VDA Acoustic Evaluation of Brake Creep Groan Noise in Vehicle Tests 314 T-pull Test This non-binding recommendation by the German Association of the Automotive Industry (VDA) has the following objectives: It shall provide a recommended standard for the subjective assessment of creep groan in vehicles. It is intended for passenger vehicles with disc brakes. May 2016 Publisher: Verband der Automobilindustrie Behrenstrasse 35 10117 Berlin Phone +49(0)30/897842-0 Telefax +49(0)30/897842-606 Internet: www.vda.de Copyright Reprints and any other form of duplication is only permissible when the source is cited. VDA Recommendation 314 May 2016 Page 2 Disclaimer VDA recommendations are freely available for general use. The user is responsible for ensuring correct application for the specific case. They represent the latest technology available at the time of issue. Application of VDA recommendations does not relieve the user from responsibility for his own actions. In this regard, all users act at their own risk. VDA and those involved with VDA recommendations do not accept any liability. Anyone applying VDA recommendations who identifies inaccuracies or possible incorrect interpretations is invited to inform VDA immediately and any errors can thus be rectified. Copyright: VDA VDA Recommendation 314 May 2016 Page 3 Table of Contents 1 2 3 4 5 6 Scope ........................................................................................................................... 4 Measurement Equipment ............................................................................................. 5 2.1 Minimum requirements ..................................................................................... 5 2.2 Optional requirements....................................................................................... 5 Test Preparation ........................................................................................................... 7 3.1 Pre-conditioning of the brakes under consideration .......................................... 7 3.1.1 New sets of parts .............................................................................................. 7 3.1.2 Used sets of parts ............................................................................................. 8 3.1.3 Mixed sets of parts ............................................................................................ 9 3.2 Preparation of the test vehicle .......................................................................... 9 Text Execution (Minimum Requirements)................................................................... 10 4.1 Basic modules ................................................................................................ 10 4.2 Creep groan with cold brake ........................................................................... 10 4.3 Creep Groan with warm brake (TDisc = 50 – 100°C) ........................................ 11 Text Execution (Optional Requirements) .................................................................... 11 5.1 “Early-Morning” creep groan ........................................................................... 11 5.2 Creep-groan with gear set to ”D“ at a slope .................................................... 11 5.3 Creep-groan with warm engine and gear set to ”D“ on level road ................... 11 5.4 Reverse creep groan ...................................................................................... 11 5.5 Creep groan during quick pedal release ......................................................... 12 5.6 Creep groan with axle switch-off ..................................................................... 12 5.7 Creep groan during automated brake release ................................................ 12 5.8 Creep groan after severe pressure application ............................................... 12 5.9 “In-Stop” creep groan ...................................................................................... 12 5.10 Creep groan with fully heated brake (TDisc = 200 – 300°C) ............................. 13 5.11 Creep groan with a wet friction couple ............................................................ 13 5.12 Creep groan after water exposure .................................................................. 13 5.13 Creep groan after salt water exposure ............................................................ 13 Test Documentation ................................................................................................... 14 6.1 Header data .................................................................................................... 14 6.2 Result data minimum requirements ................................................................ 15 6.3 Result data optional requirements .................................................................. 15 6.4 Measurement equipment minimum requirements ........................................... 15 6.5 Measurement equipment optional requirements ............................................. 