DISCOM

Noise Analysis
for Engine Test
Introduction

The DISCOM Engine Test and Noise Analysis combines order-spectra and time-
domain analysis as well as a Cycle Spectrograms to analyse engine noises.

This report shows the applied measurement techniques and results obtained from a
production site. The ongoing production was used to automatically learn limits. The
noises of production units have been analyzed and mapped to hydraulic elements of
varying fill states.

Eight engines with defects where tested. The test results are shown and discussed in
relation to the production units. When the defect is contributing to the engine noise,
the DISCOM system techniques are able to identify the problem.

The methods shown are able to pinpoint the noise sources and map them to the
different parts inside the engine.

The examples in this paper are from engine cold test. Engine hot tests have been
performed with the same package and yield similar results
DISCOM measurement system overview

Parameter
Database

Results
Database
Test Stand
Control
DISCOM analyzers

19” Industrial PC. Panel with IPC and TAS TAS USB Measurement front end.
TAS Front end Front end. AC and UPS built 10 analog channels, 4 speed inputs,
RAID system into panel D/A monitor outputs.
Dual Core and I7 CPUs Mobile system with USB power for 5
ICP sensors
Test installation

The following signals are used from the cold test stand:

• Accelerometers Cylinder Block and Engine Block

• Speed Signal Crankshaft (60-2 pulses)
• CAM Gating signal
• 0-Degree Pulse for 720° Cycle
• Command Interface for Model, Serial and Test Step information Cold test stand

Sound
&
NUC PC Archives

TAS Box

Portable version with Intel NUC PC

BKS10 accelerometer

dBg

TrnsFnc 0.0

-5.0

-10.0

-15.0

-20.0

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 k Hz

BKS10 has a linear frequency range of up
to 10 kHz and can be used to pick up the
NVH signal from unfinished surfaces.

It has a small cross-section that enables it

to fit into the narrow parts of a cylinder
head.
Sensor signals

The sensor signals from the test

stand are shown here.

All signals are also recorded in

wav files for post-processing
and optimization.
DISCOM analysis methods overview

Time Signal (rotational synchronous) Order Spectra

dB(g)
110

Traditional 100
90
Spectral analysis
80
70
60
50

DISCOM noise analysis 40

0 20 40 60 80 100 120 140 160 180 Ord
performs a rotationally → RMS, Peak, Crest, Kurtosis → spectral values
synchronous re-
sampling of the noise
New: Short time spectral analysis Recording over speed
signals. This allows
calculation of exact Cycle and modulation
order spectra and Spectrograms Order Tracks, Band Sum Tracks Ramp Spectrograms
derived values. CamShaft VS2
Ord
Ord. dB(g)

1000
1000. 115

800
800. 110

105
600
600.

100
400
400.

95
200
200.
90
3400 3500 3600 3700 3800 Upm
0
0° 80° 160° 240° 320° 400° 480° 560° 640° 720° °

→ “speed bands”
Traditional spectral analysis

The cycle information is present in the time domain.

The spectral information has spread the cycle information

Accelerometer signals, rotationally synchronous,

one motor cycle

Spectra and limits are the average behavior of the engine during a revolution.
Order spectra in high modes

Industrielle Meß- und Prüftechnik

Order Spectra Peak hold order spectra (crank
shaft orders)
9405 104 Measurements 24.04.13 05:07

High1 / TvHead High2 / TvHead High3 / TvHead

Engine Model 9405, 104 dB(g) dB(g) dB(g)

measurements overlaid 90 90 90

with limit curve. 80 80 80

70 70 70

Head sensor top, block 60 60 60

sensor below 50 50 50

40 40 40
0 5 10 15 20 25 30 35 Ord 0 5 10 15 20 25 30 35 Ord 0 5 10 15 20 25 30 35 Ord

High1 / TvBlock High2 / TvBlock High3 / TvBlock

dB(g) dB(g) dB(g)

90 90 90

80 80 80

70 70 70

60 60 60

50 50 50

40 40 40
0 5 10 15 20 25 30 35 Ord 0 5 10 15 20 25 30 35 Ord 0 5 10 15 20 25 30 35 Ord
RMS tracks during constant speeds and ramp

RMS Pegelverläufe
Industrielle Meß- und Prüftechnik

Typ 4119 27.02.13 23:33

Curves / R / Motor (FixFs,KS1) / Rms Track

dB(g)
-

125

CFC085893
120
CFC085894
CFC085895
115
CFC085896
CFC085897
110
CFC085900
CFC085901
105
CFC085902
CFC085903
100
CFC085905
CFC085906
95
CFC085899
CFC085904
90
CFC085893
CFC085894
85
CFC085895
CFC085896
80
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 Upm

Curves / R / Motor (FixFs,KS2) / Rms Track

dB(g)

125

120

115

110

105

100

95

-
90

85

80
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 Upm
Typical spectral signatures

Time signal Spectrum

Good gear

Crest!

