BMW puts new aeroacoustics and e-drive center into operation

Measuring and testing BMW puts new aeroacoustics and e-drive center into operation

2024-12-22 From | Translated by AI 3 min Reading Time

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BMW puts new aeroacoustics and e-drive center into operation

The new aeroacoustics and e-drive center of BMW has started operations at the research and innovation center. After almost forty years, the car manufacturer is thus replacing the old aeroacoustic wind tunnel.(Image: BMW) — The new aeroacoustics and e-drive center of BMW has started operations at the research and innovation center. After almost forty years, the car manufacturer is thus replacing the old aeroacoustic wind tunnel.
(Image: BMW)

The new building consists of two parts: Alongside a multifunctional section with workshop, testing, and measuring facilities as well as a prototype construction for high-voltage batteries and inverters, there is a technically and structurally new wind tunnel in the Aeroacoustic and E-Drive Center (AEZ). With a length of nearly 100 m (approx. 328 ft), a height of 45 m (approx. 148 ft), and a width of 25 m (approx. 82 ft), it is described by the manufacturer as "the world's largest acoustic wind tunnel in vertical construction and at the same time the quietest."

Precisely measure noises

With a background noise level of 54.3 dB(A) at 140 km/h (approx. 87 mph), the noises caused by the airstream on the vehicle can be precisely measured in the new wind tunnel. With a nozzle cross-section of 25 m² (approx. 269 ft²)and a maximum wind speed of 250 km/h (approx. 155,3 mph), even vehicles like the Rolls-Royce Phantom or the BMW X7 can be realistically examined. The company achieves this with a fan power of 4.5 MW and up to 100,000 m³ (approx. 130795 yd³) of air per minute at 250 km/h (approx. 155,3 mph). The wind tunnel is designed as an acoustic semi-free field room, which means that no sound reflections occur except from the hard floor. This allows for a realistic simulation of road conditions. The frequency range for the semi-free field conditions from 30 Hz covers the entire audible spectrum.

Test wind and rolling noises

The acoustic wind tunnel is equipped with modern measurement technology to advance vehicle development. A 216-microphone acoustic camera allows for precise localization of noise disturbances with an accuracy of less than one centimeter. Moreover, the wind tunnel features a laser vibrometry system, enabling the synchronous and contactless measurement of mechanical vibrations across the entire vehicle surface.

The wind tunnel is also equipped for the investigation of wind and rolling noises. A full-fledged acoustics all-wheel-drive roller test bench can be used independently of wind and weather to analyze various phenomena. The wind tunnel is designed to offer high flexibility in conducting measurements.

The wind-roll noise facility offers the possibility to separate the phenomena of rolling and wind (wind on/off, roll on/off). Additionally, various modules, such as a vehicle-drivable glass floor or a motorcycle scale, can be exchanged quickly without moving the vehicle. This enables developers to test different configurations quickly and efficiently.

Flexibility in construction

The AEZ essentially consists of two buildings constructed in an excavation pit. Structurally, the special acoustic requirements were met by uniquely decoupling the wind tunnel from the second "semi-detached house" and the surroundings. The entire building, from the 3-meter-thick base plate (approx. 10 ft) to the facade, is acoustically isolated from noise from the surroundings. All construction work was carried out while development operations continued in the adjacent buildings. To make efficient use of the building site, the wind tunnel was designed to stand upright. This was the only way to fully meet all the requirements for both buildings on the available space.

Focus on electromobility

In the second "semi-detached house" of the AEZ, there are workshops, test and measurement stands, as well as prototype lines. The focus here is also on electromobility. The company builds and tests prototypes of future high-voltage batteries for electric vehicles. For this purpose, 15,000 m² (approx. 17939,8 yd²)are available on several floors. On an additional area of 800 m² (approx. 956,8 yd²), inverters for future electric motors are manufactured on a pilot line under cleanroom conditions.

To be positioned flexibly in the long term, the areas in the AEZ are designed to be "multifunctional." This means: The company can also respond to various requirements in the future and convert the areas in a short time. (se)

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