Research Information System
Flow Measurement and Instrumentation, vol.110, 2026 (SCI-Expanded, Scopus)
Gasoline Direct Injection (GDI) systems offer enhanced fuel efficiency but have introduced significant noise challenges during high-pressure fuel pump operation. This study presents a novel, non-invasive end-of-line (EOL) testing methodology combining acoustic and vibration data to identify anomalously noisy pumps. Using cross-power spectral density analysis and a confidence interval-based statistical framework, the method enables precise detection of fuel pumps emitting above 60 dBA SPL. A small sample size, derived through power analysis, was used to ensure efficiency without compromising statistical validity. Experimental testing on Best-of-Best (BOB) and Worst-of-Worst (WOW) pump categories demonstrated reliable fault classification with over 95% confidence. The system's integration of laser vibrometer and microphone data allows robust real-time testing, improves manufacturing consistency, and reduces quality control overhead. This approach contributes to advanced diagnostics and supplier control in GDI fuel systems.