16 Copyright: VDA VDA Recommendation 314 May 2016 Page 4 1 Scope The present specification refers to acoustic investigations of wheel brakes in vehicle tests, thus, on the built-in configuration within the full vehicle. It is designed for passenger cars with disc brakes and organically bound brake pads, however, an application to alternative vehicles or friction brakes is not excluded. The vehicles under consideration do not need to be series cars. In any case, the setup of the test object (e.g. pre-series vs. prototype car) and possible deviations from the series/project state that affect acoustic transfer paths must be documented. An application of this specification is particularly recommended for any wheel brake at the beginning of the noise development process (e.g. in the phase of friction material selection), at specific project milestones that affect tool release decisions and in the phase of final system release. In order to ensure on the one hand a feasible integration into daily testing routines, and to allow on the other hand deeper studies, as they are e.g. important for correlation studies with dynamometer tests or simulation models or for the simulation of severe ambient conditions (e.g. contact of the brake parts with salt water), this specification distinguishes between minimum (section 4) and possible optional requirements (section ). An execution of the optional requirements is recommended at least twice during each development project, thereof, once in the phase of final system release. Besides, the optional requirements are recommended, whenever the oscillation system was subject to larger technical modifications (e.g. technological friction material modifications or updates of axle components). Attachment: Excel Document „EKB 3012 Assessment Brake Creep Groan.xls“ Copyright: VDA VDA Recommendation 314 May 2016 Page 5 2 Measurement Equipment 2.1 Minimum requirements For each test, the following measurement equipment is compulsory: 1) Irrespective of optional technology according to section 2.2, a sound level meter with the following specifications/settings is always required: o Integrated sound level meter, class 1, according to specification IEC 61672 with type approval o Frequency range: 20 – 20.000Hz o Fast time weighting o ‘A’ frequency weighting o Dynamic range: 120dB During testing, the sound level meter must be positioned in the middle of the vehicle slightly behind the gearshift on the gearshift’s level. For the sake of safety, an attachment directly adjacent to the driver’s ear is not part of this specification. 2) Suitable hardware to display the brake line pressure of the vehicle’s bus system, optionally: installation of separate, commercially available pressure sensors. 3) Handheld infrared thermometer, with the emission coefficient of the brake disc material being implemented. 2.2 Optional requirements Optionally, a full equipment of the vehicle with measurement technology is possible and especially recommended at release milestones or for correlations with dynamometer tests or simulations. The full setup includes: 1) Thermocouples type K, with the following locations being allowed: o Inside the brake discs (at least one per axle). The attachment must be flush mounted to the frictional surface, in radial direction ideally in the middle of the friction ring. For single piece discs, the attachment must be at the friction ring’s side that is not attached to the disc hat. For assembled discs, attachment must be on the brake disc’s outer side. This type of thermocouple positioning replaces the handheld infrared thermometer mentioned above. o alternatively: dragging along the disc’s friction surface (at least one per axle). The exact location must be defined and documented spefically for each project. This type of thermocouple positioning replaces the handheld infrared thermometer mentioned above. o alternatively: inside the brake pads (at least one per axle). The exact location must be defined and documented spefically for each project. A distance of 1 – 3mm to the friction surface must be ensured. It must be noted that temperatures inside the brake pad will deviate from those Copyright: VDA VDA Recommendation 314 May 2016 Page 6 measured on the brake disc, both, in terms of time dependence and absolute value. 2) Artificial head measurement system, head frame or interior microphone with the following technical specifications: o Diffuse-field condenser microphone o Pre-polarized and with integrated pre-amplifier (IEPE1 or similar) o Frequency range: 20 – 20.000Hz o Dynamic range: 146dB o Temperature range: –20 – 100°C o Ability to record audio files (incl. calibration data, at least 20 noise events, 10 seconds length each, for a later PC-based analysis). An artificial head measurement system or a head frame microphone carried by the driver is preferred to a simple interior microphone. If such a system is not used, the interior microphone must be installed at the identical position as the sound level meter (section 2.1). The major sensitivity direction of the microphone must be oriented to the vehicle’s front along its longitudinal axis. 3) Wheel house microphone (1 per wheel) with the following technical specifications: o Frequency range: 20 – 20.000Hz o Temperature range: –20 – 100°C o In endurance runs, water and rock fall resistance of the microphones must be ensured. The location and attachment point must be precicely documented. A photographic documentation once per project is in addition recommended. 