Intake sound control unsing pure feedforward method with order-based offline calibration

Abstract

A method for controlling induction sound of an internal combustion engine is described. The method includes computing a first sound pressure during a run up of the engine, wherein the first sound pressure is based on each order of sound generated by the engine. Next, the engine is operated engine under a plurality of operating conditions and a second sound pressure is computed for each of the operating conditions. A frequency response of a microphone and a speaker used in computing the first and second sound pressures is then determined. The method further includes obtaining current vehicle operating conditions and decomposing the first and second sound pressures and the frequency response into engine orders. A net control signal is then generated, wherein the signal is based on each of the first and second sound pressures, the frequency response and the vehicle operating conditions so as to independently control individual orders of the engine sound.

Description

FIELD OF THE INVENTION

[0002] This invention relates to noise control systems, and more particularly, to a feedforward noise control system which generates a control signal based on sound pressures that are computed offline and which are order based.

BACKGROUND OF THE INVENTION

[0003] Motor vehicle engines generate an induction sound which is primarily caused by the reciprocating motion of intake valves. Hence for a four stroke engine, a sound spectrum is generated that is comprised of the half order of the engine revolution (i.e. a full order of camshaft revolution) and higher harmonics thereof. Motor vehicles also include an air induction system having an intake orifice and a ducting arrangement which directs air from the environment to an internal combustion engine for use in a combustion process. A characteristic of such systems is that the induction sound travels through the induction system to the intake orifice in a finite amount of time which depends on duct length and other acoustic factors. The sound then propagates to the passenger compartment of the vehicle. This sound is undesirable for passengers inside the vehicle and contributes to environmental noise.

[0004] Frequently, the induction sound is attenuated by using passive devices such as Helmoltz and Quarter wave resonators, dampers and sound absorbers. A disadvantage with such devices is that they are only effective for relatively narrow frequency bands. In addition, they add non-uniformity to the resulting sound. Passive devices also tend to require relatively large amounts of space and are thus difficult to package within the tight confines of modern engine compartments. Further, such devices can only attenuate noise and cannot enhance sound.

[0005] Another technique for attenuating induction sound is through the use of an active noise cancellation system, such as a closed-loop active noise control system. Such systems utilize a Digital Signal Processor (DSP) to generate a control signal that is used to drive a speaker. The speaker then generates a sound adapted to attenuate undesirable noise so that it is reduced or cancelled. A microphone is used to monitor system performance. Information obtained from the microphone is then ultimately used to adjust various control parameters. Use of a DSP is necessitated in such systems due to the large number of computations that are needed.

[0006] Although fairly versatile, closed loop systems are expensive due to the auxiliary components that are required. In addition, the microphones utilized in such systems have many limitations and are not suited for use in an automotive environment. Closed loop systems also have limited tracking capability due to background noise and since they are based on a principle of gradual convergence. Further, such systems may become unstable under many situations due to feedback.

SUMMARY OF THE INVENTION

[0007] In one aspect of the invention, a method for controlling induction sound of an internal combustion engine is described. The method includes computing a first sound pressure during a run up of the engine, wherein the first sound pressure is based on each order of sound generated by the engine. Next, the engine is operated under a plurality of operating conditions and a second sound pressure is computed for each of the operating conditions. A frequency response of a microphone and a speaker used in computing the first and second sound pressures is then determined. The method further includes obtaining current vehicle operating conditions and decomposing the first and second sound pressures and the frequency response into engine orders. A net control signal is then generated, wherein the signal is based on each of the first and second sound pressures, the frequency response and the vehicle operating conditions so as to independently control individual orders of the engine sound.

[0008] The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself, however, both as to organization and method of operation, together with further objects and advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 depicts a block diagram for a feedforward order based open loop control system in accordance with the present invention.

[0010] FIG. 2 illustrates an example of a set of look-up tables for temperature effects on control signal amplitude.

[0011] FIG. 3 shows a flow diagram depicting aspects of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0012] While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail specific embodiments, with the understanding that the present disclosure is to be considered as an example of the principles of the invention and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar or corresponding parts in FIGS. 1-3.

