FACULY OF ENGINEERING

MECHANICAL ENGINEERING DEPARTMENT

PROJECT (1) : Engine malfunction diagnosis by

mechanical vibrations

INST : DR. NABEEL ALSHABATAT

PRESENTED BY :
1. MAHMOUD ALHOMRAN
2. MOHAMMED ABU GHAZLEH
3. ALA'A ABU SHAMIA
4. MO'ATH NABABTEH
5. AHMED ALQADERY

The purpose of this project

Focus on fault diagnosis by vibration and work on developing
. this way
Bring the attention of specialists in car maintenance about a
. new way could facilitate the process of fault diagnosis
Study of the effect of different engine faults on mechanical
. vibration values
Verify the effectiveness of fault diagnosis by mechanical
. vibrations

. Write a mini guide used as a reference

Abstract
The research study the effect of faults diagnostics by
mechanical vibrations in the engine, the project will provide
an overview of the changes to the engine when there is a
. fault in the engine

The project will be using device for checking the mechanical

vibrations ( Vibrometer ) that reads these vibrations and
. drown in the form of harmonic vibrations

The project will check two faults in the engine , These values
. will be saved for study and analysis

Background
There are many research carried out by specialists to study
the effect of the mechanical faults on the mechanical
. properties
Some research study a particular part of the engine and
other research studying the vibrations of the engine in
general ,there is also research similar to our research that
.diagnosis the engine faults by noise
We will display a summary of some of the previous
: research

Diagnostic methodology for internal combustion diesel .1

engines vibration and noise
The potential faults can be identified with the vibration pattern *
comparing with baseline normal condition pattern
the analysis techniques were used to describe some useful *
parameters

:the parameters are *

root mean square .1
variance .2
skewness .3
energy content .4
The main advantage of acoustic signal is that they are air borne
The audio signals form the IC engine are captured by using simple
carbon microphone placed in front of the engine head

:Methodology
Normally, inputs in the form of vibration signals and sound signals may
be analyzed with the help of many methods which include some like
lab view ,ANN method, ROC method .etc

:Results
Vibration and acoustic signals when analyzed with these methods give
result which define a faulty condition in an known engine
lab View gives result in the form of graphs _

.ANN method: results are calculated in 3 stage _

First stage: fault detection
Second stage: sub system identification
Third stage: source localization

:Conclusion
The benefit of these techniques is no detrimental effects to engine
performance and requires little or without engine modification
In future with more development these techniques could prove to be
an alternative tool for monitoring of engine performance and
.significantly aid condition based monitoring strategies

ENERGY CONVERSION AND MANAGEMENT .2

In the engine block vibration signal of a small displacement
diesel engine is analyzed and the relationship between the
in-cylinder pressure and the vibration trace during stationary
. and transient operation is high light

The use of microphones for combustion control and

diagnosis shows that the engine noise emission contains
useful information about the combustion process
It was highlighted that many sources contribute to the
: overall noise radiated by an engine
injection .1
combustion .2
valves .3
piston slap .4
turbocharger .5
oil pump .6
inlet and exhaust fluid induced noise .7

In the sound generation of adiesel engine is modeled based

on the cylinder pressure curve and it is used to monitor the
engine condition
The optimal position of the transducer was selected by
analyzing the combustion acoustic signal to noise ratio the
location was chosen by comparing the microphone signal
. with in-cylinder pressure trace

The microphone was able to sense the combustion process

whatever injection strategy imposed on the engine

Based on the frequency analysis of the signals frequency

band was defined in which the contribution of the

combustion process in the noise radiation was more

. evident
The engine noise emission is affected by combustion
. performance and injection process
Basing on these findings and after some processes in ECU
the combustion properties could be evaluated only by using
. the engine radiation measurement as input
this information could be then compared to target values
and new injection parameter values imposed on the engine
in order to guarantee performance requirements in terms of
available torque ,pollutants emission and sound quality
. issues

Introduction

Under the great in development in technology elements

especially in automotive technology , discovered and
developed many devices and technological tools have
facilitated humans to do different works in most life
. matters
This development was accompanied by significant evolution
in automotive maintenance methods especially in recent
. years
In the past featured new ways to diagnose car faults , these
methods facilitated the technicians know the source of the
. error in car

: And this ways is

. Acoustics analysis .1
. Infrared Thermography .2
. Vibration Analysis .3
. Ultra sound Analysis .4
. Lubricant analysis .5

1. Acoustics analysis :
With acoustics condition monitoring , a machine running
in a good condition has a stable noise spectrum changes
. when the condition changes

Identification of noise sources and comparing their

spectrum with that of a stable spectrum of the machine in
. good condition to determine the faults in the machine

