Mechanism Analysis and Integrated Optimization for Reducing Low-Speed Starting Noise in Electric Vehicles

To address the low-speed starting noise in a small electric vehicle, this study proposes and validates a systematic diagnostic and optimization methodology. A novel objective testing method, based on energy tracking and matching, is first employed for precise noise source localization. Combined with electromagnetic force wave analysis, this method identifies the coupling between a 24th-order motor excitation and a powertrain structural mode as the root cause. Subsequently, a low-cost, integrated optimization scheme is presented, which synergistically combines three strategies: motor control refinement, powertrain natural frequency tuning, and mount isolation enhancement. Experimental validation demonstrates that this multi-domain approach reduces the sound pressure level at the driver’s ear by 4–6 dB(A), effectively eliminating the abnormal audible noise during starting and significantly improving the in-cabin sound quality. This paper offers a cost-effective engineering framework for resolving low-speed, low-frequency noise problems in electric vehicles.