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The "Silent Revolution" of the battery pack: Decoding Polyenergy New Energy's NVH engineering
time：2026-07-30
When consumers talk about electric vehicles, endurance, safety and charging speed are often the focus. However, one dimension of experience is often neglected-quietness. In addition to the low frequency noise of the motor, the road noise of the tire, and the wind noise, there is also an invisible noise source: battery pack. In NVH (noise, vibration and roughness) laboratory, which gathers new energy sources, a technological revolution about "making battery pack quiet" is quietly advancing.
1. Neglected noise source: Why does battery pack sound "?
Battery pack is supposed to be a silent energy container, but in actual operation, various physical mechanisms will generate vibration and noise.
Cell Expansion Force is the primary incentive. When lithium ions are embedded and detached in positive and negative electrode materials, the thickness of cell will change periodically-charging expansion and discharge contraction. The mechanical stress generated by this "breathing effect" is transmitted to the box through the module structure, causing low frequency vibration. The expansion rate of high nickel ternary cell can reach 2%-4%, especially under fast charging conditions.
Switching action of relay and contactor it is another type of noise source. The high-voltage DC relay generates a high-frequency "click" sound when the contacts collide at the moment of suction and disconnection. Although the single sound is weak, it is frequent.In the energy storage scene of charging and discharging, the accumulated auditory experience cannot be ignored.
Coolant flow and bubble disturbance the same contribution to noise. In the liquid cooling system, the coolant flows at a high speed in the flow channel, and turbulence occurs when the elbow or cross section changes suddenly; If bubbles exist in the pipeline, random cavitation noise will be triggered.
"NVH is not luxury, but a hidden indicator of quality. "The NVH engineer of energy gathering new energy explained," when the vehicle quietness reaches the library level (below 35dB), any abnormal sound from battery pack will be infinitely amplified. "
II. Electric the rate of pillow inner vibration suppression: starting from "source noise reduction"
NVH optimization of energy-gathering new energy began cell with micro-design of modules.
Pretightening force optimization is the core strategy. Through finite element simulation and experimental iteration, the new energy source determines the optimal clamping force range of cell-which can not only inhibit expansion displacement, but also prevent uneven electrolyte infiltration due to overvoltage. The module frame adopts gradient stiffness design, with rigid support in the central region and flexible transition in the edge region to evenly disperse the expansion force and avoid structural resonance caused by stress concentration.
visco-elastic damping layer it is like wearing shock-absorbing underwear for cell ". Between the cell and the module frame, the new energy source is equipped with special polymer damping materials to convert mechanical vibration energy into heat dissipation. The loss factor of this material remains stable in a wide temperature range (-40℃ to 80℃) to ensure the vibration suppression efficiency under all climatic conditions.
III. System-level vibration isolation: a "firewall" that blocks vibration transmission"
once vibration is generated, blocking its transmission path is the key.
Box structure optimization follow the triangular balance of "mass-stiffness-damping. The new energy gathering energy adopts topology optimization algorithm, and a reinforcing rib network is arranged inside the box to move the overall modal frequency out of the common excitation frequency band (20-200Hz) of the whole vehicle. At the same time, the installation point of the box and the body adopts hydraulic bushing and rubber pad composite vibration isolation, and the transmission rate is reduced by more than 60%.
Relay noise reduction from the electromagnetic and mechanical two-pronged approach. The new energy source of energy accumulation adopts permanent magnet magnetic holding relay, which does not need to be continuously powered and maintained after suction, thus fundamentally eliminating coil ringing. The contacts are made of silver alloy composite material, which optimizes the closure velocity diagram to minimize impact.
IV. Channel acoustic design: Let the coolant "flow quietly"
noise Control of liquid cooling system is another highlight of NVH project of energy gathering.
Gradient Design of runner section the turbulence and vortex shedding caused by section mutation are avoided. Through CFD simulation optimization, the flow channel elbow adopts a large radius of curvature (R/D ≥ 3), and Baffler is arranged on the inside to restrain the flow separation in the minimum range.
Bubble management equally particular. The liquid cooling system of energy gathering new energy adopts high exhaust + vacuum filling technology to ensure that the residual rate of bubbles in the pipeline is less than 0.1%. During operation, the dissolved gas is continuously separated by removing gas tank to prevent bubbles from accumulating with circulation. The selection of coolant pump has also been optimized by acoustics. Shielded magnetism Forle pumps is used to replace traditional pump with mechanical seal, reducing fluid noise by 8dB.
V. Verification: Acoustic "physical examination" from laboratory to real scene"
NVH optimization results require rigorous verification.In the semi-anechoic chamber that gathers new energy sources, battery pack is placed in the center of the six-side microphone array and runs under simulated vehicle conditions. Sound intensity measurement, Operational Modal analysis (OMA), transmission path analysis (TPA) and other means are comprehensively applied to accurately locate the noise source and quantify the contribution.
The more realistic test comes from road testing. The test fleet of energy new energy sources covers typical road conditions such as rough asphalt, speed bump and cobblestone roads, and collects battery pack acoustic responses under vibration excitation. After the data is returned, it is cross-verified with the laboratory results and continuously iteratively optimized.
"Our goal is: under the idle state of the whole vehicle, the contribution of battery pack to the noise inside the vehicle is less than 1dB. "NVH engineers show the test report," which means that users can hardly perceive the existence of battery pack-and the best technology is to make people forget its existence. "
the silent revolution of battery pack is a deep insight into the user experience from new energy sources. When the industry is still chasing the number of endurance and fast charging rate, energy gathering new energy choose to return to the essence of senses-let electric vehicles not only run far and charge fast, but also be quiet and elegant. From micron-level suppression of cell expansion force to acoustic optimization of coolant flow, every detail is a practice of the concept of "silence is luxury.
Contact us
Dongguan Juneng New Energy Technology Co., Ltd.
137 5142 6524（Miss Gao）
susiegao@power-ing.com
Xinghuiyuan High tech Industrial Park, Dalang Town, Dongguan City, Guangdong Province
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