generates sideband orders in addition to motor pole pass orders. A comparison study is conducted to examine various sideband orders and their central frequency.