Polymer Base for Hybrid Powertrain NVH Test Installations
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Solution Overview
Problem
Conventional powertrain test installations are costly due to the need for extensive concrete floor preparation and large concrete seismic masses to absorb vibrational energy, which increases installation expenses and complexity.
Innovation Solution
A powertrain test installation using a polymer base supported on a concrete slab, where a dynamometer is mounted on the polymer base, and a frame is secured to support a powertrain component, such as an electric motor, eliminating the need for extensive concrete excavation and using a polymer composite material that dissipates vibrations and provides electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional concrete seismic mass is used to absorb vibrational energy, then vibration absorption is sufficient, but installation cost and complexity increase due to extensive floor preparation and large concrete masses
Solution Approach 1:
The patent changes the material parameter from conventional concrete to a polymer composite material with specific vibration-damping properties. This polymer material absorbs vibrational energy more effectively per unit mass, allowing reduction of the overall mass and simplification of the floor preparation while maintaining sufficient vibration absorption capability.
Solution Approach 2:
The patent employs a polymer composite material that combines vibration-damping properties with structural support capabilities. This composite material replaces the traditional concrete seismic mass, achieving both vibration absorption and structural function with reduced mass and simplified installation requirements.
2Strength
If a steel bedplate is used to support the dynamometer and motor, then structural strength is sufficient, but the steel plates occupy about 13% of the volume and increase cost
Solution Approach 1:
The patent replaces the steel bedplate with a polymer composite material that provides both structural support and vibration-damping functions. This composite material achieves the required structural strength with greater volume efficiency and lower material cost compared to traditional steel construction.
Solution Approach 2:
The polymer composite base serves multiple functions simultaneously: it provides structural support for the dynamometer and motor, absorbs vibrational energy, and electrically isolates the motor. This multi-functionality eliminates the need for separate steel bedplate and seismic mass components, reducing overall material quantity and cost.
3Strength
If the motor is mounted directly to the steel bedplate, then mechanical connection is secure, but electrical isolation is lost
Solution Approach 1:
The polymer composite material acts as an intermediary between the motor and the floor structure. It provides mechanical mounting security while simultaneously serving as an electrical insulator, thus preventing electrical interference and isolation issues that would occur with direct metal-to-metal mounting.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the overall cost of installation by minimizing floor preparation and using a polymer composite that absorbs vibration energy effectively, eliminating the need for large concrete masses and providing electrical isolation for the electric motor.
Implementation Method 1
The polymer base, which is constructed from a polymer composite material, for example. The polymer composite material dissipates the vibrational energy inputs from the motor and dynamometer during the test procedure
Implementation Method 2
A polymer base is arranged on the support floor interiorly of the gap so that the polymer base is isolated from the adjacent floor
Data Source
AI summary
A powertrain test installation is disclosed that includes a polymer base, which is supported on a concrete slab, for example. A dynamometer is mounted on the polymer base. A frame is mounted to the polymer base and is configured to support a powertrain component to be coupled to the dynamometer. The powertrain test system is installed, for example, by providing a floor, which is a concrete slab, for example. The floor is cut to provide a gap between a support floor and an adjacent floor that is arranged about the support floor. A polymer base is arranged on the support floor interiorly of the gap so that the polymer base is isolated from the adjacent floor. A dynamometer is secured to the polymer base. A frame is secured to the polymer base and is configured to support a powertrain test component, such as an electric motor.