The Challenge
In modern vehicles, auxiliary components such as compressors play a crucial role in overall comfort and efficiency. However, these components can also introduce unwanted tonal noise, particularly in the low-frequency range that is most noticeable to passengers.
One automotive client faced persistent noise peaks in the 25–100 Hz harmonic band, creating an intrusive cabin experience. The challenge was to reduce this compressor noise without adding weight, cost, or overly complex countermeasures — and to ensure that simulation results matched real-world test data for accuracy.
Goken’s Approach
Goken engineers began by analyzing test data to identify the critical frequency bands where tonal noise peaks occurred. Working closely with the client’s test team, Goken correlated dynamic forces with their CAE-based NVH models, ensuring a strong connection between physical testing and virtual analysis.
The engineering team then applied iterative design optimization to the compressor mount bushings, which were identified as a key contributor to tonal resonance. The team used advanced simulation tools such as:
HyperWorks for finite element modeling and pre/post-processing
nCode for data processing and fatigue analysis
Nastran for NVH simulation
MetaPost for post-processing and visualization
Engineers performed multiple virtual iterations of the bushing design while evaluating stiffness properties and their impact on noise reduction. The goal was to shift and dampen the problematic frequency peaks while maintaining manufacturability and cost-effectiveness.
The Results
The optimized design achieved a significant reduction in tonal noise peaks, particularly in the 30–50 Hz range, which had been the most critical for passenger perception. The final results showed a clear improvement, with noise levels after optimization substantially lower than the baseline.
Moreover, the CAE-to-test correlation was strong, validating that the optimized bushing design would perform as predicted in real-world conditions. By focusing on intelligent structural adjustments rather than expensive noise-cancelling solutions, Goken helped the client achieve:
Noticeable NVH performance improvements
A balanced solution that met cost, weight, and manufacturability constraints
A validated method that can be applied to future compressor and component designs
Conclusion
This project underscored the importance of aligning simulation with physical testing in NVH development. By targeting the true root cause of the tonal peaks, the bushing stiffness, Goken engineers delivered a solution that was both effective and practical.
