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INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol.10,No.5,pp.59-66 DECEMBER 2009 /5910.1007/s12541-009-0094-0 NOMENCLATURE SPL=sound pressure level A-SPL=A sound pressure level 1.Introduction Although there were a large amount of literatures on the analysis of severe influence of all kinds of noises on abnormal performance for many apparatus,1-4 the noises pollution was still a serious problem in many domains.With rapid development of the city construction,the removal and building of city buildings,and the construction of basic infrastructures,directly brought the great increasing noise caused by construction machinery in most cities all over the world.It not only played an adverse part in the physiology and psychology of the workers,but also seriously affected the citizens daily life.The long-time noise would do harm to workers physiology and psychology,and high level noises could also damage the persons hearing and nervous system,which made persons insomnia,dreaminess and brought worse memory.5 Diesel engine of excavator discharged a large amount of high level noise during working,for example,the inlet noise,exhaust noise,noise radiated from machine body,and gear noise.Among all above noises,the exhaust noise from engine was one of the most important noises when excavator was working,which would severely influence the complete machine performance of the excavator products.Muffler was an apparatus which was fixed on the engine to depress the inlet or output noise,So installing a muffler with high noise elimination performance on the engine was the most normal method.So,measuring and analyzing the exhaust noise level became very important for protecting the environment and improving the complete machine performance.The noise level was an important qualification criterion for evaluating the performance of construction machinery,and had been restricted by many country laws in the world.At present,many researchers had deeply studied how to measure the noises more precisely,and they had developed a series of methods for measuring noise level.Early in 1997,R.Singh had measured the noise exhausted from mufflers with the pulse method.6 Ling Zh-Y carried through the broadband measurement of the noise radiated Measurement and Analysis of Exhaust Noisefrom Muffler on an Excavator Jian-Hua Fang1,#,Yi-Qi Zhou1,Xiao-Dong Hu2 and Li Wang11 Key Laboratory of High Efficiency and Clean Mechanical Manufacture,Ministry of Education,School of Mechanical Engineering,Shandong University,Jinan,China,2500612 Shandong University of Science Technology,Qingdao,China,266510#Corresponding Author/E-mail:jhf_,TEL:+86-0531-88396551,FAX:+86-0531-88392989 KEYWORDS:Noise measurement,Insertion-loss,Muffler,Exhaust noise Through analyzing the harm of the exhaust noise from the excavator,this paper illuminated the importance of the noise measurement and analysis work,.According to some correlative measurement standards,using some instruments in hand,a set of exhaust noise measurement system especially for the excavator was designed.The exhaust engine noise from an excavator produced by a construction machinery corporation was measured and analyzed,and then,seven mufflers with different structures were designed.After analyzing the frequency spectrums of seven impedance mufflers of different structures respectively,we selected the muffler j which was of best noise elimination performance among the seven mufflers.The highest noise elimination of muffler j was up to 16.3dB,which could reduce the exhaust noise from the excavator in a larger degree.At last,we analyzed the structures and corresponding effects of noise elimination for the seven mufflers and made some important conclusions.Manuscript received:November 14,2007/Accepted:September 8,2009 KSPE and Springer 2009 60 /DECEMBER 2009 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol.10,No.5 from the submarine through the method of forming multi-frequency multiplication invariable beam width linear array beam.7 Some references8-10 acquired the acoustic characteristic of some typical noise sources by different methods.The high level exhaust noise from the engine badly affected the complete machine performance of the construction machinery,e.g.excavator.Therefore,studying the performance of the exhaust muffler,measuring and analyzing the output noise level had become an important technique(Noise measurement technology),by which the exhaust noise from the excavator could be evaluated.Not only was it an important and leading technical procedure in noise controlling engineer,but also it was a method of protecting the environment and detecting whether the noise agreed with the relevant specifications or not in labor protection work.11 According to some correlative noise measurement standards about exhaust mufflers,using some instruments we had,we designed a set of exhaust noise measurement system especially for the construction machineries.By