Woco collaborates with GM’s engineering center in Asia to develop a mid-size sedan specifically for the Chinese market.
Automotive suppliers have a choice in their business strategy: partner closely with their customers on a global scale or fade into obscurity. Woco GmbH is an excellent example of the first, working closely with GM China in a recent vehicle development program in engineering a mid-size sedan specifically for China’s road conditions, fuel requirements and customer expectations. The new vehicle is critical in GM’s plans to strengthen its position in the rapidly growing China market. Woco’s role concentrated on the development of the powertrain suspension, and they relied heavily on LMS systems at every phase of the project. LMS Test.Lab was used for fast-turnaround testing, analysis of results, and LMS Virtual.Lab quickly helped identify vibration sources, simulated the effects of design modifications and enabled Woco engineers to determine the best configuration of mounts and brackets. Reports generated by the LMS systems contained live data so engineers in China could see animated displays, manipulate views and interact with images for better insight into suspension behavior. In this way, LMS technology enabled Woco to assume responsibility for design of the complete powertrain suspension and collaborate closely with the OEM in meeting critically tight vehicle launch schedules for this important vehicle.
Car companies focus on China
Well known for low-cost manufacturing, China is now recognized for its huge potential as a consumer market for big-ticket products such as automobiles. Driving this growth are increased wealth in China and relatively few people now owning vehicles there. According to latest statistics, of every 1,000 drivers, only 20 own a car in China compared to 500 in Europe and 700 in North America.
China is currently the second largest automobile market, and passenger car sales are expected to increase 16 percent in 2006, with annual growth rate between 10 to 15 percent over the next five years. General Motors is doing particularly well in the country. In 2005, the company sold a record 665,390 vehicles there, outpacing the industry with a 35.2 percent increase and establishing a market share of 11.2 percent – up 1.8 points from the previous year.
GM attributes its success in China to an unprecedented number of new and upgraded vehicle introductions. The company continues to expand operations in the country, particularly at Shanghai General Motors Ltd. – GM’s largest joint venture in China accounting for half the automaker’s sales there. Their newest model introduced in early 2006 is the Buick LaCrosse, a premium mid-size sedan reengineered for the Chinese market at the Pan Asia Technical Automotive Center (PATAC), another joint venture of GM.
Leveraging expertise in vibro-acoustics
In developing the powertrain suspension for the LaCrosse, GM came to Woco for meeting a range of important NVH responsibilities: evaluating a competitive vehicle, developing the complete powertrain suspension system, and ensuring that engine noise transmitted through the chassis did not exceed specified levels in the passenger compartment. A major part of such high-level business for Woco comes from collaborating with OEMs on these types of noise and vibration reduction solutions. Founded in 1956 by Franz Josef Wolf, the company built an outstanding reputation as a rubber parts manufacturer. When his company began to face mounting global competition from other component producers, Wolf differentiated Woco by providing carmakers with complete NVH solutions based on decades of know-how in applying mounts, bushings, and other parts for quieting noise and damping vibration. As a result, sales have more than tripled in the last ten years, employment has more than doubled, production sites have been expanded worldwide and Woco’s client list reads like a who’s-who of major automakers including GM, DaimlerChrysler, Ford, Volkswagen, Mitsubishi, BMW, Audi, BMW, Peugeot and Renault-Nissan.
"The transformation of Woco and its continued business success depend on state-of-the-art technology in leveraging the tremendous expertise of our people in sound and vibration," says Wolf. "Such tools enable our engineers to efficiently apply their knowledge in working closely with customers around the world to develop the best solutions possible. Technology, know-how and collaboration represent our key competitive advantages and continue to ensure our business success."
As a cornerstone of this plan, the company relies heavily on technology provided by LMS International. "These advanced solutions have a strategic role throughout our NVH projects, enabling engineers to gain valuable insight into the vibro-acoustic behavior of complex automotive systems," notes Reinhard Eder, manager of vehicle and component testing, measurement and analysis at Woco. He explains that data acquisition and signal conditioning for lab and field testing is performed with a 32-channel LMS SCADAS III front end integrated with LMS Test.Lab software for analysis and display. This testing system is operated in conjunction with LMS Virtual. Lab software for noise and vibration simulation and virtual prototyping.
"As an integrated suite of solutions, LMS Test.Lab and LMS Virtual.Lab have a significant impact on our NVH engineering operations. The tools enable us to develop, test and optimize anti-noise/vibration efficiently, and to communicate critical results to our customers clearly and quickly," Eder explains. "These capabilities bring us closer to our customers by allowing us to efficiently solve their problems and provide complete NVH solutions for their products. In this respect, LMS solutions are more than just hardware and software. They represent a critical part of our business strategy in positioning Woco as a full service NVH provider to major automakers and other world-class manufacturing organizations."
