Research on Abnormal Starting Noise of Efficient Engine Caused by Abnormal Combustion Noise

Feng Huang; Xiaochun Zeng; Xili Wang; Xinqi Qiao; Yi Wang; Liang Fang; Yunhua Zhang; Dengcheng Liu; Yonghong Deng

doi:10.53941/ijamm.2024.100007

Abstract

An abnormal noise problem was reported in a pickup truck equipped with a 2.0 L efficient engine during start-up. The noise was reproduced by the engine anechoic chamber bench for further analysis. NVH test (conducted through audio playback and signal filtering) showed that the noise had a signal of 1–3 kHz. Analysis through cylinder-by-cylinder oil-cutting method found that the abnormal noise completely disappeared after the fourth cylinder was cut off, indicating that the noise was related to the combustion of the fourth cylinder. The combustion characteristics of each cylinder were then analyzed in the starting condition through the Kibox combustion analyzer. The noise appeared after the first fuel injection of the fourth cylinder, and the maximum pressure rise rate was 42 Bar/°, confirming that the abnormal noise was combustion noise. Further tests on the physical fuel injection signal of each cylinder found that the fourth cylinder only had the main injection signal with no pilot injection signal. Further analysis of the synchronization signal recognition method of the model and the underlying logic of the fuel injection program showed that the synchronization signal was recognized for the first time in the starting process after the calculation moment of the 4th cylinder pre-injection program, resulting in the failure of the pre-injection calculation. Finally, the bottom fuel injection interrupt program was pushed back (60° to the crankshaft angle), ensuring smooth injection of the 4th cylinder pilot injection in the starting working condition, thus solving the abnormal noise without impacting engine performance.

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