Team Leader: Christopher Morehouse (ME)Team Members: Julie Maier (ME)

Caroline Bills (ME) Ted Zachwieja (ME)

Faculty Advisor: Ed Hanzlik Customer: Dr. Alan Nye

Improve & challenge the proposed designs

Obtain assistance where needed from attendees

Project Overview Scope Overview Customers and Users Project Flow Chart Project Plan & Risks Engine Test Set-up Engine Test Data Design Concepts ImagineRIT Demo Set-up Expected Outcomes – Near Future Plans Questions & Discussions

1. Investigate physics of sound generation & transmission

2. Identify & locate major noise contributors in an ICE

3. Analyze & model noise generation of an ICE4. Create design(s) for noise reduction

mechanism 5. Provide sufficient background to EE team for

active noise cancellation system6. Produce simple engine test stand for proof of

concept

(ICE = Internal Combustion Engine)

Engine Sound Model◦ Frequency response for varying RPM◦ For EE team

ANC System Constraints◦ EE team will follow

Develop Engine Test Stand

Develop prototype noise reduction mechanical systems

Create demonstrator for ImagineRIT

MechanicalProposals

Research Topics

Electrical (ANC)

Analyze SAE Engine NOISE

REDUCTION

Analyze Lawnmower

Engine

Engine Test Stand

MechanicalProposals

Research Topics

Electrical (ANC)

Sound Internal Combustion

Engine

Sound Generation

Gather Data

ActivePassive

Specs & Documents

Packaging & Layout

Analyze SAE Engine

Current Muffler/Exhaust

Systems

Resonator Absorptive Resonator

NOISEREDUCTION

Analyze Lawnmower

Engine

Create Sound Field Map

Engine Test Stand

Gather Data

Add Load to Engine

MountEngine

Engine Test Stand

Create Muffler Adapter

Create Testing Methodology

Scale:9 very important3 moderately important1 somewhat important

CN # Importance Description

CN 1 9 Reduce noise from exhaust.CN 2 9 Use SAE sound measuring technique.CN 3 9 Apply noise reduction to other motors.CN 4 3 Do not inhibit performance.CN 5 9 Design packaging and system layout for EE ANC.CN 6 9 Provide EEs with engine characterization.CN 7 9 Design is practical for manufacture and use.CN 8 9 Design and produce demonstrator for ImagineRIT in spring quarter.

Scale:9 very important3 moderately important1 somewhat important

ES # Importance Source Specification (Description) Unit of MeasureMarginal

ValueIdeal Value Comments/Status Person

ES 1 9 1 Reduce noise level dBA 3-4 10

ES 2 3 2Maximum length extending from rear axle

in 17.6 17.7 SAE Rules

ES 3 3 2 Maximum distance above the ground in 23.5 23.6 SAE Rules

ES 4 1 1,2Passes B10.2.1 of the SAE Formula rules

dBA, fast weighting

110 <110 SAE Rules

ES 5 3 4,6,7 System Power Draw Watts 180 0 Discuss with SAE team TedES 6 3 7,8 System Life hours 10 40 Discuss with customer & SAE Team CarolineES 7 9 7,8 Component Costs $ 1200 500 Discuss with customer Chris

ES 8 3 7 Exhaust Envelope (volume of space) ft3 4 4 Discuss with SAE team Ted

ES 9 9 7Internal Exhaust Components Survivable Temp

°F 1000 1600 Define from analytical data Caroline/Julie

ES 10 9 7Internal Exhaust Components Survivable Pressure

psiaDefine from analytical data / ballpark value from Honda Motorcyle engine

Caroline/Chris

ES 11 3 7 Component Shock Threshold g 2.5 4 Discuss with SAE team Caroline/ChrisES 12 3 4,7 Change in Engine Max Power HP -2 0 Discuss with SAE team CarolineES 13 3 4,7 Weight limit on exhaust system lbs 12.5 15 SAE team to determine Caroline

ES 14 3 4,7 Maximum allowed back pressure psi 2.5 0Define from analytical data/literature research