Four-point powertrain suspension for the LaCrosse
On the LaCrosse project, Woco began by studying the behavior of a powertrain suspension on a comparable midsize competitive benchmark vehicle. LMS Test.Lab was used to gather and analyze frequency-response data from accelerometers and microphones at key locations in the vehicle interior for a range of gears and engine speeds. Sets of response-amplitude versus frequency plots then compared this data with similar measurements taken by testing prototypes of various concepts for the powertrain suspension. By utilizing efficient data analysis and display capabilities of LMS Test.Lab, Woco engineers in cooperation with PATAC readily showed that a fourpoint suspension (consisting of an antiroll torque restrictor strut mount, front and rear engine mounts, and a transmission mount) was more effective, lighter in weight and less expensive than the initial concept.
With the concept determined, Woco then moved on to detailed design of the powertrain suspension in which mounts and brackets were sized and positioned to deliver optimal performance for a range of operating conditions. In this phase, individual mounts as well as the suspension cradle assembly were tested at various frequencies to determine their noise transfer function (NTF) – that is, the static and dynamic stiffness properties in transmitting vibration. Also, accelerometers were placed on a GM prototype concept vehicle to measure accelerations at mount locations while microphones at the driver and passenger seats measured interior noise for acceleration run-up, idle behavior, engine shake and key-on/off.
"Tests were quickly set up with the help of prompts and other automated features of LMS Test.Lab, and measurements were taken very efficiently," says Eder. "The broad bandwidth and number of channels enabled us to gather multiple types of data at one time, including vibration as well as acoustics. Also, analysis of the data such as determination of resonances (order analysis) could be done on the spot, and we had the capability to view selected results in real time if necessary, to identify parts of the test that might need further study later. Moreover, transferring results data from LMS Test.Lab to LMS Virtual.Lab was easy because of the tight integration between the two systems."
Virtual models simulate product performance
Eder explains that with LMS Virtual.Lab, he was able to model the complete powertrain suspension system, with total frequency response computed by multiplying the system’s NTF by its operating structural input loads for each mount based on its particular stiffness and operational displacement. In this way, transfer path analysis (TPA) in LMS Virtual. Lab determines the combined vibration at selected locations (ears of the driver and passenger) in the vehicle interior. After validating the correlation of the virtual model with test data, Woco engineers had a way to predict the effect of changes in the configuration of the suspension. Thus, they could optimize the behavior of the assembly by modifying the size and position of the mounts in the virtual world instead of on physical hardware. Guided by simulation results, engineers were able to significantly improve the anti-noise/ vibration performance of the suspension with modifications of the static and dynamic behavior of the mounts.
"LMS Virtual.Lab enabled us to study the impact of a variety of changes to the powertrain suspension and quickly arrive at the best overall design," says Waldemar Hermann, engineering development supervisor of the LaCrosse powertrain suspension project at Woco. "In this way, only a few hours were needed for us to work with simulations in evaluating a range of alternative configurations that otherwise would have taken weeks of trial and error in building and testing in hardware prototypes."
Eder points out that such simulation was particularly helpful in resolving a particular problem with a "booming"
"Contribution analysis is a powerful tool that enables us to see the source and intensity of vibrations immediately on plots and color-map displays," notes Hermann. "In this way, we are able to quickly determine which parts of the vehicle are responsible for the highest structural contribution in a certain problem zone. Without this capability, considerably more testing and guesswork would be needed to find the root cause of problems."
Collaboration with GM China
According to Eder, the efficiency of the LMS systems helps Woco work closer with customers such as GM China’s PATAC by providing quick turnaround in resolving problems and in meeting tight schedule deadlines throughout the program. Moreover, Woco and PATAC readily have the opportunity to exchange data files for further analyses and additional simulation work by the automaker on the overall vehicle. Eder found the LMS report generation features particularly beneficial in the LaCrosse program, with the capability soon to be provided for easily inserting live test data and simulation results into interactive reports.
Thus, PATAC engineers could easily click on and scroll through the data interactively to study specific areas in more detail or reuse the plots and animated images in their own documents and reports. In this way, Woco was able to demonstrate its expertise as well as its ability and willingness to collaborate globally with a customer on a critical vehicle development program.
