DESC:CROSS REFERENCE TO RELATED APPLICATION
This Application is based on and derives the benefit of Indian Provisional Application 202141036192 filed on 10th August 2021, the contents of which are incorporated herein by reference.
TECHNICAL FIELD
[001] The embodiments herein generally relate to engine air intake systems in vehicles and more particularly, to a modular noise attenuating air intake duct assembly for use in the air intake system of gasoline and diesel engines.
BACKGROUND
[002] In automobile industries, in modern vehicle development, the technologies to reduce vehicle noise and vibration are rapidly increasing. In particular, automotive engine manufacturers are focusing on reducing the noise generated by air intake system. Noise reduction of the air intake system plays a very important role in improving quality of sound and lowering the noise levels inside passenger cabin of a vehicle. Air intake noise is known to be mainly due to the pressure pulsations generated due to engine combustion, turbocharger-compressor induced noises, flow disturbances in intake line and resonance phenomena inside the intake system. In particular, the noise, vibration, and harshness (NVH) of the vehicle are important factors for vehicle users and essential for the successful commercialization of vehicles. Air intake ducts are used for sucking the air from the atmosphere and utilizing it for an internal combustion engine. Larger expansion volumes, various types of resonating devices are used in air intake system to attenuate noise. To further lower the air intake noise, porous or acoustic intake ducts are also used in modern vehicles on suction side of air cleaner. Material, porosity, thickness of these acoustic intake ducts can be adjusted to get noise attenuation in desired frequency band. These ducts are generally designed to improve visual appeal of engine compartment of a modern vehicle. Multiple variants of diesel and gasoline engines are used on a particular vehicle platform who have different source noise characteristics. Attempt of automobile manufacturers are to minimize variants of air intake system and other interfacing vehicle system components to minimize investments and development time.
[003] Hence, there exists a need of a modular noise attenuating air intake duct assembly which can be tuned to various engines being used on a vehicle platform while minimizing impact on interfacing vehicle parts.
OBJECTS
[004] The principal object of embodiments herein is to provide a modular noise attenuating air intake duct assembly for use in the air intake system of gasoline and diesel engines.
[005] Another object of embodiments herein is to provide the modular noise attenuating air intake duct assembly depending upon required NVH (noise, vibration and harshness) performance, acoustic or non-acoustic sheets can be developed using common tooling and fixtures.
[006] Another object of embodiments herein is to provide the modular noise attenuating air intake duct assembly designed with two different noise attenuation properties developed by using common tooling and fixtures (multiple variants possible) to meet NVH requirements of both the diesel and gasoline intake systems.
[007] Another object of embodiments herein is to provide the modular noise attenuating air intake duct assembly with reinforcement to have a variable air flow cross section area for better NVH performance.
[008] Another object of embodiments herein is to provide the modular noise attenuating air intake duct assembly designed with two 2 different air flow cross sections (multiple variants possible) to meet NVH requirements of both the diesel and gasoline intake systems.
[009] Another object of embodiments herein is to provide external shape of the air intake duct to be designed to have a common shape for the diesel and gasoline variants of the vehicle.
[0010] Another object of embodiments herein is to provide reinforcement and air blocker to be are designed uniquely for the gasoline and diesel variants (multiple variants possible) based on the performance and NVH requirements.
[0011] Another object of embodiments herein is to provide the air intake duct to be designed in such a way that there is no necessity for designing two different air intake ducts for both gasoline and diesel variants (multiple variants possible) of the vehicle.
[0012] Another object of embodiments herein is to provide the modular noise attenuating air intake duct assembly which reduces development and testing time for both diesel and gasoline engine variants.
[0013] These and other objects of embodiments herein will be better appreciated and understood when considered in conjunction with following description and accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[0014] The embodiments are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0015] Fig.1 illustrates an air intake system of a vehicle platform which uses the modular noise attenuating air intake duct assembly at inlet side of air cleaner, according to embodiments as disclosed herein.
[0016] Fig.2 illustrates construction of the modular noise attenuating air intake duct assembly designed specifically for diesel engine and gasoline engine air intake system variants respectively, according to embodiments as disclosed herein;
[0017] Fig. 3 depicts exploded view of the modular noise attenuating air intake duct assembly for diesel engine air intake system variant, according to embodiments as disclosed herein;
[0018] Fig. 4 depicts exploded view of the modular noise attenuating air intake duct assembly for gasoline engine air intake system variant, according to embodiments as disclosed herein;
[0019] Fig. 5 depicts colour plot and graph showing intake orifice noise reduction achieved using different modular noise attenuating air intake duct assembly designed with three different noise attenuation properties developed using common tooling and fixtures, according to embodiments as disclosed herein; and
[0020] Fig. 6 depicts graph showing intake orifice noise reduction achieved for an engine using modular noise attenuation air intake duct assembly designed with two different air flow cross sections, according to embodiments as disclosed herein.