Nick or similar

Surface waviness
“Ghost orders“

Eccentricity,
deviation from
circular shape
Side bands
Cycle spectrogram
Engine Cycle Spectrograms
Industrielle Meß- und Prüftechnik

Ord
Cylinder Head 120 dB(g)
Ord
Cylind
480 480
460 460
440 440
Pulse components of all kinds can be 420
400
420
400

Short-time spectra are computed identified with this method 380 380
360 360
340 340
over the revolution of the engine. 320 320
300 300
Several spectra are averaged and 280 280
260 260
indicate spectral abnormalities at 240
220
240
220
certain angles. 200
180
200
180
160 160

Spectral and timing information is 140

120
140
120

combined 100
80
100
80
60 60
40 40
20 20
0 0
90 dB(g)
0 90 180 270 360 450 540 630 ° 0 90 180 270
(456.0, 540): 64.2327
(260 Ord) (244 Ord)
dB(g) dB(g)
125 125
120 120
115 115
110
105
Motor cycle 110
105
100 100
95 95
90 90
85 85
0 90 180 270 360 450 540 630 ° 0 90 180 270
Cycle spectrograms VWPT loutang

Low 1 Low 2
Test step: Low 1 Test step: Low 2
Engine Cycle Spectrograms Sensor set: Test stand Engine Cycle Spectrograms Sensor set: Test stand
9405 9405
Industrielle Meß- und Prüftechnik Industrielle Meß- und Prüftechnik

Cylinder Head 120 dB(g) Cylinder Block 120 dB(g)

Ord
Cylinder Head 114 dB(g)
Ord
Cylinder Block 114 dB(g)
Ord Ord
480 480 480 480
460 460 460 460
440 440 440 440
420 420 420 420
400 400 400 400
380 380 380 380
360 360 360 360
340 340 340 340
320 320 320 320
300 300 300 300
280 280 280 280
260 260 260 260
240 240 240 240
220 220 220 220

One Engine in the modes 200

180
160
140
120
200
180
160
140
120
200
180
160
140
120
200
180
160
140
120

Low1, Low2, High1 and High2 100 100 100 100

80 80 80 80
60 60 60 60
40 40 40 40
20 20 20 20

with Spectrogram Band below

0 0 0 0
90 dB(g) 90 dB(g) 84 dB(g) 84 dB(g)
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
(456.0, 540): 64.2327 ( 0.0, 0): 82.8081 (468.0, 709): 58.1591 (492.0, 383): 48.2048
(260 Ord) (244 Ord) (268 Ord) (244 Ord)
dB(g) dB(g) dB(g) dB(g)
125 125 120 120
120 120 115 115
115 115 110 110
110 110 105 105
105 105 100 100
100 100 95 95
95 95 90 90
90 90 85 85
85 85 80 80
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °

High 1 High 2
Test step: High 1 Test step: High 2
Engine Cycle Spectrograms Sensor set: Test stand Engine Cycle Spectrograms Sensor set: Test stand
9405 9405
Industrielle Meß- und Prüftechnik Industrielle Meß- und Prüftechnik

Ord
Cylinder Head 114 dB(g)
Ord
Cylinder Block 114 dB(g)
Ord
Cylinder Head 114 dB(g)
Ord
Cylinder Block 114 dB(g)

480 480 480 480

460 460 460 460
440 440 440 440
420 420 420 420
400 400 400 400
380 380 380 380
360 360 360 360
340 340 340 340
320 320 320 320
300 300 300 300
280 280 280 280
260 260 260 260
240 240 240 240
220 220 220 220
200 200 200 200
180 180 180 180
160 160 160 160
140 140 140 140
120 120 120 120
100 100 100 100
80 80 80 80
60 60 60 60
40 40 40 40
20 20 20 20
0 0 0 0
84 dB(g) 84 dB(g) 84 dB(g) 84 dB(g)
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
(436.0, 371): 68.261 (184.0, 461): 83.942 (172.0, 686): 99.4714 (488.0, 124): 50.7565
(180 Ord) (160 Ord) (180 Ord) (160 Ord)
dB(g) dB(g) dB(g) dB(g)
120 120 120 120
115 115 115 115
110 110 110 110
105 105 105 105
100 100 100 100
95 95 95 95
90 90 90 90
85 85 85 85
80 80 80 80
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
Cycle spectrogram bands

