KU Leuven LMSD & Toyota Motor EuropeBreaking barriers in powertrain NVH research

Long story short

The KU Leuven’s LMSD (Laboratory for Mechanical Systems and Dynamics) team specializes in integrating simulation and real-world data to improve the performance, reliability and lifespan of mechatronic systems, such as automotive powertrains. To support their cutting-edge research, they collaborated with CTRL Engineering, known for its expertise in automotive test benches, to provide the necessary validation tools for their advanced simulations.

“CTRL Engineering helped us from accurate requirement setting up to the delivery of a high accuracy test bench, which made us a very happy partner 😊🔧🎯”
Claus Claeys – Research Manager @ KU Leuven LMSD

The Challenge: Advanced NVH Evaluation in Next-Generation Powertrains

As hybrid and electric vehicles (EVs) redefine powertrain performance, Toyota Motor Europe (TME) partnered with KU Leuven’s LMSD team to evaluate the NVH (Noise, Vibration, Harshness) characteristics of advanced components. To validate their simulations, the team required a state-of-the-art test bench. CTRL Engineering was tasked with designing a custom solution that could replicate real-world conditions and ensure accurate model validation.

Critical requirements for the test bench included high-speed data acquisition, sub-microsecond encoder accuracy, high dynamic load simulations, seamless model-based software integration, and safety features for high-voltage systems.

The Solution: A Custom Test Bench Built for Precision

CTRL Engineering tackled the challenging requirements by developing a bespoke test bench that seamlessly integrated advanced hardware and software solutions. The system was designed to endure dynamic loads and high-speed operations, all while delivering precise NVH measurements.

A key innovation was the incorporation of an FPGA-based edge device, which enabled timestamping of all encoder data with an angular position accuracy of about 0,1 arcseconds at the nominal input speed of 3000 rpm. This precision allowed the team to monitor the dynamic behavior of powertrain components with a level of detail exceeding one-tenth of an arcsecond, capturing even the slightest variations in noise and vibration.

The mechanical design was optimized to reduce any interference with vibration measurements, focusing on maintaining a low natural frequency under 5 Hz. This ensured that potential resonances did not compromise the quality of the NVH data being recorded.

Energy efficiency was enhanced through the use of a shared DC bus, which minimized power losses during motor operation and enabled regenerative energy recovery, resulting in up to 20% lower energy consumption compared to conventional systems.

Real-time synchronization and control were achieved via EtherCAT communication, which allowed for high-speed, deterministic data transmission. This ensured precise coordination between motors, sensors, actuators, and data acquisition systems, enabling tests to be performed with millisecond-level precision while reducing latency to a minimum.

Results: Bridge the gap between simulation and validation

This partnership enabled LMSD to accelerate research validation by utilizing the advanced test bench, which allowed for rapid iteration and validation of simulation models. It also helped optimize drivetrain design, as the insights gathered from rigorous testing significantly improved NVH (Noise, Vibration, Harshness) performance. Furthermore, the collaboration enhanced commercial readiness, with reliable data validating the motor’s capabilities and supporting future scalability and customer discussions.

This groundbreaking collaboration ensures that LMSD and TME are well-positioned to meet and exceed industry expectations, delivering powertrain systems that set new benchmarks for efficiency and reliability.

Why it matters to you?

This partnership demonstrates the importance of precision in powertrain validation, especially as the automotive industry embraces electrification. Accurate NVH testing ensures that new powertrain technologies are reliable, efficient, and meet regulatory standards.

CTRL Engineering’s custom test benches provide the high-speed data acquisition, precision timing, and real-time control needed to validate complex systems, helping automotive manufacturers reduce time-to-market and improve product quality as they transition to hybrid and electric vehicles.