In this paper, the noise of HEV(hybrid electric vehicle)-relay module during the turn-on and turnoff switching is experimentally analyzed and an effective method is proposed to reduce the impact noise. First, enclosure methods of 100A relay part with urethane and silicon are tested to find out a better material to isolate the noise. This result shows that the urethane is a better for the noise isolation of relay, so the relays enclosed by urethane are installed in the relay module. Second, the noise of HEV-relay module is analyzed experimentally to identify the noise generation mechanism. From this result, it is found that the vibration transmitted to battery pack through bolt generates the structural borne noise with the frequency band of 200~2000 Hz, which is more serious when the switch is turned off. Finally, the direction of switching and the joint structure are modified in order to isolate the vibration transmitted to battery back. Both methods are very effective to reduce the switching noise.
