As manufacturers and engineers design testing facilities to meet the evolving demands of the automotive industry, particularly the shift from Internal Combustion Engines (ICE) to Electric Vehicles (EVs), traditional methods of constructing these spaces and gathering data are often expensive, time-intensive, and may not adequately address future requirements. How can companies establish adaptable, future-proof vehicle NVH testing environments that strategically integrate physical infrastructure with digital innovation to address the ICE to EV transition?

Industry Edge’s “NVH Testing Evolution: Internal Combustion Engine to Vehicle Electrification With Randy Rozema” podcast recently featured a compelling discussion on the shifting frameworks in the design of industrial testing facilities, underscoring the necessity for adaptable and forward-looking methodologies in the context of vehicle electrification. Hosted by Danielle Neely, the episode explored how the thoughtful integration of digital modeling and simulation is redefining how manufacturers approach the creation of EV NVH testing environments, moving beyond conventional construction practices to enable more agile and efficient development tailored to the unique challenges of EV testing.

Neely engaged in a detailed conversation with Randy Rozema, Director, Acoustics & Vibration, and Principal at ACS. Their discussion delved into the broader implications of facility design on a manufacturer’s capacity to respond to industry changes, specifically the nuances of NVH testing for both ICE and the increasingly prevalent EV. The conversation also touched upon specific technological tools that are increasingly intertwined with the NVH testing facility design process itself, considering the different noise and vibration profiles of these powertrains.

Rozema shared his insights on how an inside-out design philosophy, a crucial aspect of creating future-proof NVH facilities, can lead to greater efficiency and accuracy in testing the distinct characteristics of ICE and EV noise and vibration. He also emphasized the vital role of combining digital models with physical planning to ensure that both efficiency and the fidelity of real-world testing, across different vehicle types, are thoroughly considered. “By beginning with the product’s testing requirements and data needs, you can tailor the facility design to precisely meet those parameters, avoiding the limitations of adapting a pre-existing structure to the specific demands of EV NVH testing,” said Rozema. The discussion further highlighted the growing importance of digital simulation as an inherent part of designing advanced NVH testing facilities, demonstrating how virtual models can enhance efficiency while upholding the necessary accuracy for both ICE to EV analysis, crucial for the broader ICE to EV transition.

Neely and Rozema also examined the role of modern technologies, such as digital twins, in the planning and validation phases of NVH testing facility development, offering a virtual space for optimizing layouts and experimental protocols specific to electric vehicle noise and vibration.

Through their conversation, Neely and Rozema covered the evolving nature of designing NVH testing facilities in an era of increasing technological sophistication and the automotive industry’s transition towards electrification, underscoring the need for a strategic and integrated design approach, essential for building environments that are both flexible and prepared for the future of vehicle NVH testing. This proactive approach is key to successfully navigating the shift from ICE to EV and ensuring comprehensive vehicle NVH testing.

Be sure to listen to the full podcast here.