DETAILED DESCRIPTION
[0021] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0022] The embodiments herein achieve a modular noise attenuating air intake duct assembly for use in the air intake system of gasoline and diesel engines. Further, embodiments herein achieve the modular noise attenuating air intake duct assembly designed with two different air flow cross-sections (multiple variants possible) and two acoustic ducts having different noise attenuation properties (multiple variants possible), developed using common tooling and fixtures, to meet orifice noise reduction requirements of both the diesel and gasoline air intake systems.
[0023] Fig.1 illustrates an air intake system of a vehicle platform which uses the modular noise attenuating air intake duct assembly (100) at inlet side of air cleaner (10), according to embodiments as disclosed herein. Modular design of noise attenuating air intake duct assembly enabled development of two different ducts for diesel and gasoline variants achieving respective intake air noise reduction targets. Fig.2 illustrates construction of the modular noise attenuating air intake duct assembly designed specifically for diesel engine and gasoline engine air intake system variants respectively, according to embodiments as disclosed herein. Two noise attenuating air intake duct assembly (100, 200) are designed both have exactly external shape, size and appearance. Two noise attenuating air intake duct assembly (100, 200) have different air flow cross sections and uses acoustic ducts having different noise attenuation properties.
[0024] Fig. 3 depicts exploded view of the modular noise attenuating air intake duct assembly (100) for diesel engine air intake system variant, according to embodiments as disclosed herein. Fig. 4 depicts exploded view of the modular noise attenuating air intake duct assembly (200) for gasoline engine air intake system variant, according to embodiments as disclosed herein. In an embodiment, the modular noise attenuating intake air duct assembly (100) includes a noise attenuating air intake duct (102), an air inlet duct connector (104), an air outlet duct connector (106) and a reinforcement member (108). In another embodiment, the modular noise attenuating intake air duct assembly (200) includes noise attenuating air intake duct (202), an air inlet duct connector (204), an air outlet duct connector (206) and an air blocker (208).
[0025] The noise attenuating air intake duct (102, 202) includes an upper air intake duct section (102A, 202A) and a lower air intake duct section (102B, 202B). The lower air intake duct section (102B, 202B) is connected to the upper air intake duct section (102A, 202A) thereby providing passage for intake air to flow therethrough. The noise attenuating air intake duct (102, 202) is a porous type duct which attenuates noise of intake air. The noise attenuating air intake duct (102, 202) defines a rectangular cross section. The air inlet duct connector (104, 204) is adapted to connected to an intake air inlet (102Y, 202Y) of the noise attenuating air intake duct (102, 202). The air inlet duct connector (104, 204) defines a rectangular cross section. The air inlet duct connector (104, 204) is located in vicinity of a front grill of a vehicle. The air outlet duct connector (106, 206) is adapted to connected to an intake air outlet (102Z, 202Z) of the noise attenuating air intake duct (102, 202). The air outlet duct connector (106, 206) is connected to an air cleaner (10) of an engine. The air outlet duct connector (106, 206) defines a rectangular cross section. The reinforcement member (108) is located inside the noise attenuating air intake duct (102). The reinforcement member (108) is adapted to reinforce the noise attenuating air intake duct (102). The reinforcement member (108) defines a plurality of air openings (108P) adapted to allow intake air to flow therethrough.
[0026] The air blocker (208) is disposed inside the noise attenuating air intake duct (202). The air blocker (208) extends along a lengthwise direction of the noise attenuating air intake duct (202). The air blocker (208) is adapted to block a portion of the intake air inlet (202Y) and the intake air outlet (202Z) of the noise attenuating air intake duct (202) thereby attenuating noise of intake air. The air blocker (208) includes an air passage frame (208F) near or away from a center of the air blocker (208). The air passage frame (208F) defines a plurality of air openings (208Y) adapted to allow intake air to flow therethrough.
[0027] The engine is a diesel engine when reinforcement member (108) is disposed inside the noise attenuating air intake duct (102). The engine is a gasoline engine when air blocker (208) is disposed inside the noise attenuating air intake duct (202). The air inlet duct connector (104, 204) and the air outlet duct connector (106, 206) are common for both gasoline engine and diesel engine.
[0028] Different engines including a diesel and another gasoline engine for example, has different source noise characteristics and draw different air mass flow rates to produce targeted power and torque. To meet desired intake orifice noise performance, air intake system of these two engines requires intake ducts to be tuned suitably. In one embodiment, as elaborated through Fig. 2, modular air intake duct design uses components which are of same shape, profile and size which allows to develop both diesel and gasoline intake ducts through same tools and fixtures saving investments and time.
[0029] In one embodiment, as elaborated through Fig. 2, modular air intake duct design uses components which are of same shape, profile and size which allows vehicle platform using different engines to have common engine compartment layout both from package and from aesthetics perspective. In one embodiment, as elaborated through Fig. 3 and Fig. 4, to meet intake noise reduction targets, different acoustic duct materials are used for diesel and gasoline which have different noise attenuation properties.
[0030] Fig. 5 depicts colour plot and graph showing intake orifice noise reduction achieved in 500 Hz to 3000 Hz frequency band, using different acoustic intake duct designed with three different noise attenuation properties developed using common tooling and fixtures. In one embodiment, as elaborated through Fig. 3 and Fig. 4, to meet intake noise reduction targets, using different design of reinforcements and air blocker for diesel and gasoline respectively, air flow across section is varied. Extent of restriction air flow cross section is optimized to find right balance between engine performance and NVH performance.