analyzing the noise signals collected,seven kinds of impedance mufflers of different complicated structures were designed.After analyzing the frequency spectrums of seven mufflers respectively,the muffler which had better noise elimination performance was selected.2.Performance evaluation standards for the muffler Transmission loss and insertion-loss were the main performance evaluation standards for mufflers.Transmission loss was the relative comparison between the entrance energy of the muffler and the exit energy,and it was the difference between the entrance sound power level and the transmission sound power level.The transmission loss,which was mufflers own attribute,was independent of pipe system and sound sources.Insertion-loss was the difference of sound power level from the sound source,before and after installing the muffler,and it was not a particular performance that a muffler own had.That was to say,the insertion-loss could only show the acoustic performance change of the whole system(muffler,pipes and noise sources included)before and after fixing mufflers,and it couldnt indicate the mufflers own noise elimination performance.When measuring and analyzing the noise elimination performance of the muffler in practice,researchers often studied the insertion-loss.This was mainly because when the transmission loss was measured,the SPL of the entrance sound wave of mufflers needed to be measured.But the entrances of mufflers were usually inside the body of the construction machinery,which was not suitable for noise measuring.Additionally,other noise sources,radiated noise from the engine body,and noise from machine parts near the orifice of the exhaust manifold,might bring some errors for the noise measurement.So in practical measuring engineer for muffler,while evaluating and analyzing the noise elimination performance,we generally considered the insertion-loss of the muffler.Here,the insertion-loss of the exhaust muffler on an excavator engine would be measured and studied.3.Influence of the measuring environment 3.1 Background noise and its correction Background noise was the environmental noises existing in practical measurement,and it would still exist around when the measured noise source stopped sounding.Background noise would affect the accuracy of the measurement,so during measuring noise,we should avoid the impact of the background noise upon the measurement.When the exhaust muffler noise was measured,owing to the influence of the background noise,the total noise level measured usually was the sum of the noise source to be measured and the background noise,which made that we couldnt directly determine the noise level of the measured object.If the difference between the background noise and the exhaust noise from engine was bigger than 10dB,the influence of the background noise could be ignored,or the amendment noise value L should be subtracted from the measured engine exhaust noise.Table 1 was a series of amendment noise values when the difference between the exhaust noise and the background noise was smaller than 10dB.Table 1 Background noise amendment table Difference(dB)3 34-56-9Amendment(dB)Select other quiet measure environment-3-2-1 3.2 Influence of the reflected sound Some bigger reflectors near the noise source or around the microphone would bring bigger errors,e.g.,walls,grounds,mechanical equipments,and worker bodies were all reflectors.So during the course of measuring noise,the microphone should be far away from these reflectors,and one meter was the best distance.In order to reduce the influence of the reflected sound,the workers measuring noise should be lateral to the sound source.Because when the workers faced to the sound source,they would be considered as some bigger reflectors for sound wave.The sound wave reflected back would bring some impact on the measuring result.Being lateral to the sound source,the reflected area was smaller,so the impact on the measuring results would be less.3.3 Influence of the wind noise If the noise was measured in the presence of wind,the air flow blew onto the microphone and generated pressure change on the membrane,which would bring the wind noise and it would influence the accuracy of the measurement.Outdoor measurement should be taken place when there was no wind.If the wind force scale was smaller than 3,a windshield on the microphone should be necessary for the measurement.While the measurement shouldnt be proceeded if the measured noise strength was not big enough or the wind force scale was bigger than 3.INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol.10,No.5 DECEMBER 2009 /61 4.Choice of measuring essentials 4.1 Measuring time If the environmental noise was very high,measuring the exhaust muffler noise from the excavator should be taken place when the environmental noise was minimal(e.g.late at night).This measurement was carried out in the excavator factory after work,when the environmental noise was lower relatively,so the influence on