fuel line acoustic nonlinear analysis ... - gamma technologies€¦ · 2014 gamma technologies...
TRANSCRIPT
![Page 1: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/1.jpg)
2014 Gamma Technologies North America UGM
1
Fuel Line Acoustic Nonlinear Analysis
&
Evaporative Emissions System
Flow Analysis
Eric Myers
Fuel System CAE
Ford Motor Company
November 3, 2014
![Page 2: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/2.jpg)
2014 Gamma Technologies North America UGM
• Fuel line nonlinear acoustic analysis• Problem statement
• Model setup and assumptions
• Results
• Evaporative emissions system analysis• Objective
• Component modeling considerations and correlation
• Evap system model and correlation
Agenda
![Page 3: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/3.jpg)
2014 Gamma Technologies North America UGM
• Customer complaint about a vibrational noise in the
cabin while driving• Occurs on the diesel Fusion powertrain
• Termed “roar noise”
• Noise coming from left side floor
• Noise source isolated to the fuel lines• Fuel line vibrating in clips
• Fuel line clips to frame
• Frame to rear seat foot well floor
Problem Statement: Fuel Line Analysis
![Page 4: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/4.jpg)
2014 Gamma Technologies North America UGM
• No issue from prior model year
• Prior model year used dual plunger high pressure
injection pump (HPP)• Changed to single plunger high pressure injection pump
• Root cause • Pressure pulsations in return fuel line
• Dual plunger pump cancelled/prevented the pulsations
• Single plunger pulsations propagate down fuel lines
Problem Statement: Fuel Line Analysis
![Page 5: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/5.jpg)
2014 Gamma Technologies North America UGM
Diesel Fuel System Overview
High Pressure Injection Pump
Fuel return line (supply line not shown)
Fuel cooler
Fuel injection
common rail
Fuel tank connection
![Page 6: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/6.jpg)
2014 Gamma Technologies North America UGM
Model Assumptions: Fuel Line Analysis
• Roar noise source isolated to fuel return line• Pressure pulsations propagating from pump
• Pulsations induce line vibration
• Considered components• High pressure pump (HPP)
• Return line and fuel cooler to tank connection
• Injection side of pump not required for model• Injector leakage fed back to HPP
• Diesel fuel properties as defined in GT• Includes air content in fuel
• Fuel line materials• Nylon
• Low carbon steel
![Page 7: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/7.jpg)
2014 Gamma Technologies North America UGM
Model Approach: Fuel Line Analysis
• Return line assembly analysis procedure• Nonlinear analysis
• Calculates resonance frequencies
• Monitor pressure waveform through return line
• Used as indicator for noise origination
• Frequency sweep analysis• Simulates pump return flow through frequency range
• Locate max pressure peak within line assembly
• Frequency sweep analysis with rubber hose• Proposed solution to dampen pressure pulsations
• Evaluate effectiveness of hose
• Monitor max pressure peak
![Page 8: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/8.jpg)
2014 Gamma Technologies North America UGM
Model Approach: Nonlinear Analysis
• Determine resonance frequencies• Consider frequencies within HPP operating range
• System driven by white noise source
• System open at tank end, applied nominal line pressure
• Roar noise worst at about 2300 engine RPM• Corresponds to 76.67Hz HPP frequency
• Check for resonance at 76.67Hz
• If not, pulsations purely from pump back flow
![Page 9: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/9.jpg)
2014 Gamma Technologies North America UGM
Results: Nonlinear Analysis
• Resonances
Calculated HPP Operating
Frequency Range
Return Line Assembly Resonance
Frequencies Within HPP Operating
Range
Return Line
Resonance
Frequency
(Hz)
22
46
76
98
124
![Page 10: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/10.jpg)
2014 Gamma Technologies North America UGM
Results: Nonlinear Analysis
• Pressure contour plot @ 76Hz
![Page 11: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/11.jpg)
2014 Gamma Technologies North America UGM
Results: Nonlinear Analysis
• Max pressure pulse location
![Page 12: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/12.jpg)
2014 Gamma Technologies North America UGM
Results: Nonlinear Analysis
• Pressure waveform through return line @ 76Hz
![Page 13: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/13.jpg)
2014 Gamma Technologies North America UGM
Model Approach: Frequency Sweep Analysis
• Perform sweep analysis on return line assembly• Boundary conditions
• System driven by pump replicating return flow curve
• System open at tank end with applied nominal line pressure
• Evaluate pressure waveform at 76Hz resonance• Use as base case for comparisons to proposals