[0013] Motor vehicle engines generate an induction sound which is primarily caused by the reciprocating motion of intake valves. Hence for a four stroke engine, a sound spectrum is generated that is comprised of the half order of the engine revolution (i.e. a full order of camshaft revolution) and higher harmonics thereof. In the present invention, each camshaft order is independently controlled so that any desired sound characteristic can be achieved.

[0014] Motor vehicles include an air induction system having an intake orifice and a ducting arrangement which directs air from the environment to an internal combustion engine for use in a combustion process. The induction sound travels through the induction system to the intake orifice in a finite amount of time which depends on duct length and other acoustic factors.

[0015] The engine intake sound at an orifice for any given order n is represented by:

{tilde over (P)} n,Ω ={tilde over (P)} n,Ω (h,T,Pa,L1,k1 . . . km)  Equation 1.

[0016] Here

[0017] {tilde over (P)}: complex sound pressure

[0018] n: order number

[0019] Ω: camshaft rpm

[0020] h: throttle opening

[0021] T: mean air temperature

[0022] L1: acoustic length from intake valves to orifice

[0023] Pa: ambient barometric pressure

[0024] ki: miscellaneous engine control parameters

[0025] Referring to FIG. 1, a block diagram for a feedforward order based open loop control system 10 for active noise control is shown. In the present invention, a vehicle is run on a vehicle dynamometer while a microphone located at the intake orifice is used to measure the intake sound of the engine during a gradual run-up under a wide open throttle condition (block 12). The sound pressure is then computed for each order as a function of engine RPM (block 14). By way of example, the sound pressure for up to 32 frequency bands may be computed. This data is arranged as amplitude and phase with respect to a reference signal that is indicative of an angular position of a camshaft that drives the intake valves of the engine. In a preferred embodiment, the reference signal is obtained from a sensor that directly measures the angular position of the camshaft such as a sensor found in an engine management system utilized on many vehicles. In addition, a digital time capture may be used to measure a camshaft signal.

[0026] In the present invention, a speaker 22 is utilized which serves as a secondary source of sound for providing noise control. The speaker 22 may be a commercially available item whose size and characteristics are determined by the acoustic power requirements. In many instances, the speaker 22 will be sufficiently small so as to fit inside a vehicle air induction system. The speaker 22 is mounted at the intake orifice and forms part of a secondary path that includes associated electronic components and the same microphone that was used to measure the intake sound. It is noted that the microphone is used for calibration purposes and not for noise control. A calibration of the secondary path is performed offline by having the speaker emit a broadband noise which is detected by the microphone. The frequency response at the microphone is then obtained. The frequency response is given by:

{tilde over (H)} (f)={tilde over (H)}(f,T,Pa,L2)  Equation 2.

[0027] Here

[0028] {tilde over (H)}: complex transfer function

[0029] f: signal frequency

[0030] L2: acoustic length of secondary path

[0031] The baseline control signal is computed using the knowledge of the sound pressure (Equation 1) and the transfer function (Equation 2) as follows:

Ũ n,Ω ={tilde over (H)} −1 (f)×{tilde over (P)}n,Ω  Equation 3.

[0032] Here

[0033] Ũ: the baseline control signal.

[0034] The parameters n, Ω and f are related by:

f=Ω×n/ 60  Equation 4.

[0035] As all data is computed in frequency domain, the effect of {tilde over (H)}−1(f) is equivalent to adding a phase and applying a gain to the amplitude (block 16). This helps in avoiding using extensive digital filters, which operate in typical time-domain systems. Thus, an [n1×n2] matrix table is obtained for each amplitude and phase, where n1, is the desired number of controlled orders and n2 is the number of rpm steps.

[0036] Once the baseline control signal is obtained, the system 10 is configured so that it is adaptable to a plurality of externally varying conditions that may occur such as temperature, ambient pressure, throttle opening, engine speed, and other vehicle specific engine control parameters that may affect engine sound. In order to achieve this, each condition is simulated and the resulting engine sound spectra is mapped and recorded. For instance, a recording is made for a part open throttle (for example, 75°), such that {tilde over (P)}n′ is the new sound spectrum at 75° throttle. This information is supplemented with the baseline values to obtain a correction factor as follows:

{tilde over (C)} 75° throttle ={tilde over (P)} n ′/{tilde over (P)} n   Equation 5)block 18).

