You are on page 1of 59

P11221 - Noise Reduction for

Internal Combustion Engines


Team Leader: Christopher Morehouse
Mechanical Engineers: - Julie Maier
- Caroline Bills
- Ted Zachwieja
Faculty Advisor:
Ed Hanzlik
Customer:
Dr. Alan Nye

Agenda

Problem Overview
Project Objectives
Customers and Users
Project Flow Chart & Plan
Engine Model Overview
Design Options
Design Feasibility
Next Steps
Questions & Discussions

Background
Noise abatement - growing field
Formula SAE Sound Constraints
Conventional Methods Reduce
Performance
No RIT Background in this Field
Multiple Applications Possible
Customer:
Users:

Dr. Nye
Formula SAE Team
EE 2010-2 Team

Project Scope

Investigate physics of sound generation and transmission


Identify and locate major noise contributors in ICE
Analyze and model noise generation of ICE
Propose design for noise reduction mechanism
Provide background to EE team for parallel ANC project
Provide noise reduction demonstrator for Spring 2011
ImagineRIT

Project Deliverables
Engine Sound Model
ANC System Constraints
Demonstrator for ImagineRIT

Project Overview

Project Breakdown
Research
Topics

Electrical
(ANC)
NOISE
REDUCTION
Analyze
SAE Engine

Mechanical
Proposals

Detailed Project Breakdown


Packaging
& Layout

Research
Topics

Specs &
Documents

Sound

Electrical
(ANC)
NOISE
REDUCTION

Sound
Generation

Mechanical
Proposals

Analyze
SAE Engine
Passive

Active

Gather Data
(Engine Characterization)
Resonator

Absorptive

Resonator

Internal
Combustion
Engine

Current
Muffler/Exhaust
Systems

Customer Needs

Engineering Specifications

Relationship Diagram

ES 1

Reduce noise level

ES 4

Passes B10.2.1 of the SAE Formula rules

ES 7

Component Costs

ES 12 Change in Engine Max Power

The Plan
ID
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

Task Name
Project Planning
Obtain Customer Needs (continuous)
Define Engineering Specifications
Create Preliminary Plan
Define Possible Risks (preliminary)
Create / Define Team Norms & Values
Choose Team Leader
Benchmarking / Research
Physics of Sound
Sound Measurement
Internal Combustion Engine
Current Noise Reduction Methods
Concept Generation (Noise Reduction)
Contact Acoustics Experts (D-R & Dr. Wyffels)
Validate Assumptions
Become Familiar with Sound in Mufflers
Research Absorption Materials - Muffler Design
Research Anti-Phase Design
Create List of Design Options
System Analysis
Feasibility Study of Available Designs
Risk Assessment - Updated
Obtain Actual Sound Exhaust Recording & Measurements
Create Visual Aids - Exhaust System Layout (black boxes)
Compile Presentation & Practice
Perform System Level Design Review

Duration

Start

Finish

15 days
8 days
8 days
1 day
1 day
1 day
1 day
7 days
7 days
7 days
7 days
7 days
10 days
2 days
2 days
12 days
2 days
7 days
4 days
5 days
3 days
1 day
2 days
1 day
2 day
1 day

Fri 9/10/10
Fri 9/10/10
Fri 9/17/10
Thu 9/23/10
Thu 9/23/10
Thu 9/23/10
Thu 9/23/10
Fri 9/10/10
Fri 9/10/10
Fri 9/10/10
Fri 9/10/10
Fri 9/10/10
Fri 9/24/10
Mon 9/27/10
Mon 10/4/10
Fri 9/24/10
Wed 9/29/10
Fri 9/24/10
Fri 10/1/10
Mon 10/4/10
Mon 10/4/10
Wed 10/6/10
Mon 10/4/10
Wed 10/6/10
Wed 10/6/10
Fri 10/8/10

Fri 9/24/10
Fri 9/17/10
Fri 9/24/10
Thu 9/23/10
Thu 9/23/10
Thu 9/23/10
Thu 9/23/10
Thu 9/16/10
Thu 9/16/10
Thu 9/16/10
Thu 9/16/10
Thu 9/16/10
Tue 10/5/10
Tue 9/28/10
Tue 10/5/10
Tue 10/5/10
Thu 9/30/10
Thu 9/30/10
Mon 10/4/10
Fri 10/8/10
Wed 10/6/10
Thu 10/7/10
Tue 10/5/10
Wed 10/6/10
Thu 10/7/10
Fri 10/8/10

