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It is quite common practice in automotive and aircraft engine maintenance, operation, and research to employ any one of several types of instruments now on the market for determining the air-fuel ratio by exhaust gas analysis. It was the purpose of this investigation to determine the most important operating characteristics, especially range and accuracy, of each of these types of instruments. The theory underlying the operation of this kind of apparatus was studied critically, and certain tests were performed on representative makes in order to observe the operation of each type under service conditions. These tests consisted essentially of connecting the analyzers to the exhaust pipe of a single-cylinder engine and comparing the analyazer readings with the true air-fuel ratio determined by accurately measuring the air and fuel supplied to the engine while the instruments were being observed. This procedure was repeated for a number of different carburetor settings, all other factors being kept as nearly constant as possible during a given series of runs. The effect of variations in engine spark advance and the pressure of the gas supplied to the instruments was also investigated. The test revealed several interesting facts. Study of the operating principles of the several instruments indicated that they were limited te air fue1 ratios below about 14 to 1, and this has been conclusively proved by these experiments. This limitation applies to thermal conductivity, hot-wire catalytic, and relative density types. W While the most expensive makes of instruments were not tested, it was found that, in general, the limit of accuracy is not greater than one-half of one air-fue1 ratio, regardless of the operating principle employed. Large variations in the pressure and rate of flow of the exhaust supplied to the analyzers were found to cause considerable deviations in those instruments which did not employ some kind of device to insure a steady and uniform supply. Certain features of design and construction which effect the reliability of the various types of exhaust gas analyzers are also reviewed in this thesis, and some of the more important chemical methods of analysis are treated briefly. / Master of Science

For an engine running at a constant speed, both exhaust and intake processes are periodic in nature. This inspires the muffler designer to go for the much easier and faster frequency domain modeling. But analogous to electrical filter, as per Thevenin’s theorem, the acoustic filter or muffler requires prior knowledge of the load-independent source characteristics (acoustic pressure and internal impedance), corresponding to the open circuit voltage and internal impedance of an electrical source. Studies have shown that it is not feasible to evaluate these source characteristics making use of either the direct measurement method or the indirect evaluation method. Hence, prediction of the radiated exhaust or intake noise has been subject to trial and error. Making use of the fact that pressure perturbation in a duct is a superposition of the forward moving wave and the reflected wave, a simple hybrid approach has been proposed making use of an interrelationship between progressive wave variables of the linear acoustic theory and Riemann variables of the method of characteristics. Neglecting the effect of nonlinearities, reflection of the forward moving wave has been duly incorporated at the exhaust valve. The reflection co-efficient of the system downstream of the exhaust valve has been calculated by means of the transfer matrix method at each of the several harmonics of the engine firing frequency. This simplified approach can predict exhaust noise with or without muffler for a naturally aspirated, single cylinder engine. However, this proves to be inadequate in predicting the exhaust noise of multi-cylinder engines. Thus, estimation of radiated noise has met only limited success in this approach. Strictly speaking, unique source characteristics do not exist for an IC engine because of the associated non-linearity of the time-varying source. Yet, a designer would like to know the un-muffled noise level in order to assess the required insertion loss of a suitable muffler. As far as the analysis and design of a muffler is concerned, the linear frequency-domain analysis by means of the transfer matrix approach is most convenient and time saving. Therefore, from a practical point of view, it is very desirable to be able to evaluate source characteristics, even if grossly approximate. If somehow it were possible to parameterize the source characteristics of an engine in terms of basic engine parameters, then it would be possible to evaluate the un-muffled noise before a design is taken up as a first approximation. This aspect has been investigated in detail in this work. A finite-volume CFD (one dimensional) model has been used in conjunction with the two-load or multi-load method to evaluate the source characteristics at a point just downstream of the exhaust manifold for the exhaust system, and upstream of the air filter (dirty side) in the case of the intake system. These source characteristics have been extracted from the pressure time history calculated at that point using the electro-acoustic analogy. Systematic parametric studies have yielded approximate empirical expressions for the source characteristics of an engine in terms of the basic engine parameters like engine RPM, capacity (swept volume or displacement), air-fuel ratio, and the number of cylinders. The effect of other parameters has been found to be relatively insignificant. Unlike exhaust noise, the intake system noise of an automobile cannot be measured because of the proximity of the engine at the point of measurement. Besides, the intake side is associated with turbocharger (booster), intercooler, cooling fan, etc., which will make the measurement of the intake noise erroneous. From the noise radiation point of view, intake noise used to be considered to be a minor source of noise as compared to the exhaust noise. Therefore, very little has been done or reported on prediction of the intake noise as compared to the exhaust noise. But nowadays, with efficient exhaust mufflers, the un-muffled intake noise has become a contributing factor to the passenger compartment noise level as a luxury decisive factor. Therefore, in this investigation both the intake and the exhaust side source characteristics have been found out for the compression ignition as well as the spark ignition engines. Besides, in the case of compression ignition engines, typical turbocharged as well as naturally aspirated engines have been considered. One of the inputs to the time-domain simulation is the intake valve and exhaust valve lift histories as functions of crank angle. It is very cumbersome and time-consuming to measure and feed these data into the program. Sometimes, this data is not available or cannot be determined easily. So, a generalized formula for the valve lift has been developed by observing the valve lift curves of various engines. The maximum exhaust valve lift has been expressed as a function of the swept volume of the cylinder. This formulation is not intended for designing a cam profile; it is for the purpose of determining approximate thermodynamic quantities to help a muffler designer for an initial estimation. It has also been observed during the investigation that from the acoustic point of view, sometimes it is better to open the exhaust valve a little earlier, but very slowly and smoothly, and keep it open for a longer time. Although the exact source characteristics for an automobile engine cannot be determined precisely, yet the values of source characteristics calculated using this methodology have been shown to be reasonably good for approximate prediction of the un-muffled noise as well as insertion loss of a given muffler. The resultant empirical expressions for the source characteristics enable the potential user to make use of the frequency-domain cum-transfer matrix approach throughout; the time consuming time-domain simulation of the engine exhaust source is no longer necessary. Predictions of the un-muffled sound pressure level of automotive engines have been corroborated against measured values as the well as the full scale time-domain predictions making use of a finite-volume software.