Chris

ES 15 9 2Measure sound level according to SAE specs

dBA SAE Rules

Most Important Engineering Specs:ES 1 - Reduce noise levelES 9 - Internal Exhaust Components Survivable TempES 10 - Internal Exhaust Components Survivable PressureES 15 - Measure sound level according to SAE specs

CN # ↓ ES # → Weight ES 1 ES 2 ES 3 ES 4 ES 5 ES 6 ES 7 ES 8 ES 9 ES 10 ES 11 ES 12 ES 13 ES 14 ES 15

CN 1 9 9 1CN 2 9 3 3 1 9CN 3 9CN 4 3 3 3 3 3CN 5 9CN 6 9 3CN 7 9 3 3 3 3 9 9 3 3 3 3CN 8 9 3 3

Importance 81 27 27 18 63 54 54 27 81 81 27 36 36 36 81

Importance 13% 4% 4% 3% 10% 8% 8% 4% 13% 13% 4% 6% 6% 6% 13%

Concrete DateTopicTask

x complete task

Concrete DateTopicTask

x complete task

Concrete DateTopicTask

x complete task

Risk # Description of Risk Possible ConsequencesProbability of Risk

(9 = high)Severity of Risk

(9 = high)Overall Risk

(9 = high)Preventative Measures Contingency Plan

1

Not proficient with computer software required for modeling engine.

Engine is not able to be modeled.

3 3 9Use software that is simple or already known by a group member.

Set up appointment with an advisor to assist with the software.

2New engine will not run or breaks down.

No engine to create design for.

1 3 3Test engine and check performance characteristics. Preventative maintenance.

Pull new engine

3Report to EEs is insufficient.

EEs are not able to correctly design a noise reduction device.

3 9 27

Ensure all technical data is in a clear, easy-to-understand format. Show to some EEs to make sure all technical jargon is understandable.

Team members will be available spring quarter for clarification.

4Engine is characterized incorrectly.

Exhaust system design might be incorrect and need to be modified. EEs would be working with bad data.

1 9 9

Double-check measurements, units, etc. Always work with a partner when collecting data. Validate with analytical data.

Retake data and remodel.

5 Customer needs change.

Project plan no longer completes customer needs by the end of senior design.

3 3 9

Stay up-to-date with plan. Double-check that each task is allotted a feasible time frame.

Change the project plan to accommodate changes and talk over the feasibility of the changes with customer.

6Deviation from project timeline.

Entire project is set back. 3 3 9Double-check that each task is allotted a feasible time frame.

Remove unrequired tasks. Simplify and re-prioritize tasks.

7Oversimplified or bad assumptions lead to incorrect data.

Exhaust system design might be incorrect and need to be modified. EEs would be working with bad data.

3 3 9

Double-check all assumptions with subject matter expert, test assumption with data collection.

Exhaust design would have to be modified to accommodate misconceptions.

Scale:9 very important3 moderately important1 somewhat important

Scale:9 very severe3 moderately severe1 minor

Scale:9 very important3 moderately important1 somewhat important

Scale:9 very severe3 moderately severe1 minor

Risk # Description of Risk Possible ConsequencesProbability of Risk

(9 = high)Severity of Risk

(9 = high)Overall Risk

(9 = high)Preventative Measures Contingency Plan

8Design is not feasible to build.

Design would need to be refined spring quarter.

1 9 9Spend extra time considering design-specific risks when designing.

Exhaust design would have to be modified to accommodate misconceptions. Team members will be available spring quarter.

9 Lack of budget.Design not able to be created spring quarter.

1 9 9

Go through each aspect of the design, keeping in mind cost considerations. Scrounge as much material from ME department as possible

Be thrifty when can. May need to ask for money. Beg, borrow or steal.

10Exhaust system does not withstand exhaust gas.

Design would need to be refined spring quarter.

1 9 9

Ensure all materials can withstand more than necessary in the exhaust environment.

Exhaust design would have to be modified to accommodate misconceptions.

11Absorption muffler housing geometry to difficult to manufacture.

Absorption muffler designs would need to be simplified

3 9 27Dialogue with machine shop to ensure practicality of design fabrication

Change materials or geometry, outsource

12Resonator not practical for new engine.

No resonator design present at ImagineRIT.