2. Infrared thermography :
It is an infrared camera can be used to make the
invisible to the human is visible

: Meaning of the term

. Infrared : below last visible color ( Red )
. Therm : Greek word for heat
. Graph : Writing or representation of heat
. It is a graphical representation of heat
3. Vibration analysis :
The element of the machines generate a vibrations at
specific frequencies , the amplitude of the vibration
indicates the performance of machine , An increase in
the vibration amplitude is a result of failing elements or
parts , based on the speed , the frequencies can be
calculated and compared to the measurements to
. identify the fault
4. Ultra sound analysis :
It is an instruments receive high frequency emissions
produced by operating equipments , electrical
. emissions and by leak
These frequencies typically range from 20 KHz to 100
KHz and are beyond the range of human hearing , the
instruments electronically translate ultra sound
frequencies through a process called heterodyning ,

down into the audible range where they are heard ,

. then the data downloaded to computer for analysis
5. Lubricant analysis :
These technique used in monitoring low-speed
machines ( Less than 5 rpm ) , it is an inspection of the
oil , to make sure about lubricant health via lubricant
contamination and degradation lubrication testing ,
there are a technique similar to lubricant analysis
called wear debris analysis , it is the inspection of wear
metals with oil testing equipments to determine the
. origin wear mechanism and contamination levels

Engine Vibrations

The causes of vibrations in the engine too many , so that

. any failure in any engine parts causing a vibrations
Practically , the value of vibration in the engine cannot be
zero , but the goal of designers and technicians is to make
. the least possible vibration value
Engine vibration value vary from fault to another , but there
. can be a faults have a very close vibration values

Tools
Four cylinder, four stroke spark ignition Mitsubishi .1
Lancer sedan engine (1.6 L) model 2006

.
Mechanical vibration measurement device .2
.( Vibrometer )

Theory

The tests were done on a Mitsubishi Lancer car engine ,

. using Vibrometer
The tests were done on the faults which can then restore
engine to normal without a cost or the need to replace parts
. that have been tested

.Both spark plug and MAP sensor were disabled

: Method of work

The engine will checked in normal before making .1

. modifications , To read natural vibration rate of the engine

The engine will be checked after making modifications at .2

the parts that will be changed and check engine vibrations
. and taking a device reading

The difference between two readings measured and .3

. saved
These values transferred to the computer to analyze .4
.and represent graphically
The graphs shows the difference between normal .5
.condition and abnormal condition
MAP sensor .1

The manifold absolute pressure sensor provides

instantaneous manifold pressure information to the
engine's electronic control unit (ECU). The data is
used to calculate air density and determine the
engine's air mass flow rate, which in turn determines
.the required fuel metering for optimum combustion
When the MAP sensor disconnected this means the
air mass flow rate will be incorrect , so the
combustion will be not optimum , this increase the
vibration in the engine
.

The following graphs represent the normal and MAP

: sensor vibration curves

(2^s/m) g

53.0
3.0
52.0
2.0
51.0
1.0
50.0

lamron
pam

(ces/ver ) mpr

Nomral-Map at 1700 rpm

2^s/m) g

54.0
4.0
53.0
3.0
52.0
2.0
51.0
1.0
50.0

lamron
0

pam

(ces/ver) mpr

Normal-Map at 2000 rpm

(2^s/m) g

8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0

lamroN
0

paM

(ces/ver) mpr

Normal-Map at 2500 rpm

(2^ces/m) g

8.0
6.0
4.0
2.0

lamroN

paM

(ces/ver) mpr

Normal-Map at 3000 rpm

Spark plug .2
is a device for delivering electric current from an ignition
system to the combustion chamber of a spark-ignition
engine to ignite the compressed fuel/air mixture by an
electric spark , when the spark plug disconnected from any

cylinder this lead to many problems like misfire , so increase

the vibrations in the engine

.
The following graphs represent the normal and spark plug
: vibration curves

(2^s/m) g

21.0
1.0
80.0
60.0
40.0
20.0

lamroN

paM

(ces/ver) mpr

Normal-SP at 900 rpm

(2^s/m) g

52.0
2.0
51.0
1.0
50.0

PS

lamroN

(ces/ver) mpr

Normal-SP at 1500 rpm

(2^s/m) g

5.0
54.0
4.0
53.0
3.0
52.0
2.0
51.0
1.0
50.0

lamroN
PS

(ces/ver) mpr

Normal-SP at 2000 rpm

(2^s/m) g

7.0
6.0
5.0
4.0
3.0
2.0
1.0

lamroN
0

PS

(ces/ver) mpr

Normal-SP at 2500 rpm

2.1
1
8.0
6.0
(2^s/m) g

4.0
lamroN

2.0

PS

(ces/ver) mpr

Normal-SP at 3000 rpm