4) Acceleration sensor with the following technical specifications: o Piezo-electric sensor with integrated pre-amplifier, ideally triaxial (IEPE1 or similar) o Frequency range (± 5%): 20 – 5000Hz o Temperature range: –20 – 100°C o Temperature resistance: ≥ 150°C o Mass: < 5g The acceleration sensor must be attached with two-component adhesive (e.g. X60) in such a way that the sensitivity direction/s is/are in line with the brake’s coordinate system. Especially for correlating vehicle tests with simulation models or dynamometer setups, optional acceleration sensors are recommended. One should be attached to one of the screws that fixes the caliper against the knuckle. (Quantification of the vibrational excitation introduced into the axle). 1 IEPE - Integrated Electronics Piezo Electric Copyright: VDA VDA Recommendation 314 May 2016 Page 7 3 Test Preparation 3.1 Pre-conditioning of the brakes under consideration 3.1.1 New sets of parts With regard to newly assemled wheel brakes, it is up to the user of this specification to execute a run-in procedure prior to testing or not, depending on the test objective. The following procedures are possible: No run-in procedure, thus, tests are executed on purpose with „green“ friction couples Run-in procedure according to a brand or company specific standard The standard used (e.g. company specification) must be noted in the test documentation. Run-in via a short distance of 2 x 50km (± 10km) = 100km (± 20km), interurban driving profile including urban situations, decelerations within the range of typical customer behaviour In case the disc’s surface does not show a significantly modified, homogeneous contact (e.g. with NAO brake pads), additional 50km (± 10km) can be run. This case must be noted in the test documentation. The maximum brake disc temperature should not exceed 200°C. In any case, values beyond 250°C must not be reached. This type of preconditioning requires temperature measuerment technology according to section 2.2. Specifically for the project, the route must be defined and documented. GPS data can serve as a basis, as well as company specifications that describe an exact route. Subsequent to this procedure, the vehicle must be put to rest at the test location for at least 6 and maximum 18 hours. The exact boundary conditions during the rest period must be documented, especially approximate temperatures and air humidity. It is recommended to put the vehicle to rest over night (12-14 hours). In case of high demands on the later test reproducibility, dry ambient conditions are recommended. After pre-conditioning and before starting the actual test, the brakes should be applied only that much that the vehicle safely comes to a standstill. Copyright: VDA VDA Recommendation 314 May 2016 Page 8 3.1.2 Used sets of parts For brake systems that were subject to severe or unknown thermal pre-conditioning or that have been used in a driving profile beyond the standard customer usage, it is recommended to newly assemble all wheel brakes. The same yields for optical conspicuities (e.g. temper or corrosion spots at the disc surface), which make it questionable that the vehicle and its parts are part of a representative sample. In detail, it is the responsibility of the user of this specification to decide whether the wheel brakes must be replaced or not. For all vehicles with wheel brakes that have already been used (e.g. due to previous tests with another technical focus), a complete documentation is required that summarizes the pre-conditioning of the brake parts prior to the creep groan tests. For minimum requirements see section 6. In order to homogenize the contact and friction physics, the following steps are required, unless already done in identical parameter regimes during previous driving: 50km (± 10km) interurban driving profile including urban situations, decelerations within the range of typical customer behaviour In case the disc’s surface does not show a significantly modified, homogeneous contact (e.g. with NAO brake pads), additional 50km (± 10km) can be run. This case must be noted in the test documentation. The maximum brake disc temperature should not exceed 200°C. In any case, values beyond 250°C must not be reached. This type of preconditioning requires temperature measuerment technology according to section 2.2. Specifically for the project, the route must be defined and documented. GPS data can serve as a basis, as well as company specifications that describe an exact route. Rest period at the