There is a strong competition among automotive manufacturers to reduce the radiated noise levels. One important source is the engine exhaust where the main noise control strategy is by using efficient mufflers. Stricter vehicle noise regulations combined with various exhaust gas cleaning devices, removing space for traditional mufflers, are also creating new challenges. Thus, it is crucial to have efficient models and tools to design vehicle exhaust systems. In addition the need to reduce CO2 emissions puts requirements on the losses and pressure drop in exhaust systems. In this thesis a number of problems relevant for the design of modern exhaust systems for vehicles are addressed. First the modelling of perforated mufflers is investigated. Fifteen different configurations were modeled and compared to measurements using 1D models. The limitations of using 1D models due to 3D or non-plane wave effects are investigated. It is found that for all the cases investigated the 1D model is valid at least up to half the plane wave region. But with flow present, i.e., as in the real application the 3D effects are much less important and then normally a 1D model works well. Another interesting area that is investigated is the acoustic performance of after treatment devices. Diesel engines produce harmful exhaust emissions and high exhaust noise levels. One way of mitigating both exhaust emissions and noise is via the use of after treatment devices such as Catalytic Converters (CC), Selective Catalytic Reducers (SCR), Diesel Oxidation Catalysts (DOC), and Diesel Particulate Filters (DPF). The objective of this investigation is to characterize and simulate the acoustic performance of different types of filters so that maximum benefit can be achieved. A number of after treatment device configurations for trucks were selected and investigated. Finally, addressing the muffler design constraints, i.e., concerning space and pressure drop, a muffler optimization problem is formulated achieving the optimum muffler design through calculating the acoustic properties using an optimization technique. A shape optimization approach is presented for different muffler configurations, and the acoustic results are compared against optimum designs from the literature obtained using different optimization methods as well as design targets. / <p>QC 20121016</p>

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