• Determine method to best dampen pressure pulsations• Resonator
• Rubber hose
• Pulse damper
![Page 14: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/14.jpg)
2014 Gamma Technologies North America UGM
Results: Frequency Sweep Analysis
• Frequency sweep pressure contour for 76Hz
![Page 15: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/15.jpg)
2014 Gamma Technologies North America UGM
Results: Frequency Sweep Analysis
Component peak pressures at determined location
![Page 16: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/16.jpg)
2014 Gamma Technologies North America UGM
Model Approach: Frequency Sweep Analysis w/
Rubber Hose
• Perform sweep analysis on return line assembly• Boundary conditions
• Same as frequency sweep analysis
• Replaced portion of existing line with rubber hose
• Evaluate effectiveness of hose to base case
![Page 17: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/17.jpg)
2014 Gamma Technologies North America UGM
Comparison of component peak pressures at determined location
Results: Frequency Sweep Analysis w/
Rubber Hose
![Page 18: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/18.jpg)
2014 Gamma Technologies North America UGM
Conclusions
• Fuel line analysis– Analysis results aligned with physical system
• Determined mechanism of the vibration– Resonance condition
• Trial and error possible solutions to dampen pulsations– Avoid excessive testing on a vehicle
– Rubber hose proposal• Validated with testing
• Moved forward to production in return line design
![Page 19: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/19.jpg)
2014 Gamma Technologies North America UGM
Evaporative Emissions System Flow Analysis
Evaporative Emissions System
• Objective– Replicate full system bench testing used for calibration
• Reduce required testing
• Provide calibration flow map earlier in the vehicle development cycle
• Evaluate flow map shift due to system design change– Support “White Paper” flow map validation
![Page 20: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/20.jpg)
2014 Gamma Technologies North America UGM
Evaporative Emissions System Model: Overview
Canister Purge Valve (CPV)
Carbon Canister
Canister Load Line
Fresh Air Line
Purge Line
![Page 21: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/21.jpg)
2014 Gamma Technologies North America UGM
Evaporative Emissions System Model
• Model considerations– CPV and carbon canister need most consideration
– CPV model • Pulse Width Modulated (PWM) valve
– Controls flow by setting a duty
cycle to voltage signal
» Higher the duty cycle yields higher
flow
– Electro magnetic actuation
– Moving seal armature
– Account for seal armature
movement effects to flow
![Page 22: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/22.jpg)
2014 Gamma Technologies North America UGM
Evaporative Emissions System Model
• Model considerations– Carbon canister
• Stores fuel vapor displaced in fuel tank– Using clean canister – no stored vapor
• Not considering any internal valves
• Account for air/void volumes
• Account for flow restriction due to
carbon bed
![Page 23: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/23.jpg)
2014 Gamma Technologies North America UGM
Evaporative Emissions System Model
• Model correlation– CPV
• Steady state test
• Averaged pressure from
model
![Page 24: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/24.jpg)
2014 Gamma Technologies North America UGM
Evaporative Emissions System Model
• Model correlation– Carbon canister
• Steady state test
• Steady state model
![Page 25: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/25.jpg)
2014 Gamma Technologies North America UGM
Evaporative Emissions System Model
• Model correlation– Evap System
• Steady state test
• Averaged pressure
from model
• Wrong valve used
from test
![Page 26: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/26.jpg)
2014 Gamma Technologies North America UGM
Conclusions
• Evaporative Emissions System Flow Analysis– Good correlation for CPV
• For steady state condition – Reasonably capturing flow effects of moving armature
– Reasonably capturing electromagnetic force applied to armature
– Good correlation for carbon canister• For steady state condition
– Capturing flow restriction due to internal geometric features
– Capturing flow restriction due to the carbon beds
– Promising correlation to evap system testing• Expect that model will correlate with testing
– Update CPV model to the high flow valve
![Page 27: Fuel Line Acoustic Nonlinear Analysis ... - Gamma Technologies€¦ · 2014 Gamma Technologies North America UGM 1 Fuel Line Acoustic Nonlinear Analysis & Evaporative Emissions System](https://reader033.vdocuments.site/reader033/viewer/2022050111/5f4927d8a4df9604af7a5c7e/html5/thumbnails/27.jpg)
2014 Gamma Technologies North America UGM
Q & A
Thank You