September
10 17 24
x x x
x x
x x
x
x
x
x
x x
x x
x x
x x
x x
x
x
x
x
x

Concrete Date
Topic
Task
complete task

October
8 15 22 29

x
x
x

x
x

x
x

The Plan
ID
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51

Task Name
Engine Characterization
Define Process & Inputs
Look at Current Formula car
Determine Sensors & Equipment need
Acquire Sensors & Other Equipment (if needed)
Set-up Formula Car for Testing
Obtain Data from Formula Car
Analyze Data - Create "Map" of engine
Detailed Design Analysis
Update Risk Assessment
Develop Best Mechancial Option(s)
Develop System Layout (Anti-Phase Design)
Develop Packaging (Anti-Phase Design)
Final Design Analysis
Update Risk Assessment
Formalize Engine Characterization results
Compile Data & Information for EE's
Perform Detailed Design Review
Project Review
Perform Project Review
Complete & upload all documentation on EDGE
MSD II Preparation / Planning
Order materials and parts needed
Create Specification Sheet and Summary for EE's
Create WBS and Plan / Schedule

Duration

Start

Finish

7 days
2 day
1 day
1 day
5 days
1 day
1 day
2 days
28 days
1 day
28 days
28 days
28 days
7 days
1 day
2 days
2 days
1 day
1 day
1 day
3 days
7 days
2.5 mo
2 days
6 days

Mon 10/4/10
Mon 10/4/10
Fri 10/8/10
Tue 10/5/10
Tue 10/5/10
Thu 10/14/10
Thu 10/14/10
Thu 10/14/10
Sat 10/9/10
Sat 10/9/10
Sat 10/9/10
Sat 10/9/10
Sat 10/9/10
Wed 11/3/10
Thu 11/4/10
Wed 11/3/10
Wed 11/3/10
Fri 11/5/10
TBD
TBD
Mon 11/15/10
Mon 11/15/10
Mon 11/15/10
Tue 11/16/10
Fri 11/12/10

Thu 10/14/10
Tue 10/5/10
Fri 10/8/10
Tue 10/5/10
Sat 10/9/10
Thu 10/14/10
Thu 10/14/10
Fri 10/15/10
Thu 11/4/10
Sat 10/9/10
Thu 11/4/10
Thu 11/4/10
Thu 11/4/10
Thu 11/4/10
Thu 11/4/10
Thu 11/4/10
Thu 11/4/10
Fri 11/5/10
TBD
TBD
Wed 11/17/10
Wed 11/17/10
Mon 2/28/11
Wed 11/17/10
Wed 11/17/10

September
10 17 24

Concrete Date
Topic
Task
complete task

October
8 15 22 29

x
x

November
5 12 19

Risk Assessment

Risk Assessment

Risk Assessment

Research & Benchmarking

Sound is Pressure

http://www.school-forchampions.com/science/noise_cancellation.htm

How We Measure Sound


Digital Signal
Processing
Decibel Meters
Sound Pressure
Indicators

IC Engine Sources

Pressure Waves

Engine Model

MECHANICAL DESIGN
OPTIONS

Current Design
Glass Pack
Low Flow
Restriction
Low Noise
Attenuation

Unpacked Concentric Tube


Resonators
Design #1: Single-pass
Design #2: Multi-pass
Passive

http://www.eastsidemufflers.com/mufflers.htm

Design #1: Single-pass


Resonating
Chamber

Inner Pipe

Exhaust Gas
Flow

Sound Waves
Holes in pipe

Design #2:
Multi-pass
Exhaust Gas
Flow

Resonating Chamber

Exhaust Gas
Flow

Packed Concentric Tubes


Design #3: Metal Foam
Design #4: Full Length of the Exhaust System
Design #5: Rock Wool and Stainless Steel Wool

www.stainlessworks.net

Designs #3 & #4: Metal Foams

www.bundesregierung.de

Foams

Permeability
Pore Size
Level of Reticulation
Absorption Area
Length
Curves

Thickness
Scott Acoustical Laboratories

Foams

www.bundesregierung.de

Optimal Foam Structure

Industrial Noise Control Handbook.


