This invention relates to an active noise cancellation muffler for automotive and industrial use that has double expansion chambers which can also be varied in size relative to one another while keeping the total muffler capacity constant.

Active noise cancellation mufflers have been developed by Noise Cancellation Technologies, Inc. and are the subject of pending applications #07/435,499 and PCT #US89/00665. In the continuing refinement of these designs it has been found that, in certain applications, a double chambered muffler produces the desired results. It has been proved very effective with minimum loss of power and the length of the chambers and pipes are quite critical to performance. In some instances the relative sizes of the chambers can be varied relative to one another by moving the partitioning wall between them. Accordingly, it is an object of this invention to provide a unique double chambered anti-noise cancellation muffler.

Another object of this invention is to provides a double chambered muffler with a partitioning wall.

These and other objects will become readily apparent when reference is had to the accompanying drawings in which

Fig. 1 is a plot of transmission loss against frequency based on the muffler view dimensions accompanying it.

Fig.2 is general configuration of the double chamber muffler of this invention,

Fig. 3 is a plot of the transmission loss curve versus frequency, and Fig. 4 shows the double chamber muffler with a movable partition.

An expansion chamber geometry (Fig. 1), having a length "£ " and an abrupt change in cross-sectional area at each end provides Transmission Loss (TL) in the absence of a steady air flow by the Equation (1):

S Cross sectional area of expansion chambers

S j Cross sectional area of duct

Wave Number

Expansion Chamber length

m = Sc

Sd

The addition of a second chamber of different length permits each chamber to attenuate further the other's passband (Fig. 2). Transmission Loss of the two chambers can be approximately defined by Equation (2):

r = 101og[l-_-i( -i) ² sin ² (^ ][l+i(m- ) ² sin ² ( ₂ )] Eq. (2)

Most passbands can be attenuated by making the inlet and outlet pipes protrude into each chamber. For a pipe intrusion of length Q _e ), a series of narrow attenuation

spikes occurs at the frequencies such that t _t = — = — ( ninteger number 1, 2, 3..).

4 4/ The Fig. (3) shows the general shape of Transmission Loss Curve.

The following parameters basically govern the acoustical performance of reactive muffler.

1 - Noise specification in terms of required TL and radiated sound power level at a known distance. 2 - Source characteristics described in terms of source impedance and source strength

Z _s ,( us).

3 - Muffler location which can be described in terms of length of exhaust and tail pipes.

4 - Termination characteristics which can be described in terms of radiation impedance (Zr). r Among the parameters particularly affecting the performance of the Double Expansion Chamber Muffler are several which are hereinafter described.

The Muffler arrangement has proved very effective with minimum loss of power, though prediction of its performance would be extremely complicated. The relative lengths of the chamber and pipes are quite critical to the performance, requiring accurate manufacturing and precision.

Experimental and theoretical work proved the suitable chamber length ratios, which prevent coinciding passbands below about 10 KHz, are 1.1, 1.6 and 2.2. The larger chamber should be placed in first (. \,> 12) to minimize power loss. . The TL of an expansion chamber with pipe is reduced by high air flow (over 30 m/sec). For air flow under 15 m/sec, air flow has little effect on TL, for air flow between 15 to 30 m/sec. the effect is about 6 to 10 db. The following parameters were used in the design of a specific compressor muffler.

Duct Diameter = 0.05 m Chamber Diameter ≤ 0.25 m

Chamber Length ≤ 0.5 m

Speed of Sound at the compressor temperature = 426 m/sec

Mean Flow Speed = 18 m/sec For a Double Chamber Muffler:

O.δmeters

Assuming then, _t _ _{§ β} \.\e then, _x » 0.27m, > £ ₂ « 0.23m The Equation (2) describes the TL, substitute the above values into the equation which provide us the following:

0.27Ω ^

TL = 10 log! l + 156sin ² 1 + 156 sin 2 0.23Ω Eq. (3) 426 426 )\

In analyzing the attenuation level at the frequencies : = 130, 260, 390, 520 and 650 Hz. These are the fundamental noise frequencies and its harmonics. Table 1 shows the attenuation as a function of frequency. In the first column of the table, the attenuation levels are described at the fundamental frequency and its harmonics, at the second column the attenuation of the fundamental and its harmonics is shifted by 20% and the last column if ^ _^ and £ change to 0.255 m and 0.245 m at the shifted frequencies.

The above chart shows that the Double Chamber Muffler can provide significant attentuation at the desirable frequencies. But it is highly sensitive to the frequencies of operation. The 20% shift (increase) of the fifth harmonic reduces the attenuation at this frequency by 20 dB.

If we assume 20 dB is the minimum requirement for the TL, the attenuation for the fifth harmonic is not acceptable if it is shifted by 20%. Now if we change £ _t , and to 0.255 m and 0.245 m ( + ₌ Q.5 _W ), the minimum requirement for the fifth harmonics will be met (21 dB attenuation). Considering the above sensitivity, an adaptive control system must be developed to accommodate this limitation and take advantage of the capabilities of the Double

Chamber Muffler.

According to the analysis and Equation (2), the ratio of the length of the chamber has a major impact on the TL ₊ g = constant). This ratio can be used as a single variable to modify the performance accordingly. Any deviation in the dynamics of the system such as shift in fundamental frequency or its harmonics, temperature, air flow, source and tonal impedance,...etc can be accomodated by changing the ratio of the length of the two chambers.

To develop an adaptive muffler, an electronic controller plays a major role in the system. A linear motor/actuator controller should be used to execute this adaptation (Fig.

4). The other components of the system are: an error microphone, and a linear motor or actuator.

An internal plate with the attached pipe(s) should be moved inside a slot in both directions (±Δx) o change the length ratio of the chambers. This motion is derived and controlled by the motor controller under the command of the electronic controller that continuously monitors the error microphone and tries to minimize the overall noise level. The adaptation starts when the internal plate is located at χ = o. The error microphone detects the noise, the electronic controller analyze the noise level at the fundamental frequency and its harmonics, sends an appropriate command to the motor

controller to move the plate by an increment of _. This process continues until the n minimum noise level is achieved.

The electronic controller continuously modify the location of the internal plate to accommodate all the changes of the system parameters (temperature, air flow,..etc.) The Equation (2) is a basic equation that describes the overall performance of a

Double Chamber Muffler, A number of parameters should be analyzed, determined and optimized before the adapting system is applied to the muffler in each application. The steps are:

1. Quantify the physical dimensions of the Muffler: chamber diameter, duct diameter, chamber length, length of the internal pipe, number of internal pipes, intrusion of inlet and outlet pipes, offset between inlet and outlet pipe, ..etc.

2. Calculate the TL as a function of frequency, estimate the sensitivity to changes in ambient pressure, temperature and air flow. 3. Quantify the effect of the adaptive element on the performance and the^equired value for Δχ ) . Determine the best location for χ=o (starting point).