Understanding Fuel Economy and NVH trade-offs with Effective Use of Rotating Machinery Analysis

LMS International

Peter Schaldenbrand, LMS North America 2008 Testing Expo

Outline

Engine design challenges and NVH trends The NVH testing process Advanced NVH engine analysis techniques: Order tracking Crank angle analysis Torsional vibration analysis Conclusion

2 copyright LMS International - 2005

Engine Development Challenges

Emissions and Power are priority design drivers Cost

High fuel efficiency / power Better combustion Lower size/weight Improve durability Structural integrity Compliance to legislation Exhaust emissions Noise legislation Comfort NVH Drivability

Emissions

Engine Design Polygon

Durability Is expected to be designed for infinite life

Power

Noise & Vibration Drivability Are differentiators (and market entry requirements for low end engines)

Investments driven by Emissions and Fuel Consumption

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NVH Calibration while meeting emissions and fuel consumption targets

Noise: Certification to PBN Sound quality Vibrations Relate to mechanical phenomena Piston dynamics Valve dynamics Torsional vibrations Relate to Combustion process Combustion profile Misfire Durability testing Endurance test of components Infinite life check Simultaneously taking into account: Controls and ECU strategies Transmission and drivability objectives Core engine fuel consumption, performance and emisions objectives
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Noise

Vibrations

Durability

Core engine Specificaitions Electronics

Transmission

NVH basic model Receiver = Transmission x Sources

Test Process Flow

Receiver
Operational Performance
Noise Vibration Stress Fatigue

Transmission
Structural Properties

Sources
Operating Loads
Forces Moments

Modal characterisitcs Intertia/Mass Fluid (Air) Properties

Noise

=
Structural Modes

x
Combustion Mechanical dyn. Fluids flow Unbalance

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Powertrain NVH Mechanical & combustion noise, structure & air-borne

2nd order excitation level & linearity

Air Borne

Accel

SPL

dB/dB

spectrum shape

Transmission Loss

dB SPL SPL Accel

discrete frequencies

SPL

discrete frequencies

Structure Borne

2nd order excitation

transfer function

spectrum shape

Accel

Accel

harmonic pattern

mount characteristics

Dynamic stiffness

chassis dynamics

Body Noise TF

dB/N

harmonic pattern

Isolation

Transfer

Excitation

Vehicle Interior Noise

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Engine Testing Process Methodology

Phase 1: Benchmark current status Harmonic analysis ODS Psycho-acoustics Source localisation Phase 2: Engineering cycle - Diagnosis Contribution of sources to receiver Structural characteristics Mechanical dynamics Combustion analysis Phase 3: Engineering cycle Evaluation of alternatives Evaluate contributions (sources and paths) Evaluate structural modifications Evaluate mechanical changes Evaluate combustion changes Phase 4: Validation of design modification Same tools as in phase 1
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Fast identification of harmful noise & vibrations Order tracking

Traditional approach gives good overview of NVH issues No need for high pulse per revolution tacho signal Identify normal and abnormal engine vibrations in different operating conditions Differentiate between Orders and Resonances

A u t o Po w e r C y lin d e r s :1 : - Y W F 1 1 0 [ 1 8 0 0 .9 - 2 8 9 1 . 3 r p m ] 2 9 0 0 .0 0

0 .5

18

326e-6

Tacho1 (T1)

Amplitude

rpm

1 8 0 0 .0 0 0 .0 0 Hz C y lin d e r s :1 : - Y ( C H 8 )

1334
1 5 0 0 .0 0

3 7 .3 e - 9

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Crank-angle analysis - Relating to root-causes Combustion N&V

Analyse combustion-stability Engine knock Non-or irregular ignition Synchronised measurement of ECU parameters Cross-check modification impacts on combustion performance (P-V, IMEP) Immediate estimation on sound characteristics based on combustion pressure and structural characteristics Combustion P 1/3 Octave content Engine/ear transfer function Driver ear noise
0.00 0.00

Combustion pressure profile

g dB

dB 141.25 Octave 1/3 Hz 22387.21 A L

/
-50.00 -50.00

Relate measurements to crank angle

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Crank-angle analysis - Relating to root-causes Mechanical N&V

Investigate irregular impacts and timing Piston slap, croak, ticking, Valve dynamics Torsional vibrations Requirements Angle domain 1-720 pulses per rev

Relate measurements to crank angle

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Example of piston mechanical noise

Rattling Speed range: 2500-3500 rpm Angle range: -2 to 3 degrees Load range: 20-40% Sound: clear metallic pattering Freq range: 2.5 - 5 kHz Croaking Speed range: 1000-2200 rpm Angle range: 0 30 degrees Load range: 10-50% Sound: Dull, diesel like hollow sound Freq range: 1.2 - 2.5 kHz

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Parallel frequency and angle domain analysis Gated processing

Wavelet or Short time Fourier transform Relating angle position events to frequency content Cylinder to cylinder comparison Cycle to cycle comparison

Gate 1: After TDC

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Gate 2: Before spark

Tracked evolution of maximum and angle of max versus RPM

Valve dynamics
Use laser vibrometer or induction probes for displacement Accelerometers, Mics, and strain High speed encoder (e.g. 720 ppr) Motored operation Track design target metrics: valve opening duration valve lift, velocity, acceleration vs. time or crank angle float (measured vs. theoretical & float vs. angle) bounce (measured vs. theoretical & bounce vs. angle) angular position for dynamic valve open angular position for dynamic valve close pre-lift loss apparent pre-lift loss kinematic closing lift total lift loss valve seating velocity

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Torsional vibrations Belts & pulleys analysis, Gear train rattle & whine, Transmission error
Multiple tacho channels Online torsional vibration calculation Online calculations: belt slip % stretch transmission error belt/chain linear displacement, velocity, acceleration shaft angular displacement, velocity, acceleration shaft relative angular displacement, velocity, acceleration (between 2 shafts) Gears: Visualisation of angular looseness / clearance between gears Gear flank testing/certification Transmission error % calculation

Torsional vibrations if not managed can lead to higher fuel consumption and decreases in performance as well as rattle & whine NVH problems 14 copyright LMS International - 2005

Predictive analysis of Engine/Driveline Torsional Vibration Model and Verification

Torsional vibration in driveline with automatic gearbox will create increased fuel consumption and lower comfort

Full engine/driveline was modeled for predictive analysis using MBS

Verification measurements were done to validate approach

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Predictive analysis of Engine/Driveline Torsional Vibration Verification Measurements

4 microphone signals 120 acceleration signals 9 torsional vibration signals

Campbell torsional vibration pulley 3rd order torsional vibration at flywheel measured vs. predicted

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Conclusion Following the Green trend

Systematic/ Efficient methodologies Multi-attribute Testing systems

Engineering challenges

Complex systems

Eco-friendly market requirements are driving major engineering challenges Clean sheet redesign or improvement of existing platforms Increasing need for efficient multi-attribute testing Systematic engine testing with Advanced NVH analysis technology platforms like LMS Test.Lab provide a means to accurately capture and understand the processes influencing fuel consumption as well as NVH Order tracking for overview picture Crank-angle analysis for multiple root-causes identification Torsional vibration measurement for gears, blets, transmission dynamics
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Noise Vibrations Durability

Core engine

Transmission Electronics

Thank you

Peter Schaldenbrand, LMS North America 2008 Testing Expo