Noise Analysis And Improvement On Electrical Fuel Pumps

Noise complaint is a common issue occurred frequently during new project development of electrical fuel pumps,as well a major complaint for fuel pump warranty in the aftermarket.It is important to perform noise analysis and design optimization basing on engineering test and experience.The purpose of the thesis is to seek an optimized solution for the noise issue of the TXX fuel pump produced by an automotive component company.Thus in each charpter,it is discussed about the current noise issue status of the TXX pump,its architecture features and noise affecting factors,the seletion of problem solving approach and testing methods,the set-up of noise testing system,noise testing and analysis,and finally the confirmation testing of the optimized design.First of all,for the fuel pump noise issue,in this thesis,the noise requirements of several main car manufactures have been summarized.The current noise performance of fuel pump is discussed also.Basing on the real experience,the difficulities to solve the fuel pump noise issue are summaried.Solutions against those difficulities have been raised.Strategy and direction is defined accordingly.Secondly,the mechanism of noise generation is discussed basing on the analysis on typical pump structure.Speclially,the TXX fuel pump,as analysis target of this thesis,has been analyzed.It includes the current noise status of the TXX pump,the components and features and the potential factors which may affect the pump noise performance.Then the Taguchi Method is introduced,as well the implementation steps.The application steps for this specific TXX fuel pump noise issue are also defined.The design levels of the factors have been defined.The testing plan has been defined basing on the orthogonal array selected.The detail set-up of the testing system has been discussed.It is also defined for the hardware performance and selection.The function and operation of the software is introduced.Fuel pump samples were built according to the test plan.Noise tests were conducted on those samples.All test data has been recorded.Analysis tools of Taguchi Method were used to perform the calculations.The relationship between pump noise and factors was discussed.Basing on it,the optimized design levels have been selected.The comfirmation test of the optimization design was conducted on 20 fuel pumps.The result is close to expectation.The variation of pump noise is observed also.At last,the job done has been summarized for this thesis.Some weak points have been discovered.At the mean time,the application of potential new fuel pump technologies was discussed.