Investigation of Model-Based Multiphysics Analysis on Vibro-Acoustic Noise Sources Identification In Brushless DC Motor for Electric Vehicles

Purpose: The brushless direct current motor is gaining attention due to its dynamic characteristics, such as high density, power, and efficiency, but the vibration and noise resonance levels are high during various real-time driving conditions. Methods: This research describes a novel approach to analysing the various noise and vibration sources of the BLDC motor for electric vehicle applications. This study integrates model-based simulation and experimental analysis under real-time driving conditions. Further, various vibroacoustic noise sources are examined through transient model-based multiphysics analysis. Results: From the experimental results, greater noise and vibration levels are observed at different frequencies of 265.6, 620.2, 750.4, 1170.2, 1510.3, and 1790.5 Hz of the BLDC motor due to the uneven electromagnetic forces. To verify the presence of experimental vibro-acoustic noise resonance levels at different frequencies, the model-based transient analysis is investigated. The simulation results reveal an identical trend in frequency levels compared to experimentation. Conclusion: Finally, the overall observation of simulation and experimental results revealed that electromagnetic forces, load current changes, flux density, cogging torque fluctuations, etc. are the significant reasons for developing maximal vibro-acoustic noise amplitudes in the BLDC motor under different real-time driving conditions.