Ref: TP/8/ADM/6/I/Q2017G 22 nd May 2008

1. Overview of Design tool for cost effective reduction of noise from enclosed power generators (Drone) project Ref: TP/8/ADM/6/I/Q2017G 22nd May 2008

2. Aims of the project • To develop a multidisciplinary design tool to predict noise from enclosed noise sources. • To capture state-of-the-art knowledge in noise source identification and transmission. • To apply this knowledge to obtain competitive environmental noise performance. • To apply the resulting design tool to a number of test cases.

3. Objectives of the project • Identification of noise sources and prediction through complex impedance paths. • Modelling of the manufacturing cost impact of design changes. • Capture of expertise and knowledge to enable Knowledge Based engineering (KBE) of the design process. • Lead time reduction through analysis compression. • Competitive cost for improved environmental noise performance.

4. Technical Approach Engine noise • Number of noise sources in open genset. • Engine, fan and alternator are main sources. • Complicated by mechanical transmission through baseframe. Fan noise Alternator noise Mechanical transmission

5. Technical Approach Airborne path Mechanical path Coupled sound transmission • The response of close fitting enclosures to sound loads is complex. • Sound escapes through ventilation openings and through the enclosure panels. • Induced vibrations from engine etc force the enclosure to vibrate and radiate sound Airborne path Airborne path Mechanical path

6. Technical Approach • Use of computational Indirect Boundary Element (IBE) approach to simulate the radiation and scattering of sound generated and transmitted. • Approach involves the idealisation of complex noise sources into several radiating components as inputs to the model (IBE). • LMS UK will develop a new theoretical model to account for the fan and its interactions. • The modelling strategy for the enclosure will be to simulate the dynamic response of the enclosure through modal analysis methods.

7. Technical Approach • Cost modelling will be based on manufacturing cost information supplied by FG Wilson. • Cost Estimating Relationships (CERs) will be established driven by the key design parameters that influence enclosure noise. • A model will be established to look at the trade off of design variables that drive cost and acoustic performance. • All of these technical approaches will be developed and integrated into a generic environment to produce a design tool that can be used to analyse close fitting enclosures.

8. Work package1: Research and Benchmarking • The project has been divided into 8 work packages for ease of management. • The purpose of the first package is to: • Carry out a review of existing work on noise source identification. • Define a simplified test case to verify test methods. • Define procedures to be used for testing and modelling. • Apply current LMS software to the test case.

9. Work package 2: Training and Deployment of LMS software • The purpose of work package 2 is: • To plan for and provide basic training on LMS software. • Software training was completed 6th / 7th May. • Hardware training completed 19 – 21st May. • Develop materials for an advanced training course towards end of project. • Deliver advanced training course to project partners.

10. Work package 3: Characterisation of Noise sources • The purpose of work package 3 is : • To specify which noise sources (engine, fan, alt etc) will be characterised in the study. • To plan for and perform a measurement campaign on the different sources. • To plan for and perform a simulation campaign to model the noise from the sources. • Compare simulation results with actual test measurements.

11. Work package 4: Noise Transfer Path Analysis • The purpose of work package 4 is: • To define the strategy to be used to characterise the noise transfer path. • To plan for and perform a measurement campaign to determine the contribution from transfer paths. • To plan for and perform a simulation campaign on the noise transfer paths identified. • To compare the simulation results with actual test measurements.

12. Work package 5: Design Tool Environment • The purpose of work package 5 is to: • Plan for and develop the design tool structure for the various noise sources identified. • Plan for and develop the design tool structure for the noise transfer paths identified. • Customise the design tool for noise enclosure applications. • Provide feedback from the partners on the ease of use of the final version of software.

13. Work package 6: Cost Modelling • The purpose of work package 6 is: • To generate a life cycle cost breakdown structure for the product range. • To develop cost modelling architectures based on the FG Wilson bill of material. • To develop specific cost models based on the manufacturing processes to be used. • To complete verification and validation studies. • To assist in integration into the design tool.

14. Work package 7: Case Studies • Work package 7 will: • Define and run a case study on a wall partition to be provided by Masters’ choice. • Define and run a case study on a genset to be provided by FG Wilson. • Define and run a case study on a high speed genset to be provided by Houchin Aerospace. • Deliver case study reports for dissemination.

15. Work package 8: Dissemination of Results • The purpose of work package 8 is: • To write and deliver papers on noise source identification, contribution analysis and cost modelling. • To organise and conduct an industrial workshop to roll out the final version of the software to interested parties. • To write and submit papers to appropriate journals and conferences.

16. Exploitation of the Technology • Within the UK there are currently no design tools to optimise design and manufacturing cost of enclosures for noise reduction. • Specifically no tools that link conceptual design parameters, acoustic analysis of these parameters and cost. • Currently expensive prototypes have to be produced to determine actual performance. • The approach we are taking will produce a framework for application across many industrial sectors, e.g. aerospace, automotive, marine and construction.

17. Market Potential • Targeted market is the power generation industry, specifically sound attenuated gensets. • Market is globally worth an estimated £2.7 billion for products up to 2000kVA. • FG Wilson currently build over 60% of UK total exports of gensets. • Houchin Aerospace currently build 60% of the European requirement for Ground Power Units. • Masters’ Choice fills 20% of the estimated £2m market for acoustic partitions in Ireland. • Use of the developed technology could reduce validation time by up to 30%.

18. Roles and Responsibilities

19. Roles and Responsibilities • FG Wilson will be the project lead partner. FG Wilson are the largest genset manufacturer in the UK and as such have considerable experience in the design of genset enclosures. • FG Wilson will: • Co-ordinate team meetings, quarterly review meetings and technical meetings as required. • Carry out the administration tasks required from the project lead. • Provide access to our Hemi-anechoic chamber and reverberation room for experimental measurement and validation. • Provide a diesel generator to be used as a test case. • Provide engineering resources to assist in testing.

20. Roles and Responsibilities • Queens University Belfast (QUB) has considerable experience in Vibro-acoustics and numerical tools for multi-disciplinary applications. QUB also have expertise in cost modelling. • QUB will: • Be the work package leader on the Research and benchmarking, characterisation of noise sources, noise transfer path analysis, cost modelling, case studies and dissemination packages. • Be responsible for the production of a number of reports from these work packages. • Provide expertise in the form of academic staff and research fellows. • Provide computing time on their super computers.

21. Roles and Responsibilities • LMS UK is a software developer and supplier in the area of acoustics modelling. • LMS will: • Provide a number of seats of their LMS Virtual Lab software. • Provide basic and advanced training on their software. • Develop a near field fan noise model. • Customise their software to suit noise enclosure applications. • Provide technical expertise on noise source and transfer path characterisation.

22. Roles and Responsibilities • Houchin Aerospace is one of the foremost names in the manufacture of high speed gensets for ground support to aircraft. Houchin supply gensets to airlines and military forces around the world. • Houchin will: • Attend the project quarterly reviews. • Participate in the LMS software / hardware training. • Provide a high speed genset to be used in a case study.

23. Roles and Responsibilities • Masters Choice design and manufacture acoustic partitions for achieving accredited acoustic ratings in accordance with BS5812. • Masters Choice will: • Attend the project quarterly reviews. • Provide a representative wall partition to be used in a case study.

24. Roles and Responsibilities • Bombardier is the third largest civil aircraft manufacturer in the world. The Belfast facility is the largest manufacturing company in Northern Ireland. It is a Centre of Excellence in the design and manufacture of fuselages, nacelles, flight controls and advanced composites. • Bombardier will: • Attend the project quarterly reviews. • Provide a Chief Technical Engineer to act in a consulting role throughout the project.