location of testing for at least 6 and maximum 18 hours. The exact boundary conditions during the rest period must be documented, especially approximate temperatures and air humidity. It is recommended to put the vehicle to rest over night (12-14 hours). In case of high demands on the later test reproducibility, dry ambient conditions are recommended. After pre-conditioning and before starting the actual test, the brakes should be applied only that much that the vehicle safely comes to a standstill. Copyright: VDA VDA Recommendation 314 May 2016 Page 9 3.1.3 Mixed sets of parts It is not recommended to equip the vehicle with differently pre-conditioned parts, e.g. new parts at the front axle in combination with parts from an endurance run at the rear axle. If a vehicle is in such a state, it is recommended to newly assemble all wheel brakes together with an application of section 3.1.1. If this is not possible at all, at least each axle must be equipped with identically preconditioned parts. In this case, section 3.1.2 must be applied. 3.2 Preparation of the test vehicle In order to ensure reproducible tests, the following steps with regard to vehicle settings are required: Climate compressor and radio must be switched off Ventilation must be set to level 1 or lower All doors (including trunk) must be closed. For convertibles, the soft/hard top must in addition be closed. Setup and documentation of a defined opening of the side windows Opening of the side windows must be documented specifically for each project. In addition, tests with fully open side windows are recommended at least in the phase of final system release. Defined (de-)activation and documentation of driver assistance systems, which automatically control the wheel brakes at low speed and/or at rest („auto hold“, „hill hold“ etc.) Copyright: VDA VDA Recommendation 314 May 2016 Page 10 4 Text Execution (Minimum Requirements) 4.1 Basic modules In order to execute the tests, both, a level road and a constant slope must be available. The inclination must be defined and documented specifically for each project, with a slope of 10 – 16% being recommended. As basic modules, to which is referenced in the following sections, the following two sequences are defined: 1) Groan with gear set to “D” on level road (automatic transmission, only) Holding of the vehicle via the service brake (parking brake being released), then slow release of the brake line pressure until the vehicle starts to move, therein, modulation of the brake line pressure via the pedal, such that the vehicle and its wheel brakes are a maximum amount of time within the stickslip regime (goal is to hold the groan noise the maximum amount of time possible). Execution of 5 tests in total. For these tests, the engine idle speed prior to starting the procedure must be documented. If the test is run without the combustion engine being switched on, the engine idle speed must be documented as zero (e.g. battery electric or hybrid vehicle). 2) Groan with engine running idle / with gear set to ”N“ at a defined slope Holding of the vehicle at the beginning of the slope via the service brake (parking brake being released), then slow release of the brake line pressure until the vehicle starts to move, therein, modulation of the brake line pressure via the pedal, such that the vehicle and its wheel brakes are a maximum amount of time within the stick-slip regime (goal is to hold the groan noise the maximum amount of time possible). Execution of 5 tests in total. For these tests, a documentation of the engine idle speed is not required. However, if tests are run without the combustion engine being switched on, the engine idle speed must be documented as zero (e.g. battery electric or hybrid vehicle). For hybrid vehicles, it is up to the user of this specification to run the tests in fully electric mode or with the combustion engine being switched on. In case the combustion engine is automatically switched on or off during the test sequence (within the 5 individual tests), the respective module must be repeated and the new background sound pressure level documented. 4.2 Creep groan with cold brake Execution of the basic modules (section 4.1) immediately after the vehicle’s rest period (cold engine, cold brakes) according to section 3.1. The brake disc temperature at the beginning of the tests must be documented. Copyright: VDA VDA Recommendation 314 May 2016 Page 11 4.3 Creep Groan with warm brake (TDisc = 50 – 100°C) Execution of the basic modules (section 4.1), with the vehicle and its wheel brakes being conditioned as follows: Adjustment of brake disc temperatures in the range of 50 – 100°C Therefore, stop brake applications from 60km/h to 5km/h, deceleration being 0,3g (± 0,1g) Time between two consecutive brake applications being 20 – 40 seconds 5 Text Execution (Optional Requirements) The following tests represent optional supplements to the content of section 4. It is up to the user of this specification or the responsible person in charge of the particular project to define, if the full content or only some subsections are defined as relevant. In any case, an overall test sequence in line with the sequence of the following subsections is recommended. 