Electric vehicles generate high-frequency noises like whirring from vibrating power electronics and inverters. Current insulation mats used to reduce this noise are expensive, heavy, and reduce drivetrain efficiency.
Researchers at Otto von Guericke University Magdeburg have developed an innovative solution: a granulate made from recycled car tyres. This material fills existing cavities within power electronics components, where the particles move to damp vibrations before they can create unwanted noise.
Laboratory tests demonstrated significant improvements, reducing noise levels by 6.5 decibels in the most critical frequency range, and component vibrations by up to 9.7 decibels. The method requires precise calculation of particle characteristics and placement for optimal results. This particle damping technology promises quieter, more pleasant-sounding EVs, with potential applications across various drivetrain components.
Electric vehicles generate sound from a range of sources, including tyre-road interaction, aerodynamic effects and onboard electronics. Researchers at the Institute for Engineering of Products and Systems at Otto von Guericke University Magdeburg have focused on the latter. Power electronics, inverters and other vehicle components can produce high-frequency noises such as whirring, humming or high-pitched whistling sounds. These noises are typically caused by vibrations and oscillations.
To reduce these noises, manufacturers have so far relied mainly on insulation mats. However, these components are comparatively expensive and add weight, which can reduce drivetrain efficiency. Prof. Hermann Rottengruber and his research associate Dr-Ing. Braj Bhushan Prasad therefore investigated alternative materials for damping power electronics and lowering noise emissions. Their research led them to an unconventional solution: recycled car tyres.
The researchers developed a granulate from recycled tyre rubber that can be filled into existing cavities within power electronics components. The particles move within these cavities and damp vibrations before they can generate unwanted noise. In laboratory tests, the approach reduced noise levels by 6.5 decibels in the most critical frequency range, while vibrations of a component cover fell by up to 9.7 decibels.
“Particles behave very differently depending on their size, material, filling quantity, temperature, component geometry, and excitation. That’s why simply filling a component with granulate isn’t enough. We must calculate and test which particles, in what quantity and at which location, achieve the best results,” explains Braj Bhushan Prasad, outlining the challenges of the new method.
“Our findings show that even small particles made from recycled tyre rubber can make a noticeable difference in reducing noise in electric vehicles,” says Prof. Hermann Rottengruber. “We now aim to develop this into a tool for designing future electric vehicles, so they not only drive cleaner but also sound more pleasant.”
According to the engineers, the new particle damping technology could in future be used not only in power electronics but also in inverters, control units, and other vibration-prone components of electric drivetrains.
ovgu.de (in German)
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