Cycle Spectrogram bands allow to overlay different engines. Limit curves can be self-learned

Test step: Low 1 Main Band

Engine Cycle Spectrograms
Different Bands Sensor set: Test stand 100 Engines overlaid
9405
Industrielle Meß- und Prüftechnik

are evaluated with Limit Curve

Ord
Cylinder Head 120 dB(g)
Ord
Cylinder Block 120 dB(g)

480 480
460 460
440 440
Spectra / Low 1 / Cam Shaft (STA,TvHead) / Spectrogr. Band / Mai nOrderBand
420 420
400 400 dB(g)
380 380
360 360
340 340
320 320
300 300
280 280
260 260
240 240 90
220 220
200 200
180 180
160 160
140 140
120 120
100 100
80 80 70
60 60 0 90 180 270 360 450 540 630 °
40 40
20 20
0 0
90 dB(g) 90 dB(g)
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
(456.0, 540): 64.2327 ( 0.0, 0): 82.8081

Main Band
(260 Ord) (244 Ord)

Order 260
High Band
dB(g) dB(g)
125 125
120 120
115 115
110 110
105 105
100 100
95 95
90 90
85 85
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
Measurement application: TasAlyser

The measurement application activates the Tas

box and initiates signal recording when the test
run starts. All calculations and evaluations are
performed in real time on the PC.
The TasAlyser application runs in multiple
processing threads and thus can fully exploit
the potential of modern multi-core CPUs.

TasAlyser is modular software that can be easily

adapted to specific project requirements.
Special analysis methods can be added as
needed (e.g., shift force analysis, temperature
measurement)
The measurement application has numerous
data display capabilities for the noise signals
and evaluation results.
Some TasAlyser features

TasAlyser provides a number of additional features for optimizing the

analysis results and performing investigations “offline”:

Signal gain display and

audio monitoring (hear Individual setup Recording of complete test runs
the noise signal on the of user interface as wave files and replay
PC sound output) and windows including test stand commands
(“test run playback”)

Filters can be added

for single channels,
e.g., A filter, band
pass, parametric
filters (order
masking). Calibration procedure with automatic signal detection
Sound recording and off-line analysis

IO NIO

Round-robin storage of last N

good units and last M bad units. Off-line analysis of
Several options for data recorded data on
acquisition and storage. Capture the user’s PC’s.
of test stand commands. Monitoring of sounds
during playback.
Spectral limits

Hats for gear mesh orders and their side bands

dBg

MaxBnd 100

80
MinBnd

60
StdDev

40
AW-avg
20
SK1-lim

10 20 30 40 50 60 70 80 90 Ord

Limit curve from Average + Offset + n times standard deviation. Overridden by minimum
and maximum polygons and by the fixed hats.
Learning process

The learning of the limits is done in two steps: base

learning and additional learning.
The base learning encompasses only a few units (e.g.,
five). During base learning the measured value is
compared to the upper bound from the parameter
database. At the end of the base learning the
preliminary limits are set.
Base learning Additional learning Limits fixed
The additional learning encompasses a lot of units
(e.g., 200). Each unit is for the time being tested Total learn count
against the previous limit values. If it is found to be ok
it will be added to the statistics. This way the limit
values are fine-tuned.
Learning parameter:
The automatic learning also permits the unattended Exponential time constant
start of a new gearbox type at a test bench and
provides “reasonable“ beginning limit values that can
⅓
be refined through the parameter database. T
The learning process can be restarted or extended at
any time – also for single gears or specific values. It is
controlled from the parameter database.
Test cycle

The DISCOM System performs its measurements in the following cycles

For every test cycle, the following 1500 RPM

measurements are taken,

Speed
evaluated and stored:

• Order Spectra 1000 RPM

• Order and RMS tracks
• Cycle Spectrograms
• Spectrogram Bands Time

Low1 Low2 High1 High2 High3

OILP Buildup OILP OK VVT VVT VVT
Off On Off
Understanding the engine

Valve Action Points VWPT 1.4 TSI

Valve Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4

Intake Opens 360 173 534 714

Exhaust Opens 152 691 329 512

Intake Closes 600 413 60 240

Exhaust Closes 540 335 690 180

+446 (Discom Offset)

Intake Opens 86 619 260 440

Exhaust Opens 598 417 55 238

Intake Closes 326 139 506 686

Exhaust Closes 266 61 416 626

Cycle action lubrication phase low 1

40° later C C C C C C C C
when oil 3 1 4 3 2 4 1 2
is missing E I E I E I E I

Spectra / Low 1 / Cam Shaft (STA,TvHead) / Spectrogr. Band / Mai nOrderBand

dB(g)

90

70
0 90 180 270 360 450 540 630 °
TDC4 TDC2 TDC1 TDC3
86° 266° 446° 626°
During Lubrification: Four large impacts 40° after Intake valve activation
Oil build-up phase

Source of the noise during oil pressure build up

Green Lifters:
Rock Arm During Oil Build Up,
impact noise by compressing
hydraulic lifter to its minimal size
before the valve is operated.