Cheremisinoff and Cheremisinoff

Absorption Area

Industrial Noise Control Handbook.


Cheremisinoff and Cheremisinoff

Metal Foams

Available in a variety of densities


Available in a variety of pore sizes
ERG Duocel
Test kit en route
Aluminum
Copper
Silicon Carbide
Reticulated Vitreous Carbon (RVC)

ERG Duocel Metal Foams

ERGaerospace.com

Design #5: Rock Wool

A fibrous insulation made from basalt


Custom Muffler and Auto Repair, LA
Cone Engineering, Inc., CA
MagnaFlow Exhaust

Rock Wool

Design #7: Exhaust Silencer Insert


Applied to exhaust tip
Reflects Sound Waves
back into exhaust
stream

Design #8: Active Single-pass


Frequency Data

Moves laterally

Exhaust Gas
Flow

Resonating Chamber

Design #9: Active Multi-pass


Moves laterally
Frequency Data
Resonating Chamber

Exhaust Gas
Flow

ELECTRICAL DESIGN
OPTION

Design #10:
Active Noise Cancellation (ANC)

This generates more sound by


the adding of two waves.

ANC continued

Introducing a wave 180 degrees


out of phase of the targeted noise
being cancelled.

How ANC Applies to Cars


Three Major components of sound generation occur in a car
Dominating noise comes from the muffler

Feed Forward Control

Feedback Control

http://focus.ti.com.cn/cn/lit/an/spra042/spra042.pdf

Installation Options

CONCEPT SELECTION

List of Design Options


Current Glass Pack*
1. Unpacked Concentric Tube Resonator
2. Multi-pass Resonator
3. Metal Foam*
4. Entire Length of Exhaust System Wrapped
5. Lava Rock/Rockwool and Stainless Steel Wool*
6. Multiple Exhaust Pipes (Combination)
7. End Cap Silencer (Combination)
8. ANC
9. Variable Length Resonator - Single Pass
10. Variable Length Resonator - Multiple Pass

Criterion List
Criteria
Importance Importance (%)
3%
Ease of Manufacture
1
3%
Ease of Application
1
30%
Noise Reduction
9
10%
Power Usage
3
3%
System Life
1
10%
Weight
3
10%
Cost
3
30%
Effect on Back Pressure
9

Simple Concept Matrix

Simple Concept Matrix (cont.)

Simple Concept Matrix (cont.)

Weighted Concept Screening


Matrix

Weighted Concept Screening


Matrix

Weighted Concept Screening


Matrix

Results

Resulting Design Options


Unpacked Concentric Tube Resonator
Packed Concentric Tube:
Metal Foam
Lava Rock/Rockwool and Stainless Steel Wool

Variable Length Resonator - Single Pass


ANC
(End Cap Silencer, Multiple Exhaust Pipes)

Critical Action Items


Action Item
Design Commitment
Data Collection (CB)
Engine Model (CM)
Design Resonator (JM)
Detailed BOM & Budget (CB)
Detailed ANC Component
Requirements (TZ)
Detailed ANC Layout
& Mounting Schematic (TZ)

Goal
Oct. 14
Oct. 18
Oct. 22

No Later Than
Oct. 15
Oct. 21
Oct. 25
Oct. 25
Oct. 29

Oct. 22

Oct. 29

Oct. 29

Nov. 1

Sources

http://www.eastsidemufflers.com/mufflers.htm

Picture Sources
Slide 1
http://www.motorcycle-usa.com/photogallerys/03CBR600RReuro_DetG.jpgSlide2
Slide 2
http://www.emspowered.com/
http://www.motorcycle.com/manufacturer/honda/2003-cbr-600-track-test-1225.html
Slide 5
http://www.impactlab.net/2010/07/01/new-drug-could-reverse-hearing-loss-caused-by-loud-noises/
Slide 35
http://www.dirtwerkz.com/images/products/dbdawg/db-Dawg_Black_450.jpg

You might also like