the measurement was not big.4.2 Measuring place During the course of noise measurement,the muffler was considered as a noise source,and the sound field nearby the machine(that was say,near-field region)was not stable.Near the machine,the position of the microphone changed a little and the sound level measured would change a lot.So we should avoid this area when measuring the noise.Outside of the near-field region there was the free-field region,where the distance between the sound source and the measuring spot increased one times,the sound pressure would decrease 6dB,so noise measurement should be taken in this field.When the measuring position was too far from the sound source but too near to some walls or other objects,the reflection would be very severe,and this region would turn into a reverberation one,where the measurement should neither be taken in such a region.11 In a construction machinery corporation,the characteristic of the exhaust muffler noise on an excavator was measured.There were neither anechoic room nor reverberation room,and there were also so many instruments in the assembly rooms where the transmission of the sound waves was very complicated,so the noise measurement test was taken in an opener outdoor field in the corporation,where excavator products were tested,and it could satisfy the measurement requirement for the exhaust muffler noises.The measuring spot was about 400 meters far away from the city road in front of the corporation.The test was carried out late at night,when all the noisier machines in the factory had stopped running,and with a fine and windless weather,which made sure that the impact of the air flow on the measurement could be ignored,so all above external environmental factors almost wouldnt bring too much influence on the measurement.4.3 How to choose the measuring position The measuring position was defined as the relative position between the sound-level meter and the exit of the muffler,and its selection was very important for the ultimate measuring result,so the measuring position must be indicated before noise measurement was taken place.For different kinds of noise measurements,the arrangements of the measurement points were different from each other.The layout of measuring point should be arranged according to all the noise measuring specifications.Depending on these specifications,12 when the exhaust muffler noise from the construction machinery was measured,the axis of sound-level meter should be parallel to the floor and in the same height with the exhaust orifice of the muffler.Its distance to the floor must be bigger than 1m,and at the same time 0.5m away from the exhaust orifice must be guaranteed.To keep away from the muffler outlet and air flow from mufflers,the angle between the meter and the axis of the exhaust muffler orifice should be kept 45 degrees.In addition,the distance from measuring point to the other reflectors also should be twice bigger than that to the sound source,and in order to guarantee that the sound waves were in the same incident direction,the measuring point should be kept invariant during the measuring noise course.5.Measuring apparatus and their installation 5.1 Measuring apparatus Sound-level meter,spectrum analyzer,automatic recorder,magnetic tape recorder,and so on,was the common noise measuring apparatus.Sound-level meter was a sort of device which could be used to measure the SPL or sound level according to frequency weight and time weight based on the international standards,and it was the most fundamental and was used most commonly in acoustic measurement.Sound-level meter could be used to measure room noise,environmental noise,machinery noise,architecture noise and any other ones.Microphone,amplifier,weighting network,filter,attenuator and display screen composed a sound-level meter.Microphone was an electric-energy transducer which could convert the sound wave signal into electric one.Sound-level meter practically was a voltmeter reading and writing sound wave signals,and it transformed sound wave into corresponding electrical signals which could be amplified to a certain level.Then,after measuring the level,the relevant voltage could be determined according to the sensitivity of the microphone,and the frequency characteristic could be analyzed furthermore.In this measurement test,precise integral sound-level meter P&k2230 was used and it was a capacitance integral sound-level meter made by Brel&Kjaer Corporation,which was a world-famous acoustical instrument company in Denmark.Fig.1 Main interface of Vibration and Dynamic Signal Gathering Analysis System 62 /DECEMBER 2009 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol.10,No.5 Signal gathering device used was Vibration and Dynamic Signal Gathering Analysis System(CRAS V6.1),which was produced by Nanjing Anzheng software engineering limited company in China.three modules,AdCras(data collection and processing),SsCras(signal and system analysis),Ntrp(analysis of correlation