Filled Lifter:
Quiet operation of valve after the
lifter is filled with oil, maintains it‘s
Valve size and the valve is lifted without
compressing the lifter.
Hydraulic
Lifter
Oil distribution during lubrication

Intake valve
hydraulic lifters filled later.
Still in Green Stage

Oil flow

Exhaust valve
hydraulic lifters
filled first

During oil pressure build up the hydraulic lifters of the exhaust valves are mostly filled and operating.
The intake valves take longer to operate correctly. Therefore the noise during oil buildup has the
timing of the input valves shifted about 40 degrees because of lifter compression.

Sometimes the Exhaust lifter is not yet filled and makes noise as well
Cycle action low 1 VWPT 1.4 TSI

40° later C C C C C C C C
when oil 3 1 4 3 2 4 1 2
is missing E I E I E I E I

Spectra / Low 1 / Cam Shaft (STA,TvHead) / Spectrogr. Band / Mai nOrderBand

dB(g)

90

70
0 90 180 270 360 450 540 630 °

Green: Intake valve lifters soft during lubrification Blue: Exhaust valve lifters sometimes still soft
Cycle action with oil pressure low 2

40° later C C C C C C C C
when oil 3 1 4 3 2 4 1 2
is missing E I E I E I E I

Spectra / Low 2 / Cam Shaft (STA,TvHead) / Spectrogr. Band / Mai nOrderBand

dB(g)

85

65
0 90 180 270 360 450 540 630 °

Oil TDC1 446°

Cycle action high 1 VWPT TSI

40° later C C C C C C C C
when oil 3 1 4 3 2 4 1 2
missing E I E I E I E I

Spectra / Hi gh1 / Cam Shaft (STA,TvHead) / Spectrogr. Band / Mai nOrderBand

dB(g)

85

65
0 90 180 270 360 450 540 630 °

TDC1 446°
Cycle action high 2 VWPT TSI

40° later C C C C C C C C
when oil 3 1 4 3 2 4 1 2
is missing E I E I E I E I

Spectra / Hi gh2 / Cam Shaft (STA,TvHead) / Spectrogr. Band / Mai nOrderBand

dB(g)

100

95

90

85

80

75

70

65
0 90 180 270 360 450 540 630 °

TDC1 446°
Test of engines with defects

Eight engines with the following defects have been tested:

Type Serial Defect Recognized Hearable

9405 1.4 TSI 808111 Piston cylinder 2 wrong orientation Yes Yes
9405 1.4 TSI 808113 Soft hydraulic lifters Yes Yes
9405 1.4 TSI 809609 Conrod Bearing Shell missing Yes Yes
9405 1.4 TSI 809609 Main Bearing Cap wrongly assembled No No
9405 1.4 TSI 809120 Cam Shaft Surface Damaged No No
9405 1.4 TSI 809110 Conrod Cap wrongly assembled Eventually No
9405 1.4 TSI 810706 Rock Arm displaces Intake Cylinder 2 Yes Slightly
9405 1.4 TSI 810724 Metal Part in Cylinder 3 Yes Yes
Piston: Wrong orientation

Large impact noise during VVT operation in High2

1500 RPM
Speed

1000 RPM

Time
Low1 Low2 High1 High2 High3
OILP Buildup OILP OK VVT Off VVT VVT
On Off
Piston2: Wrong orientation detected in high 2

Piston2 touches Intake Valve

Test step: High 2
Engine Cycle Spectrograms Sensor set: Test stand
9405
Industrielle Meß- und Prüftechnik

Ord
Cylinder Head 110 dB(g)
Ord
Cylinder Block 110 dB(g)

480 480
460 460
440 440
420 420
400 400
380 380
360 360
340 340
320 320
300 300
280 280
260 260
240 240
220 220
200 200
180 180
160 160
140 140
120 120
100 100
80 80
60 60
40 40
20 20
0 0
86 dB(g) 86 dB(g)
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
(104.0, 709): 94.8581 (240.0, 495): 88.1963
(192 Ord) (168 Ord)
dB(g) dB(g)