[0037] Since the system 10 is linear, the control signal is influenced by the same amount as the raw noise, so that: 1$\begin{array}{cc}{\tilde{U}}_{n,\Omega }^{\prime }={\tilde{U}}_{n,\Omega }\times \tilde{C}=\&LeftBracketingBar;{\tilde{U}}_{n,\Omega }\&RightBracketingBar;\times \&LeftBracketingBar;{\tilde{P}}_{n,\Omega }^{\prime }/{\tilde{P}}_{n,\Omega }\&RightBracketingBar;\times \left[\angle {\tilde{U}}_{n,\Omega }+\angle \left({\tilde{P}}_{n,\Omega }^{\prime }/{\tilde{P}}_{n,\Omega }\right)\right].& \mathrm{Equation}6\end{array}$

[0038] Here, Ũ′ is the modified control signal with necessary corrections. This mapping is conducted for all external conditions and the corresponding correction factors are tabulated. Similarly, the frequency response is measured under different conditions. This provides a complete mapping of the control signal corresponding to the basic raw engine sound.

[0039] Sound may controlled to either attenuate or enhance the sound at any given speed and order. Both of these functions may be represented by a single gain parameter β(block 20), where

β=β(Ω,n)  Equation 7.

[0040] A value of β=1 implies no control (unity gain), β<1 implies attenuation and β>1 implies sound enhancement. Thus, β=0 will be equivalent to full cancellation. The net control signal is derived from the baseline value and the β value by:

{tilde over (V)} n,Ω ′=(βn,Ω−1)×Ũn,Ω′  Equation 8.

[0041] Here, Ũn,Ωincludes the effects of all external parameters, and {tilde over (V)}n,Ω′ is the final control signal. Clearly, for β<1, Equation 8 will yield a negative control signal, which has the same effect as an out-of-phase sound wave. Once the vehicle parameters have been determined, the only user input is the β table for obtaining the desired sound characteristic. The system 10 also includes an audio amplifier 24 that covers the entire frequency range of interest so that a sufficient audio output is provided by the speaker 22.

[0042] As such, the engine sound, frequency response and vehicle effects are each decomposed into engine orders (multiples of engine fundamental frequency) and control is executed for each individual order independently.

[0043] In accordance with the invention, an algorithm is implemented in real-time at a sampling frequency that is sufficient according to the Nyquist criterion. Other algorithm refinements include data interpolation for different vehicle parameters, accurate rpm and phase determination from the cam signal and incorporating time delays between different engine events. The system 10 may be controlled by a conventional automotive microcontroller having sufficient internal memory to hold all data tables. Referring to FIG. 2, an example of a set of look-up tables 42 for temperature effects on control signal amplitude is shown. A transceiver is used for transmitting and receiving signals from the vehicle databus. Finally, a digital anti-imaging filter is used at the output with an upsampling filter, so that a simple low-order analog filter can be used for the analog signal.

[0044] Referring to FIG. 3, a flow diagram 28 depicting aspects of the present invention is shown. In step 30, a first sound pressure is computed based on orders of sound generated during a run up of the engine. The engine is then operated under a plurality of operating conditions and a sound pressure is computed for each of the operating conditions (step 32). A frequency response of the secondary path previously described in relation to FIG. 1 is then computed (step 34). Next, current vehicle operating conditions are obtained from the vehicle databus at step 36. The engine sound, frequency response and vehicle effects are each decomposed into engine orders (multiples of engine fundamental frequency) at step 37. At step 38, a net control signal is computed in real time based on each of the first and second sound pressures, the frequency response and the current vehicle operating conditions to either attenuate sound or enhance sound, wherein each individual order is controlled independently.

[0045] It has been established that with the knowledge of all necessary operating conditions, variations in vehicle intake sound are minimal over time and amongst actual vehicles. There is likely to be some statistical variation amongst vehicles which will persist as an error in the system. It has been determined that the effect of such residual errors is acceptable in view of other performance benefits of the system.