between vibration and noise)were mainly used.The main interface of this software was displayed in Fig.1.In order to shield from the interfering signals from outside,diminish the influence of noise signal outside,and guarantee the accuracy of transmitting data,shielded wires of good quality were chosen as the data wires.This system measuring exhaust noise had very good characteristic of real time and its data format could also be easily read,written and stored.5.2 Installation of the measuring apparatus Fig.2 displayed the configuration scheme of noise measurement system designed.In the system,all the apparatus were connected with shielded wires according to the order of first the sound-level meter,then the signal gathering unit and at last the computer.Sound-level meter had two output interfaces,DC and AC interfaces,of which we chose the AC interface during measuring.On the signal gathering unit,there were 16 channels,of which the first one was selected.Before measuring,the sound-level meter must be adjusted and debugged.Fig.3 showed the scene scheme of exhaust noise signals gathering system.Fig.2 Configuration scheme of noise measurement system a Front view b Left view c Vertical view d Full view Fig.3 Scene scheme of practical noise signals gathering system 6.Measurement of exhaust noise Following installing all the measuring apparatus and laying them in proper positions according to the Fig.2 and Fig.3,the environmental noise first and then the exhaust muffler noise would be measured.After gathering the exhaust noise signal data for seven kinds of mufflers on the same excavator at different load speeds,the SPL of the octave frequencies band whose center frequencies were 63,125,250,500,1000,2000,4000 and 8000 Hz would be gotten.6.1 A sound-level formula According to the reference,13 the octave frequency SPL from each measuring point could be converted into A sound-level,the formula was as follows(equation(1),0.1()110lg10piinLLAiL=(1)In equation(1),piL was the sound level of each octave frequency band.iL was the A-weighted network amendment of the ith octave frequency band,with unit dB,and n was the number of the total octave frequency bands.The SPL of each frequency band and total pressure level were respectively equal to the average SPL of six measurement points,and it could be presented by.L The formula was as follows(equation(2),6120.10.10.110101010lg6LLLL+=(2)In the Tables 2,it was displayed that the A-weighted network amendment from 63Hz to 16000Hz.Table 2 A-weighted network amendment iL Frequency(Hz)63125250500 1000 2000 4000 8000 16000iL(dB)-26.2-16.1-8.6-3.2 0 1.2 1.0-1.1-6.6 6.2 Collection of the noise signals 6.2.1 Measurement of the background noise Late at night,the factory was in the no-production state,and there were no machines running in the corporation,when it was suitable for measuring the exhaust muffler noise from excavators.The environmental noise was very important for noise measurement,and its influence on the muffler noise results was very big,so before measuring the exhaust noise from engine,the current environmental noise should be acquired at first.Then the judgment that whether the muffler noise test should be taken or not could be given.The decibel value of octave SPL about the environmental noise measured was displayed in Table 3,and the Fig.4 gave the noise spectrum curve of the current environmental noise.In that current measuring environment,the background noise pressure level was 51.2dB.And in the following part,some engine source noise values would be acquired to see if the environmental condition would answer for the measuring requirements.If not,another new measuring environment in other place or a later measurement in future should be taken.INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol.10,No.5 DECEMBER 2009 /63 Table 3 Octave SPL decibel value of the environmental noise Frequency(Hz)63 125 250 500 1000 2000 4000 A-SPL(dB)SPL(dB)-16.1 13.5 21.9 26.5 34.1 34.9 34.7 51.2 Table 4 Exhaust noise when excavator sample was in different speed unit:dB Frequency(Hz)63 125 250 500 1000 2000 4000 A-SPL(dB)600 r/m 40.9 42.5 56.4 66.2 68.7 78.6 74.4 84.9 900 r/m 49.4 55.5 59.7 70.4 81.3 79.1 77.8 89.4 1200 r/m 39.1 63.4 74.4 76.1 81.5 84.6 80.8 94.4 1500 r/m 34.3 57.2 74.6 76.9 88.5 93 86.9 100.3 1800 r/m 54.8 64.7 73.6 87.690 94.6 92.8 102.9 2050 r/m 55.4 63 75.9 87.7 93.5 98 93.3 104.8 Fig.4 One-third octave spectrum curve of the environmental noise 6.2.2 Exhaust noise measurement using substitute pipe Weichai ZH4100 was the main engine used in this excavator sample,and the engine was four-strokes and four air-cylinders.when the engine was using the substitute pipe as the muffler,we could regard the exhaust noise values as the engines own exhaust noise.Here,in order to find out the noise characteristic of the measured engine in detail,more kinds of speeds should be studied,and noise signals at six load speeds,600,900,1200,1
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