120 115
115 110
110 105

105 100

100 95

95 90 Engine Type 9405, Serial 808111

0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
Piston2: Wrong orientation, detected in high 2

Piston2 touches Intake Valve @ 180°

from TDC Cylinder 1 which is Cylinder 2‘s Exhaust/Intake TDC

Spectra / Hi gh2 / Cam Shaft (STA,TvHead) / Spectrogr. Band / Mai nOrderBand

dB(g)

105

100

95

90

85

80

75

70
0 90 180 270 360 450 540 630 °

TDC4 TDC2 TDC1 TDC3

86° 266° 446° 626°
EDC2
Engine Type 9405, Serial 808111
Soft lifter
Industrielle Meß- und Prüftechnik
Spectrogram Bands PeakSoft
holdExhaust
band sums
Soft Exhaust side Lifters in side Lifters
calculated in cycle
from engine
Main Band Sensor: Cylinder Head Low1: 24.04.13 05:17 spectrograms
Low2:
(50-450)
Oil Build Up Oil pressure OK
Runin Low1 Low2
dB(g) dB(g)
First run of engine with soft
lifter in Blue.
110 110 110

100 100 100

Four consecutive tests are
90shown. The expected shift of 90 90

valve action of 40° is clearly

80 80 80
seen.
70 70 70
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °

High1 High2 High3

dB(g) dB(g) dB(g)

110 110 110

100 100 100

90 90 90

80 80 80

70 70 70
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °

Engine Type 9405, Serial 808113. First run clearly faulty, Later runs OK.
 100 100 100

90 90 90

Conrod bearing shell missing

80 80 80

70 70 70

60
0 90
Industrielle Meß- 180
und Prüftechnik 270
Spectrogram Bands
360 450 540 630 720
60
0 90 180 270 360 450 540 630 °
60
0 Peak
90 hold
180 band
270 sums
360 450 540 630 °
Head Sensor, Main Band calculated from engine cycle
Main Band High1 Sensor: Cylinder Block High2 24.04.13 13:11 spectrograms High3
dB(g)
(50-450) dB(g) dB(g)

100 Runin 100 Low1 100 Low2

dB(g) dB(g)

90 90 90
100 100 100

80 80 80
90 90 90

70 70 70
80 80 80

60 60 60
70 0 90 180 270 360 450 540 630 ° 70 0 90 180 270 360 450 540 630 ° 70 0 90 180 270 360 450 540 630 °

TDC1, EDC4 446°

60 60 60
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
Block Sensor, Main Band
High1 High2 High3
dB(g) dB(g) dB(g)

100 100 100

90 90 90

80 80 80

70 70 70

60 60 60
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °

Engine Type 9405, Serial 809609. Piston touches Intake valve of Cylinder 4
Main bearing cap wrongly assembled

Spectrogram Bands
Industrielle Meß- und Prüftechnik Peak hold band sums
calculated from engine cycle Industrielle Meß- und Prüftechnik
Spectrogram Bands Peak hold band sums
High Band Sensor: Cylinder Head 24.04.13 13:22 spectrograms calculated from engine cycle
(300+) High Band Sensor: Cylinder Block 24.04.13 13:23 spectrograms
(300+)
Runin Low1 Low2
dB(g) dB(g) Runin Low1 Low2
dB(g) dB(g)

100 100 100

100 100 100

90 90 90
90 90 90

80 80 80
80 80 80

70 70 70
70 70 70

60 60 60
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 60 60 60
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °

High1 High2 High3

dB(g) dB(g) dB(g) High1 High2 High3
dB(g) dB(g) dB(g)

100 100 100

100 100 100

90 90 90
90 90 90

80 80 80
80 80 80

70 70 70
70 70 70

60 60 60
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 60 60 60
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °

Industrielle Meß- und Prüftechnik

Spectrogram Bands Peak hold band sums Industrielle Meß- und Prüftechnik
Order Spectra Peak hold order spectra (crank
calculated from engine cycle shaft orders)
Main Band Sensor: Cylinder Head 24.04.13 13:26 spectrograms 9405 108 Measurements 24.04.13 13:29
(50-450)

Runin Low1 Low2 High1 / TvHead High2 / TvHead High3 / TvHead

dB(g) dB(g) dB(g) dB(g) dB(g)

100 100 100 90 90 90

80 80 80
90 90 90

70 70 70
80 80 80
60 60 60

70 70 70
50 50 50

60 60 60 40 40 40
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 5 Ord 0 5 Ord 0 5 Ord