9 1 9Dialogue with subject matter expert, evaluate alternative resonator designs.

Design demonstration model to be used with function generator at ImagineRIT, prepare detailed correlation with application to larger (SAE) engines.

13Inclement Weather at ImagineRIT.

Logistics of planning event become more complicated.

3 3 9 Get a canopy. Consider alternate location.

14 Demonstator fails at ImagineRIT.

Have time when one of the muffler options cannot be demonstrated

1 3 3 Have a spare engine ready. Use spare engine.

Risk # Description of RiskPossible

ConsequencesProbability of

Risk (9 = high)Severity of Risk

(9 = high)Overall Risk

(9 = high)Preventative Measures

Contingency Plan

3Report to EEs is insufficient.

EEs are not able to correctly design a noise reduction device.

3 9 27

Ensure all technical data is in a clear, easy-to-understand format. Show to some EEs to make sure all technical jargon is understandable.

EEs would need further data spring quarter.

11Absorption Muffler Housing geometry to difficult to manufacture.

Absorption muffler designs would need to be simplified

3 9 27Dialogue with machine shop to ensure practicality of design fabrication

Change materials or geometry, outsource

TOP VIEW FRONT VIEW

45 deg

0.5 m(19.68 in)

Microphone

Muffler

Exit

0.5 m(19.68 in)

Microphone

Muffler

Microphone

Muffler

Sound Recording Waveform – Without Muffler

Frequency Analysis – Without Muffler (at 10,200 RPM)

Engine Firing Freq: 53.3

Test #1: ◦ Cart stationary, Decimeter rotated◦ Exhaust pointing into alley

towards dumpster

deg dB

0 9345 9190

135 93180 95225 96270 95315 94

0 deg

90 deg

180 deg

270 deg

Muffler

0 deg

90 deg

180 deg

270 deg

Test #2: ◦ Cart & Decimeter rotated

deg dB

0 9490 93180 94270 93

Engine101.596.59591.5

103

99

98

92

100.5 95.5 93 90

98

95

93.5

91

98.5

96

94

89

102

98

95

93

99

95

96

91

101.5

97

94.5

93

20”

40”

60”

120”

Sound Pressure Level Map:Top View, Horizontal Plane

Glass Pack◦ Low flow

restriction◦ Low noise

attenuation

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)

Current Formula◦ Honda 600cc◦ 85hp◦ 4-Cylinder◦ 4-Stroke

Lawnmower◦ Briggs & Stratton◦ 5.5hp ◦ 1-Cylinder ◦ 4-Stroke

Holes in pipe

Resonating Chamber

Inner Pipe

Exhaust Gas Flow

Sound Waves

Formula SAE Lawnmowerrpm f (Hz) λ (m) 1/2 λ (m) 1/2 λ (ft)500 4.17 81.67 40.84 124.47

1000 8.33 40.84 20.42 62.231500 12.50 27.22 13.61 41.492000 16.67 20.42 10.21 31.122500 20.83 16.33 8.17 24.893000 25.00 13.61 6.81 20.743500 29.17 11.67 5.83 17.78

rpm f (Hz) λ (m) 1/2 λ (m) 1/2 λ (ft) 1/2 λ (in)

500 17 20.42 10.21 31.12 373.41000 33 10.21 5.10 15.56 186.71500 50 6.81 3.40 10.37 124.52000 67 5.10 2.55 7.78 93.42500 83 4.08 2.04 6.22 74.73000 100 3.40 1.70 5.19 62.23500 117 2.92 1.46 4.45 53.34000 133 2.55 1.28 3.89 46.74500 150 2.27 1.13 3.46 41.55000 167 2.04 1.02 3.11 37.35500 183 1.86 0.93 2.83 33.96000 200 1.70 0.85 2.59 31.16500 217 1.57 0.79 2.39 28.77000 233 1.46 0.73 2.22 26.77500 250 1.36 0.68 2.07 24.98000 267 1.28 0.64 1.94 23.38500 283 1.20 0.60 1.83 22.09000 300 1.13 0.57 1.73 20.7