5.1 “Early-Morning” creep groan Execution of the sequence according to section 4.2, with all brake disc temperatures being below 10°C during the last 6 hours prior to the test. At least in the phase of final system release, tests at negative Celsius temperatures are recommended. 5.2 Creep-groan with gear set to ”D“ at a slope Repetition of part 2) according to section 4.1 with gear set to “D” (automatic transmission, only). The vehicle’s idle speed must be documented. Prior to the test, all brake disc temperatures must be below 50°C. 5.3 Creep-groan with warm engine and gear set to ”D“ on level road Repetition of part 1) according to section 4.1, with the combustion engine having run for at least 20 continuous minutes prior to the test (automatic transmission, only). Prior to the test, all brake disc temperatures must be below 50°C. 5.4 Reverse creep groan Execution of the basic modules (section 4.1), however, with the vehicle driving backwards / being oriented backwards at the slope. Prior to the test, all brake disc temperatures must be below 50°C. Copyright: VDA VDA Recommendation 314 May 2016 Page 12 5.5 Creep groan during quick pedal release Execution of the basic modules (section 4.1), however, in contrast to the descriptions above, it is not the goal to hold the groan noise the maximum amount of time possible. It is rather the aim to simulate typical customer behavior and not the most critical state. Prior to the test, all brake disc temperatures must be below 50°C. 5.6 Creep groan with axle switch-off Execution of the basic modules (section 4.1), however, with a previously mounted axle deactivation, the front or rear axle is not active during the test procedure. The axle deactivation must be documented. In addition, it must be considered that release pressure and torque will differ from the situation with both axles being active. Prior to the test, all brake disc temperatures must be below 50°C. 5.7 Creep groan during automated brake release Assessment of all functions with respect to creep groan noise that automatically release the vehicle brake while torque is applied. The assistance systems (e.g. “hill hold”, “auto hold”) must be used according to the later average customer. Prior to the test, all brake disc temperatures must be below 50°C. 5.8 Creep groan after severe pressure application Execution of the basic modules (section 4.1), however, prior to the test, a brake line pressure of 80 – 100 bar must be applied for a time of 10 – 15 seconds, with the vehicle being at rest. Prior to the test, all brake disc temperatures must be below 50°C. 5.9 “In-Stop” creep groan Assessment of creep groan noise in the phase of the vehicle coming to standstill. Prior to each of the test cycles with 5 brake applications specified below, all brake disc temperatures must be below 50°C. After each test cycle, the final disc temperatures must be documented. 5 stop brake applications at 30kph, brake line pressure being 5bar 5 stop brake applications at 30kph, brake line pressure being 10bar 5 stop brake applications at 30kph, brake line pressure being 15bar Copyright: VDA VDA Recommendation 314 May 2016 Page 13 5.10 Creep groan with fully heated brake (TDisc = 200 – 300°C) Execution of the basic modules (section 4.1), with the vehicle and its wheel brakes being conditioned as follows: Adjustment of brake disc temperatures in the range of 200 – 300°C Therefore, stop brake applications from 60km/h to 5km/h, deceleration being 0,3g (± 0,1g) Time between two consecutive brake applications being 20 – 40 seconds This type of pre-conditioning strongly requires installed temperature measurement equipment according to section 2.2. 5.11 Creep groan with a wet friction couple Execution of the basic modules (section 4.1), with all brakes being sprayed with standard tab water in such a way that the outer friction ring of each disc is homogeneously covered with a water film. No water should be sprayed into brake caliper openings. Before starting the test, the vehicle must be moved according to three disc revolutions, in order to allow the water to also reach the brake pads. Prior to the test, all brake disc temperatures must be below 50°C. Following this test, it is not allowed to execute tests other than the ones specified in section Fehler! Verweisquelle konnte nicht gefunden werden., Fehler! Verweisquelle konnte nicht gefunden werden. and Fehler! Verweisquelle konnte nicht gefunden werden.. In case other modules are required, a new experiment including new pre-conditioning according to section 3.1 must be set up. 5.12 Creep groan after water exposure Identical procedure as the one described in section Fehler! Verweisquelle konnte nicht gefunden werden., however, the vehicle must be at rest for at least 6h after water spraying and prior to the test (soaking time). Following this test, it