High1 High2 High3 High1 / TvBlock High2 / TvBlock High3 / TvBlock

dB(g) dB(g) dB(g) dB(g) dB(g) dB(g)

100 100 100 90 90 90

80 80 80
90 90 90

70 70 70
80 80 80
60 60 60

70 70 70
50 50 50

60 60 60 40 40 40
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 5 Ord 0 5 Ord 0 5 Ord

Engine Type 9405, Serial 808108. No noise component detected

Cam shaft surface damage

Industrielle Meß- und Prüftechnik

Spectrogram Bands Peak hold band sums Industrielle Meß- und Prüftechnik
Order Spectra Peak hold order spectra (crank
calculated from engine cycle shaft orders)
Main Band Sensor: Cylinder Head 24.04.13 14:40 spectrograms 9405 107 Measurements 24.04.13 14:37
(50-450)

Runin Low1 Low2 High1 / TvHead High2 / TvHead High3 / TvHead

dB(g) dB(g) dB(g) dB(g) dB(g)

100 100 100 90 90 90

80 80 80
90 90 90

70 70 70
80 80 80
60 60 60

70 70 70
50 50 50

60 60 60 40 40 40
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 10 20 30 40 50 60 Ord 0 10 20 30 40 50 60 Ord 0 10 20 30 40 50 60 Ord

High1 High2 High3 High1 / TvBlock High2 / TvBlock High3 / TvBlock

dB(g) dB(g) dB(g) dB(g) dB(g) dB(g)

100 100 100 90 90 90

80 80 80
90 90 90

70 70 70
80 80 80
60 60 60

70 70 70
50 50 50

60 60 60 40 40 40
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 10 20 30 40 50 60 Ord 0 10 20 30 40 50 60 Ord 0 10 20 30 40 50 60 Ord

Industrielle Meß- und Prüftechnik

Spectrogram Bands Peak hold band sums
calculated from engine cycle
Main Band Sensor: Cylinder Block 24.04.13 15:04 spectrograms
(50-450)

Runin Low1 Low2

dB(g) dB(g)

100 100 100

90 90 90

80 80 80

70 70 70

60 60 60
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °

High1 High2 High3

dB(g) dB(g) dB(g)

100 100 100

90 90 90

80 80 80

70 70 70

60 60 60
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °

Engine Type 9405, Serial 808120. No noise component detectable

 Runin Low1 Low2
dB(g) dB(g)

90 90 90

Conrod cap wrongly assembled 80

70
80

70
80

70

60 60 60

50 50 50
0 90 180 270 360 450 540 630 720 0 90
Block Sensor,
180 270 360 450
High Band
540 630 ° 0 90 180 270 360 450 540 630 °

High1 High2 High3

dB(g) dB(g) dB(g)

90 90 90

80 80 80

70 70 70

60 60 60

Test step: High 2

Engine Cycle Spectrograms
50 50 50
Test step: High 2

Industrielle Meß- und Prüftechnik

0 90 180 270 360Sensor
9405
450set: 540
Test 630
stand ° 0 90 180 270
Engine
360 450
Cycle
540 630
Spectrograms
° 0 90 180 270 360 450 540
Sensor set:
630
Test stand
°

9405
Industrielle Meß- und Prüftechnik

Cylinder Head 102 dB(g) Cylinder Block 102 dB(g)

Ord Ord
Ord
Cylinder Head 102 dB(g)
Ord
Cylinder Block 102 dB(g)
480 480
460 460 480 480
460 460
440
420
400
440
420
400
440
420
Bad unit 440
420
400 400
380
360
340
380
360
340
380
360
Serial 808110. Block Sensor 380
360
320 320 340 340
300 300 320 320
280 280 300 300
260 260 280 280
240 240 260 260
220 220 240 240
200 200 220 220
180 180 200 200
160
140
120
160
140
120
180
160
140
For reference: Good unit 180
160
140
100
80
60
100
80
60
120
100
80
Block Sensor. No impulse, also 120
100
80
40
20
0
40
20
0
60
40
20
less energy around order 300 60
40
20
78 dB(g) 78 dB(g)
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 0
78 dB(g) 78 dB(g)
( 0.0, 698): 80.6539 (436.0, 315): 69.0046 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
(180 Ord) (384 Ord) - (484.0, 461): 44.8107
dB(g) dB(g) (180 Ord) (384 Ord)
120 dB(g) dB(g)
115 85 120
115 85
110 80
105 110 80
75 105
100 75
95 70 100
90 95 70
65
85 90 65
80 60 85
80 60
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °

Engine Type 9405, Serial 808110. Block Sensor High Band somewhat noisy. Detectability low
Rock arm displaced Test step: High 3
Engine Cycle Spectrograms Sensor set: Test stand
9405
Industrielle Meß- und Prüftechnik

High3
Ord
Cylinder Head 104 dB(g)
Ord dB(g) Cylinder Block 104 dB(g)

480 480
460 460
100
440 440
420 420
400 400 90
380 380
360 360
340 340 80
320 320
300 300
70
280 280
260 260
240 240 60
220 220 0 90 180 270 360 450 540 630 °
200 200
180
160
180
160
New band or Rectangle method
140
120
140
120
necessary for clear detection.
100 100 Shown: Main Band
80 80 RMS Tracks
Industrielle Meß- und Prüftechnik

60 60 - 26.04.13 01:51

40 40
Curves / High1 / Engine (FixFs,TvHead) / Rms Track
20 20 dB(g)
-

0 0
80 dB(g) 00810603
80 dB(g)
0 90 180 270 360 450 540 630 ° 0 90 180 270
110.0
360 450 540 630
00810604 °
(360.0, 698): 80.4956 (180.0, 113): 98.0859 00810605
00810606
(216 Ord) (168 Ord) 00810607
00810608
dB(g) dB(g) 105.0
00810610
00810612
00810613
110 115 00810614
00810615
00810597
100.0
00810619
105 110 00810623
00810625

100 105 95.0

0.0 0.5 1.0 1.5
00810627
00810628
s
Classical RMS-Value:
95 100
dB(g)
Curves / High1 / Engine (FixFs,TvBlock) / Rms Track
No detection.
90 95

85 90 110.0

0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
105.0

High-energy Band around order 160. From Angle: 100.0

-

Cylinder No. 2 Intake Valve Rock Arm displaced

95.0
0.0 0.5 1.0 1.5 s
Rectangular areas in cycle spectrograms
Engine Cycle Spectrograms
Industrielle Meß- und Prüftechnik

Ord
Cylinder Head 104 dB(g)
Ord
Cy
480 480
460 460
440 440
Ord
Ord.
PistonBand 420 420
400 400
1500
1500. 380 380
360 360
340 340
320 320
1200
1200. 300 300
280 280
260 260
900
900. 240 240
220 220
200 200
180 180
600
600.
160 160
140 140
120 120
300
300. 100 100
80 80
60 60
0 40 40
0° 30° 60° 90° 120° 150° 180° 210° 240° 270° 300° 330° ° 20 20
0 0
80 dB(g)
0 90 180 270 360 450 540 630 ° 0 90 180 270
The energy in a chain of rectangular areas can also be used as a single value for (216 Ord) (360.0, 698): 80.4956
(168 Ord)
dB(g) dB(g)
defect detection. 110
For the Rock Arm detection this would 115
105 110
100
consist of two rectangles for this special arm 105

95 100

90 95

85 90
0 90 180 270 360 450 540 630 ° 0 90 180 270
Metal part in cylinder
Test step: High 1
Engine Cycle Spectrograms Sensor set: Test stand
9405
Industrielle Meß- und Prüftechnik

Ord
Cylinder Head 104 dB(g)
Ord
Cylinder Block 104 dB(g)

480 480

Spectrogram Bands
460 460
440 440
Industrielle Meß- und Prüftechnik Peak hold band sums
420 420
calculated from engine cycle
400 400
380 380
Main Band Sensor: Cylinder Head 26.04.13 02:14 spectrograms
360 360(50-450)
340 340
320 320 Runin Low1 Low2
dB(g) dB(g)
300 300
280 280
260 110
260 110 110

240 240
220 220
100 100 100
200 200
180 180
90 90 90
160 160
140 140
80 80 80
120 120
100 100
80 7080 70 70
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
60 60
40 40
20 20 High1 High2 High3
dB(g) dB(g) dB(g)
0 0
80 dB(g) 80 dB(g)
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °
(336.0, 709): 80.3654 110 (296.0,
110 675): 91.2165 110
(180 Ord) (168 Ord)
dB(g) dB(g)
100 100 100
115 115
110 110
90 90 90
105 105
80 80 80
100 100

95 95
70 70 70
90 90
0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °

0 90 180 270 360 450 540 630 ° 0 90 180 270 360 450 540 630 °

High energy in all tests. By angle information Metal part in Cylinder 3 or Cylinder 2
Summary

A new method for the detection of pulse noise from the engine is demonstrated. It combines
angular cycle information with spectral signature.