[0046] In this manner, a control signal having a desired profile may be provided for sound corresponding to each of the engine orders and half-orders, which are known to dominate the induction sound spectrum. This results in a reduction in vehicle sound emission, elimination or simplification of passive system parts and gives the vehicle a desired specific acoustic character.

[0047] The current invention is readily adaptable to different types of vehicles, including passenger sedans and sports utility vehicles, as well as different engine types. In addition, the current invention provides a robust low-cost solution for controlling engine intake sound.

[0048] Thus it is apparent that in accordance with the present invention, an apparatus that fully satisfies the objectives, aims and advantages is set forth above. While the invention has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications, permutations and variations will become apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended that the present invention embrace all such alternatives, modifications and variations are far within the scope of the appended claims.

Claims

1. Method for controlling induction sound of an internal combustion engine, comprising: (a) determining a first sound pressure during a run up of said engine, wherein said first sound pressure is based on each order of sound generated by said engine; (b) operating said engine under a plurality of operating conditions; (c) determining a second sound pressure for each of said operating conditions; (e) obtaining current vehicle operating conditions; (f) decomposing said first and second sound pressures and said frequency response into engine orders; and (g) generating a net control signal based on each of said first and second sound pressures and said vehicle operating conditions to control said sound wherein each individual order is controlled independently.

2. The method according to claim 1 further including determining a frequency response of a microphone and a speaker used in computing said first and second sound pressures.

3. The method according to claim 1 wherein said vehicle operating conditions are obtained by a transceiver from a vehicle databus.

4. The method according to claim 1 further including applying a gain factor for attenuating said sound.

5. The method according to claim 1 further including applying a gain factor for enhancing said sound.

6. The method according to claim 1 wherein said determining a second pressure level includes computing a correction factor for each of said operating conditions.

7. The method according to claim 1 wherein said net control signal drives a speaker for providing audio output for controlling said sound.

8. The method according to claim 7, wherein said net control signal is amplified prior to driving said speaker.

9. The method according to claim 1 wherein said decomposing said first and second sound pressures and said frequency response into engine orders includes generation of look-up tables.

10. The method according to claim 9 further including a microcontroller for storing said look-up tables.

11. The method according to claim 1 further including an algorithm that utilizes a Nyqist criterion.

12. The method according to claim 1 further including a time delay between said engine operating conditions.

13. Method for controlling induction sound of an internal combustion engine, comprising: (a) computing a first sound pressure during a run up of said engine, wherein said first sound pressure is based on each order of sound generated by said engine; (b) operating said engine under a plurality of operating conditions; (c) computing a second sound pressure for each of said operating conditions; (d) computing a frequency response of a microphone and a speaker used in computing said first and second sound pressures; (e) obtaining current vehicle operating conditions; (f) decomposing said first and second sound pressures and said frequency response into engine orders; and (g) generating a net control signal in real time based on each of said first and second sound pressures, said frequency response and said vehicle operating conditions to independently control individual orders of said sound.

14. The method according to claim 1 wherein said vehicle operating conditions are obtained by a transceiver from a vehicle databus.

15. The method according to claim 13 further including applying a gain factor for attenuating said sound.

16. The method according to claim 13 further including applying a gain factor for enhancing said sound.

17. The method according to claim 13 wherein said determining a second pressure level includes computing a correction factor for each of said operating conditions.

18. The method according to claim 13 wherein said net control signal drives a speaker for providing audio output for controlling said sound.

19. The method according to claim 13, wherein said net control signal is amplified prior to driving said speaker.

20. A method for controlling induction sound of an internal combustion engine, comprising: providing first look up tables based on a determination of a first sound pressure during a run up of said engine, wherein said first sound pressure is based on each order of sound generated by said engine; providing second look up tables based on a determination of a second sound pressure, wherein said second sound pressure is computed for each of a plurality of operating conditions of said engine; and obtaining current vehicle operating conditions; and generating a net control signal based on said first and second sound pressures, wherein each individual order is controlled independently.