9500 317 1.07 0.54 1.64 19.7

10000 333 1.02 0.51 1.56 18.710500 350 0.97 0.49 1.48 17.811000 367 0.93 0.46 1.41 17.011500 383 0.89 0.44 1.35 16.2

12000 400 0.85 0.43 1.30 15.6

Conclusion:◦ Resonator not feasible

for lawnmower engine

f = (RPM) * n / 120

n = number of cylinders

λ = c / f

c = speed of sound in air (340.3 m/s)

f = Frequency c = Speed of Sound in

Air L = Length of Neck A = Cross-Sectional

Area of Neck V = Volume of Chamber

Narrow frequency band

Active option too large

Will not pursue

LN 2 in

RN 0.375 in

RC 5 in

LC 9.5 inf 29.16 1/sec

Three shapes, each:◦ Length = 12 in◦ ID = 1in◦ Thickness = 2in

Four packing materials Test for optimization of sound absorption

Metal Foam Fiberglass Stainless Steel Wool

◦ Fine◦ Medium◦ Coarse

Rockwool

Packing Materials:◦ Stainless Steel Casing◦ Stainless Steel Inner Tube

Perforated Metal Sheet Metal

Metal Foam:◦ Aluminum Casing

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

Engine

Dipole Box

Parallel Pipe from

Speaker

Required SPL at Listener (dB)

Speaker Sensitivity (dB)

Speaker Distance to Listener (m)

Headroom of Amplifier

(dB)

Watts required (W)

100 85 1 10 316100 91 1 10 79100 95 1 10 3295 85 3 10 90095 91 3 10 22695 95 3 10 90

Material Size/Quantity Price Distributor Comments Speaker 1 to 2 speakers Dependant on what the EE team

decides Feedback Control System

Dependant on what the EE team decides

Power supply Directly dependant on what speakers are chosen

Feedback sensor Dependant on what the EE team decides

Amplifier for the speaker

1 amplifier Directly dependant on what speakers are chosen

Housing for speakers

1 Box Wooden box that can be set beside the engine w/ parallel pipe routed from it to the engine exhaust

Mounting Brace for parallel pipe

4’’ X 6’’ dimensions

Potentially have extra steel in the machine shop

Parallel pipe 1 inch diameter Found extra steel pipe in the machine shop

MUFFLER DESIGNSTABLE

TH

EO

RY

& P

RO

JEC

T

OV

ER

VIE

W TA

BL

E10' x 10' canopy

TV Screen

Chairs (x4)

Engine Test Stand

Create Engine Test Stand (not cart) Create posters Obtain actual car mufflers & dissect Get both engines ready (fuel & oil) Get TV & set it up

Engine fails during demonstration◦ Have backup engines

Weather◦ Find alternate location (Machine Shop?)◦ Get another canopy

1 – 10’ x 10’ Canopy 2 – Tables (approx. 5’ x 2’) 1 – Table (can be drilled into) 4 – Chairs 1 – TV Screen & accompanying cables 2 – 1hp Briggs & Stratton Lawnmower

engines 1 – Laptop 1 – Microphone 1 – Decimeter 1 – Handheld Tachometer

Action Item Goal No Later Than• Design Commitment Oct. 15• Data Collection (CB) Oct. 14 Oct. 21• Engine Model (CM) Oct. 18 Oct. 25• Design Resonator (JM) Oct. 22 Oct. 25• Detailed BOM & Budget (CB) Oct. 29• Detailed ANC Component

Requirements (TZ) Oct. 22 Oct. 29• Detailed ANC Layout

& Mounting Schematic (TZ) Oct. 29 Nov. 1

Action Item Goal No Later Than Report to EE team 11/7 11/15 Create Complete BOM 11/1211/15 Characterize Lawnmower 11/9 11/15 Finalize Absorption 11/9 11/15 Resonator Demonstrator 11/1211/15 Data Analysis SAE car 11/1211/15 Order Materials Absorption 11/19

www.rit.edu/imagine Experimental Investigation of Active Noise Controller for Internal

Combustion Engine Exhaust System by: Jian-Da Wu et al. Industrial Noise Control: Fundamentals and Applications by Lewis

H. Bell www.crownaudio.com Dr. Zheji Lui (Dresser-Rand)