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Vibracoustic, a global leader in automotive noise, vibration, and harshness (NVH) solutions, has developed a cutting-edge Thermal Management Decoupling System for battery electric vehicles (BEVs). This system enhances the integration of thermal technologies such as HVAC, optimizing space, efficiency, and assembly. Proven through rigorous testing, it is ready for serial production.
Key Highlights
- Innovative Thermal Management Decoupling System: Designed to support and isolate co-located thermal technologies in BEVs.
- Space and Efficiency Optimization: Bundles HVAC components, saving space and simplifying assembly.
- Proven Performance: Extensive testing ensures reliability and readiness for production.
- Industry Adoption: Leading international OEMs have integrated this system into their large BEVs, including SUVs, pickups, and vans.
- Advanced NVH Engineering: Isolates complex systems from vehicle chassis, improving refinement and reducing noise and vibration.
As OEMs advance their BEV offerings, the focus has shifted from new technology implementation to optimizing performance, comfort, and refinement. A critical aspect of this evolution is the efficient packaging of thermal management systems.
Traditional separation of thermal components throughout the vehicle poses challenges in maximizing packaging space. Vibracoustic’s approach of bundling these systems together addresses these challenges, simplifying routing complexity and reducing hose and cable lengths. This results in reduced pressure losses, improved system efficiency, and easier assembly and service access.
The system includes components such as the air conditioning compressor, accumulator, pumps, and heat exchanger, all mounted directly to the vehicle chassis and connected by hoses and cables. Addressing the NVH concerns of these consolidated systems required a comprehensive vehicle approach.
Early design iterations were hindered by stiffness and weight issues. However, Vibracoustic’s engineers reimagined the design, considering attachment points, cables, hoses, and the interactions within the bundled systems. They collaborated with OEMs and Tier 1 suppliers to develop lightweight, die-cast aluminum brackets fitted with custom rubber bushings for optimal isolation.
Dr. Jörg Böcking, CTO at Vibracoustic, stated, “This project was an important opportunity for us to elevate NVH management in next-generation battery electric vehicles. Co-locating thermal systems offers a number of benefits to OEMs, but it also creates substantial new challenges. As a global leader in NVH solutions, our team developed a bracket and mounting system that effectively cradles and isolates the consolidated systems, improving vehicle refinement. This project demonstrated our ability to apply comprehensive NVH expertise at every point in the supply chain, helping our partners overcome complex challenges at the forefront of sustainable mobility.”
By innovating in thermal management and NVH solutions, Vibracoustic continues to support the advancement of BEVs, ensuring improved performance, comfort, and efficiency.
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