Back-to-back eBench mechanical validation and correlation in view of xDT

This thesis presents the mechanical validation and correlation of a Back-to-Back eBench. The objective is to enhance the accuracy and reliability of mechanical performance assessments and update the extended Digital Twin (xDT) of the system. Firstly, a general overview of the NVH field is provided, highlighting its purposes, challenges and current industrial problems. The theoretical background needs to understand these topics is then outlined, focusing on the electric motors, the Experimental Modal analysis and the application of Impact and Shaker testing for real eigenvalue analysis and its corresponding mode shapes. The use of both testing method is crucial to verify results and compare analysis. To evaluate the behavior of the entire bench, particular attention is on the electric motor, identified as the most influential component from a mechanical perspective. Due to its complexity, the electric motor was tested and correlated separately for its stator and rotor components under free-free boundary conditions. Testing the complete motor further validated the consistency and reliability of the applied methods. Following the experimental phase, the optimization software HEEDS was utilized to adjust the material properties of various components, aiming to improve system performance and reliability. This optimization process was essential to correlate the simulated and experimental data. As expected, discrepancies were observed in the motor’s behavior, likely due to nonlinear effects. Finally, additional tests on the eBench were conducted to reinforce the validity of the developed model.