[0031] Fig. 6 depicts graph showing intake orifice noise reduction achieved for an engine using intake duct intake duct designed with two different air flow cross sections. Both overall noise and order noise achieved are plotted against engine speeds. In one embodiment, multiple variants of the modular acoustic intake ducts can be realized using different combinations of reinforcements and different combinations of acoustic duct materials to achieve required noise attenuation performance and engine performance for a specific engine variant on a vehicle platform.
[0032] The technical advantages of the modular noise attenuation air intake duct assembly (100, 200) are as follows. The modular design of intake duct ensures that there is no necessity for designing two completely different ducts and developing completely new tooling and fixtures for a vehicle platform powered by different engine variants. The modular noise attenuating air intake duct assembly ensures there are no design changes are required in interfacing vehicle components. The modular noise attenuating air intake duct assembly depending upon required NVH (noise, vibration and harshness) performance, acoustic or non-acoustic sheets can be developed using common tooling and fixtures. The modular noise attenuating air intake duct assembly is designed with two different noise attenuation properties developed by using common tooling and fixtures (multiple variants possible) to meet NVH requirements of both the diesel and gasoline intake systems. The modular noise attenuating air intake duct assembly with reinforcement to have a variable air flow cross section area for better NVH performance. The modular noise attenuating air intake duct assembly is designed with two 2 different air flow cross sections (multiple variants possible) to meet NVH requirements of both the diesel and gasoline intake systems. The external shape of the air intake duct is designed to have a common shape for the diesel and gasoline variants of the vehicle. The reinforcement and air blocker are designed uniquely for the gasoline and diesel variants (multiple variants possible) based on the performance and NVH requirements. The modular noise attenuating air intake duct assembly which reduces development and testing time for both diesel and gasoline engine variants.
[0033] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of the embodiments as described herein.
,CLAIMS:We claim,
1. A modular noise attenuating air intake duct assembly (100, 200) for an engine, said modular noise attenuating air intake duct assembly (100, 200) comprising:
a noise attenuating air intake duct (102, 202) having an upper air intake duct section (102A, 202A) and a lower air intake duct section (102B, 202B) connected to said upper air intake duct section (102A, 202A) thereby providing passage for intake air to flow therethrough;
an air inlet duct connector (104, 204) adapted to be connected to an intake air inlet (102Y, 202Y) of said noise attenuating air intake duct (102, 202); and
an air outlet duct connector (106, 206) adapted to be connected to an intake air outlet (102Z, 202Z) of said noise attenuating air intake duct (102, 202).
2. The modular noise attenuating air intake duct assembly (100, 200) as claimed in claim 1, wherein said noise attenuating air intake duct (102, 202) is a porous type duct which attenuates noise of intake air.
3. The modular noise attenuating air intake duct assembly (100) as claimed in claim 1, wherein said noise attenuating air intake duct assembly (100) includes a reinforcement member (108) located inside said noise attenuating air intake duct (102),
wherein
said reinforcement member (108) is adapted to reinforce said noise attenuating air intake duct (102); and
said reinforcement member (108) defines a plurality of air openings (108P) adapted to allow intake air to flow therethrough.
4. The modular noise attenuating air intake duct assembly (200) as claimed in claim 1, wherein said noise attenuating air intake duct assembly (200) includes an air blocker (208) disposed inside said noise attenuating air intake duct (202),
wherein
said air blocker (208) extends along a lengthwise direction of said noise attenuating air intake duct (202); and
said air blocker (208) is adapted to block a portion of said intake air inlet (202Y) and said intake air outlet (202Z) of said noise attenuating air intake duct (202) thereby attenuating noise of intake air.
5. The modular noise attenuating intake air duct assembly (200) as claimed in claim 4, wherein said air blocker (208) includes an air passage frame (208F) located near or away from a center of said air blocker (208), wherein said air passage frame (208F) defines a plurality of air openings (208Y) adapted to allow intake air to flow therethrough.
6. The modular noise attenuating intake air duct assembly (100, 200) as claimed in claim 1, wherein said air inlet duct connector (104, 204) is located in vicinity of a front grill of a vehicle;
said air outlet duct connector (106, 206) is connected to an air cleaner (10) of an engine;
said noise attenuating air intake duct (102, 202) defines a rectangular cross section;
said air inlet duct connector (104, 204) defines a rectangular cross section; and
said air outlet duct connector (106, 206) defines a rectangular cross section.
7. The noise attenuating intake air duct assembly (100, 200) as claimed in claim 3 and claim 4, wherein the engine is a diesel engine when reinforcement member (108) is disposed inside said noise attenuating air intake duct (102);
the engine is a gasoline engine when said air blocker (208) is disposed inside said noise attenuating air intake duct (202); and
said air inlet duct connector (104, 204) and said air outlet duct connector (106, 206) are common for both gasoline engine and diesel engine.