Automotive suppliers have a choice in their business strategy: partner closely with their customers on a global scale or fade into obscurity. Woco GmbH is an excellent example of the first, working closely with GM China in a recent vehicle development program in engineering a mid-size sedan specifically for China’s road conditions, fuel requirements and customer expectations. The new vehicle is critical in GM’s plans to strengthen its position in the rapidly growing China market. Woco’s role concentrated on the development of the powertrain suspension, and they relied heavily on LMS systems at every phase of the project. LMS Test.Lab was used for fast-turnaround testing, analysis of results, and LMS Virtual.Lab quickly helped identify vibration sources, simulated the effects of design modifications and enabled Woco engineers to determine the best configuration of mounts and brackets. Reports generated by the LMS systems contained live data so engineers in China could see animated displays, manipulate views and interact with images for better insight into suspension behavior. In this way, LMS technology enabled Woco to assume responsibility for design of the complete powertrain suspension and collaborate closely with the OEM in meeting critically tight vehicle launch schedules for this important vehicle.Car companies focus on China
Well known for low-cost manufacturing, China is now recognized for its huge potential as a consumer market for big-ticket products such as automobiles. Driving this growth are increased wealth in China and relatively few people now owning vehicles there. According to latest statistics, of every 1,000 drivers, only 20 own a car in China compared to 500 in Europe and 700 in North America.
China is currently the second largest automobile market, and passenger car sales are expected to increase 16 percent in 2006, with annual growth rate between 10 to 15 percent over the next five years. General Motors is doing particularly well in the country. In 2005, the company sold a record 665,390 vehicles there, outpacing the industry with a 35.2 percent increase and establishing a market share of 11.2 percent – up 1.8 points from the previous year.
GM attributes its success in China to an unprecedented number of new and upgraded vehicle introductions. The company continues to expand operations in the country, particularly at Shanghai General Motors Ltd. – GM’s largest joint venture in China accounting for half the automaker’s sales there. Their newest model introduced in early 2006 is the Buick LaCrosse, a premium mid-size sedan reengineered for the Chinese market at the Pan Asia Technical Automotive Center (PATAC), another joint venture of GM.
Leveraging expertise in vibro-acoustics
In developing the powertrain suspension for the LaCrosse, GM came to Woco for meeting a range of important NVH responsibilities: evaluating a competitive vehicle, developing the complete powertrain suspension system, and ensuring that engine noise transmitted through the chassis did not exceed specified levels in the passenger compartment. A major part of such high-level business for Woco comes from collaborating with OEMs on these types of noise and vibration reduction solutions. Founded in 1956 by Franz Josef Wolf, the company built an outstanding reputation as a rubber parts manufacturer. When his company began to face mounting global competition from other component producers, Wolf differentiated Woco by providing carmakers with complete NVH solutions based on decades of know-how in applying mounts, bushings, and other parts for quieting noise and damping vibration. As a result, sales have more than tripled in the last ten years, employment has more than doubled, production sites have been expanded worldwide and Woco’s client list reads like a who’s-who of major automakers including GM, DaimlerChrysler, Ford, Volkswagen, Mitsubishi, BMW, Audi, BMW, Peugeot and Renault-Nissan."The transformation of Woco and its continued business success depend on state-of-the-art technology in leveraging the tremendous expertise of our people in sound and vibration," says Wolf. "Such tools enable our engineers to efficiently apply their knowledge in working closely with customers around the world to develop the best solutions possible. Technology, know-how and collaboration represent our key competitive advantages and continue to ensure our business success."
As a cornerstone of this plan, the company relies heavily on technology provided by LMS International. "These advanced solutions have a strategic role throughout our NVH projects, enabling engineers to gain valuable insight into the vibro-acoustic behavior of complex automotive systems," notes Reinhard Eder, manager of vehicle and component testing, measurement and analysis at Woco. He explains that data acquisition and signal conditioning for lab and field testing is performed with a 32-channel LMS SCADAS III front end integrated with LMS Test.Lab software for analysis and display. This testing system is operated in conjunction with LMS Virtual. Lab software for noise and vibration simulation and virtual prototyping.
"As an integrated suite of solutions, LMS Test.Lab and LMS Virtual.Lab have a significant impact on our NVH engineering operations. The tools enable us to develop, test and optimize anti-noise/vibration efficiently, and to communicate critical results to our customers clearly and quickly," Eder explains. "These capabilities bring us closer to our customers by allowing us to efficiently solve their problems and provide complete NVH solutions for their products. In this respect, LMS solutions are more than just hardware and software. They represent a critical part of our business strategy in positioning Woco as a full service NVH provider to major automakers and other world-class manufacturing organizations."