is not allowed to execute tests other than the ones specified in section Fehler! Verweisquelle konnte nicht gefunden werden. and Fehler! Verweisquelle konnte nicht gefunden werden.. In case other modules are required, a new experiment including new pre-conditioning according to section 3.1 must be set up. 5.13 Creep groan after salt water exposure Identical procedure as the one described in section Fehler! Verweisquelle konnte nicht gefunden werden., however, instead of standard tab water, salt water with a concentration of 5 mass-% NaCl (sodium chloride) must be used. Following this test, it is not allowed to execute tests other than the one specified in section Fehler! Verweisquelle konnte nicht gefunden werden.. In case other modules are required, a new experiment including new pre-conditioning according to section 3.1 must be set up. Copyright: VDA VDA Recommendation 314 May 2016 Page 14 6 Test Documentation For the documentation of vehicle and brake data, the test preparation, the subjective and objective results, as well as the measurement equipment installed, the Excel document “EKB 3012 Assessment Brake Creep Groan.xls”, which is attached to this specification, must be used. The individual sections of the documentation are described in the following. 6.1 Header data Date and time of the experiment Test location (e.g. proving ground) Type of vehicle (project or model name) Licence number Assessor Company executing the experiment Milage of the vehicle prior to the test Vehicle weight (approx.) and information on loading conditions (partly vs. fully loaded) Vehicle state (techology demonstrator vs. prototype vs. series car) Pre-condition (new setup vs. bedded according to a brand or company specific standard vs. other driving profile described as text) Result of a visual assessment of the wheel brakes Detailed specification of the brake pads used: o Description o Batch o Version (e.g. from prototype tool vs. series parts) o Part number o Setup date (installation in the vehicle) o Setup milage o Secondary measures (anti-noise shim, chamfer) o Compressibility Detailed specification of the brake disc and caliper used, for each of them: o Description o Version (e.g. from prototype tool vs. series parts) o Part number Detailed specification of the rim and tire used, for each of them: o Description o Version (e.g. from prototype tool vs. series parts) o Part number Comments in the field ”Other“. Here, information on the test preparation Copyright: VDA VDA Recommendation 314 May 2016 Page 15 according to section 0 (active assistance systems, opening of the side windows etc.) is particularly required. 6.2 Result data minimum requirements Information on the pre-conditioning: o Ambient temperature at the vehicle o Relative air humidity at the vehicle o Rest period Conditions at the test location: o For tests at an inclination: slope in percent o Ambient temperature o Relative air humidity o Weather conditions Objective noise data: o Background sound pressure level in dBA o Engine idle speed in min-1 (zero, in case test is driven in fully electric mode) o Brake disc temperature prior to and after the test o Brake line pressure in bar during the vehicle’s onset of motion o Maximum and average sound pressure level in dBA during the 5 individual tests of each module (section 4.1) Subjective noise data: o Rating between 1 and 10 on a scale of 1 = ”annoying/long/loud“ and 10 = ”not recognizable“, with the driver ear being the location of evaluation o Evaluation of the loudness according to the categories ”loud“, ”audible“ and ”hardly audible “ o Evaluation of the noise ductility (ability to hold the groan noise) according to the criteria ”long“, ”short“ und ”almost no“ Comments to any conspicuities during the test, e.g. ”dominant drumming noise“ All entries mentioned here are required separately for each individual module. For climate data, the accuracy of internet/smartphone information is sufficient for a location being within a radius of 50km relative to the test location. 6.3 Result data optional requirements For the additional requirements (section Fehler! Verweisquelle konnte nicht gefunden werden.), the documentation is equivalent to section Fehler! Verweisquelle konnte nicht gefunden werden.. In this case, the column „module“ is not pre-filled. Instead, it is the user’s responsibility to fill this column according to the selected test modules. For the module 5.9 “In-Stop” creep groan, individual fields under ”test conditions“ are again pre-filled. 6.4 Measurement equipment minimum requirements Copyright: VDA VDA Recommendation 314 May 2016 Page 16 Data specifying the sound level meter and the thermocouples: o Mounting position o Inventory number o Type o Way of installation 6.5 Measurement equipment optional requirements Data specifying the artificial head measurement system, if installed Data specifying wheel house microphones, documentation of the installation position Data specifying all acceleration sensors, if installed Copyright: VDA if installed, including