The source of noise components from green engines was studied and lets understand how the
hydraulic lifters generate the major noise. The approach allows to locate soft hydraulic lifters for
replacement after three retest fail.

All noise engines have been identified and the reason for the noise could be tract to the
mechanical component,

All measurements have been performed in automatic operation together with a cold test bench.
The limits where auto-learned from series production without manual help.

Manual optimization allows to set limits for specific noise events which shall be passed like
certain hydraulic lifter noise.

We are much obliged to Volkswagen Powertrain Loutang for their support in these tests, and helping in performing this
study.

Loutang, Shanghai 2013-04-24, Dr. Thomas Lewien & Zhang Yangning

Computer network map

Measurement PCs at test stands

Distribution Acquisition of measurement archives (collector service)

of parameter
database

Access for evaluation

and parametrization

Server for parameter Office workstation (your desk)

database and result
database
DISCOM Data Flow

Work Group PCs have presentation software installed

DISCOM
Can use Intranet statistics via Internet Explorer
Analyzer(s)

Test Stand

Measurement
Archives
DISCOM
Presentation

Measurement
Database

Intranet Statistics

Server or Test Stand Work Group PC

Order spectra

618CKA20013288 29.Feb'2008,07:08:09

GM 6R Order Spectra
Industrielle Meß- und Prüftechnik

Mix in 6-sC
90 dBg
Ord

450

400

350

300

250

200

150

100

50

0
0 50 100 150 200 250 300 -
80 dBg
Unit x multiple runs in pink. First run
(236.0, 399.0): 72.664

dBg
MixR (264.0 -) highlighted in blue.
115

110 GM6R Silao Stand 2 Type 8CKA [80] Serial 618CKA20013288 29.Feb'2008,07:08:09
105
Transmission NOK ***
--------------------------------------------------------------------------------
100
code errortext gear value limit avg u O/Tp ch
95 16718 Transmission: Order loud in 6-Coast 6-sC 92.3/ 90.1/ 66.7 dBg 57.00 R1
90 16718 Transmission: Order loud in 6-Coast 6-sC 96.4/ 92.6/ 76.8 dBg 53.00 MixR
85
16718 Transmission: Order loud in 6-Coast 6-sC 93.5/ 93.4/ 77.5 dBg 54.50 MixR
16718 Transmission: Order loud in 6-Coast 6-sC 96.5/ 95.5/ 77.7 dBg 76.50 MixR
80
16718 Transmission: Order loud in 6-Coast 6-sC 93.8/ 88.1/ 72.1 dBg 133.00 MixR
75
16718 Transmission: Order loud in 6-Coast 6-sC 89.5/ 88.7/ 72.6 dBg 135.50 MixR
70 16718 Transmission: Order loud in 6-Coast 6-sC 89.1/ 89.0/ 72.8 dBg 136.50 MixR
65 16718 Transmission: Order loud in 6-Coast 6-sC 90.8/ 89.1/ 74.4 dBg 147.00 MixR
16718 Transmission: Order loud in 6-Coast 6-sC 93.2/ 92.8/ 77.0 dBg 166.00 MixR
60
0 50 100 150 200 250 300 350 400 450 500 Ord 16718 Transmission: Order loud in 6-Coast 6-sC 92.7/ 92.7/ 76.7 dBg 176.00 MixR
16718 Transmission: Order loud in 6-Coast 6-sC 95.1/ 91.2/ 75.4 dBg 198.50 MixR
16718 Transmission: Order loud in 6-Coast 6-sC 99.0/ 95.1/ 78.4 dBg 233.00 MixR
16718 Transmission: Order loud in 6-Coast 6-sC 96.3/ 95.2/ 78.4 dBg 234.50 MixR
Spectral statistics

Order spectra of production units can

be displayed in Campbell or in 3D
graphs.
Cuts in the order or in the unit
direction show order amplitude
versus units or the spectrum of one
unit.
The pictures show the order spectra
of 300 production units. A ghost
order of 118 is present in the first 40
units tested.
Complete data report of a single unit

Sensor Group 1

Macro controlled display of

archived data.
The database is used for
searching of serial numbers,
test results etc.
Then the presentation
software displays a full
measurement report
Intranet statistics: DISCOM Web.Pal

The information of the SQL

measurement database can be
retrieved via the intranet.
The production results and the
measurements can be seen online.
An arbitrary time interval can be
selected for the analysis.
Measurement statistics and bench comparison

Test results reports and

statistical time series
evaluation is available
with hyperlink navigation
Reject analysis, Top N

Top N graphs with link to

further evaluation is
implemented