Four-point powertrain suspension for the LaCrosse
On the LaCrosse project, Woco began by studying the behavior of a powertrain suspension on a comparable midsize competitive benchmark vehicle. LMS Test.Lab was used to gather and analyze frequency-response data from accelerometers and microphones at key locations in the vehicle interior for a range of gears and engine speeds. Sets of response-amplitude versus frequency plots then compared this data with similar measurements taken by testing prototypes of various concepts for the powertrain suspension. By utilizing efficient data analysis and display capabilities of LMS Test.Lab, Woco engineers in cooperation with PATAC readily showed that a fourpoint suspension (consisting of an antiroll torque restrictor strut mount, front and rear engine mounts, and a transmission mount) was more effective, lighter in weight and less expensive than the initial concept.With the concept determined, Woco then moved on to detailed design of the powertrain suspension in which mounts and brackets were sized and positioned to deliver optimal performance for a range of operating conditions. In this phase, individual mounts as well as the suspension cradle assembly were tested at various frequencies to determine their noise transfer function (NTF) – that is, the static and dynamic stiffness properties in transmitting vibration. Also, accelerometers were placed on a GM prototype concept vehicle to measure accelerations at mount locations while microphones at the driver and passenger seats measured interior noise for acceleration run-up, idle behavior, engine shake and key-on/off."Tests were quickly set up with the help of prompts and other automated features of LMS Test.Lab, and measurements were taken very efficiently," says Eder. "The broad bandwidth and number of channels enabled us to gather multiple types of data at one time, including vibration as well as acoustics. Also, analysis of the data such as determination of resonances (order analysis) could be done on the spot, and we had the capability to view selected results in real time if necessary, to identify parts of the test that might need further study later. Moreover, transferring results data from LMS Test.Lab to LMS Virtual.Lab was easy because of the tight integration between the two systems."
Virtual models simulate product performance
Eder explains that with LMS Virtual.Lab, he was able to model the complete powertrain suspension system, with total frequency response computed by multiplying the system’s NTF by its operating structural input loads for each mount based on its particular stiffness and operational displacement. In this way, transfer path analysis (TPA) in LMS Virtual. Lab determines the combined vibration at selected locations (ears of the driver and passenger) in the vehicle interior. After validating the correlation of the virtual model with test data, Woco engineers had a way to predict the effect of changes in the configuration of the suspension. Thus, they could optimize the behavior of the assembly by modifying the size and position of the mounts in the virtual world instead of on physical hardware. Guided by simulation results, engineers were able to significantly improve the anti-noise/ vibration performance of the suspension with modifications of the static and dynamic behavior of the mounts."LMS Virtual.Lab enabled us to study the impact of a variety of changes to the powertrain suspension and quickly arrive at the best overall design," says Waldemar Hermann, engineering development supervisor of the LaCrosse powertrain suspension project at Woco. "In this way, only a few hours were needed for us to work with simulations in evaluating a range of alternative configurations that otherwise would have taken weeks of trial and error in building and testing in hardware prototypes."Eder points out that such simulation was particularly helpful in resolving a particular problem with a "booming"
noise that appeared at 3,700 rpm during testing of the optimized powertrain suspension. Closer examination of the frequency response of the vehicle with a contribution analysis capability in LMS Virtual.Lab indicated 
that the engine mount suspension is not the cause for this " booming " at 3700 rpm. Presented with these findings, the customer did some further investigations on the exhaust system and indicated the orifice noise as the root cause for this booming problem. The customer modified the exhaust system regarding orifice noise , thus improving the vehicle design without needless delays that would have occurred when focusing on the suspension design.
that the engine mount suspension is not the cause for this " booming " at 3700 rpm. Presented with these findings, the customer did some further investigations on the exhaust system and indicated the orifice noise as the root cause for this booming problem. The customer modified the exhaust system regarding orifice noise , thus improving the vehicle design without needless delays that would have occurred when focusing on the suspension design."Contribution analysis is a powerful tool that enables us to see the source and intensity of vibrations immediately on plots and color-map displays," notes Hermann. "In this way, we are able to quickly determine which parts of the vehicle are responsible for the highest structural contribution in a certain problem zone. Without this capability, considerably more testing and guesswork would be needed to find the root cause of problems."
Collaboration with GM China
According to Eder, the efficiency of the LMS systems helps Woco work closer with customers such as GM China’s PATAC by providing quick turnaround in resolving problems and in meeting tight schedule deadlines throughout the program. Moreover, Woco and PATAC readily have the opportunity to exchange data files for further analyses and additional simulation work by the automaker on the overall vehicle. Eder found the LMS report generation features particularly beneficial in the LaCrosse program, with the capability soon to be provided for easily inserting live test data and simulation results into interactive reports.
Thus, PATAC engineers could easily click on and scroll through the data interactively to study specific areas in more detail or reuse the plots and animated images in their own documents and reports. In this way, Woco was able to demonstrate its expertise as well as its ability and willingness to collaborate globally with a customer on a critical vehicle development program.
