emission: heavy duty and off-road

Emission Test Systems

Kurt Engeljehringer AVL List GmbH

EMISSION: HEAVY DUTY AND OFF-ROAD

AVL Emission Test Systems | Engeljehringer | 1

NOTE:

AVL List GmbH, Kurt Engeljehringer

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The contents of this document may not be reproduced in any form or communicated to any third party

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omissions, which may occur in this document.


CONTENT

Emission Legislation / Regulation Trends

Euro-VI

GTR-4: Global technical regulation Heavy Duty

USA Heavy Duty (CFR1065) and Off-Road


EMISSION STANDARDS AND TECHNICAL REGULATIONS

Any Emission Control Legislation contains 4 main elements:

• Emission Limits, which define the maximum allowed tailpipe emissions

• Test cycle, how the engine or vehicle is operated

• Test procedures and specifications for the test- and measurement systems.

• Formulas and reporting defining how the final result is calculated and reported.

• In the past all 4 elements were defined in one “Book”, new legislations separate it into 2 “Books”

New European Legislation: “Split Level Approach”

• The legislation part defines the emission limits

• A global technical regulation defines how the measurement is done, including the test

cycle, specifications and formulas.

• EU defines the limits and references for the technical regulation to the UN-ECE

New USA Legislation: “Standard setting part” and “Technical regulation”

• The “Standard setting part” defines the emission limits and the test cycle

• The “Technical regulation” defines how the measurement is done, including specifications

and formulas.

• US-EPA (plus CARB) defines the standard setting part and the technical regulation


EMISSION STANDARDS AND TECHNICAL REGULATIONS

New European Legislation: “Split Level Approach”

• The legislation part defines the emission limits

• A global technical regulation defines how the measurement is done,

including the test cycle, specifications and formulas.


TECHNICAL REGULATIONS

GTR-15

RDE

GTR-4 GTR-11 / ISO 8178

CFR-1065

GTR-2

NTE

CFR-1066

EU, UN-ECE US and CARB Legend: Applied regulations for the emission standards of

GTR-10

Engine

Test Bed

Vehicle

Chassis

Dyno

Vehicle

on the

road


UN-ECE GLOBAL TECHNICAL REGULATIONS

GTR’s: Global Technical regulations:

GTR-01: Door locks and door retention components (Adopted 2004)

GTR-02: Measurement procedure for two-wheeled motorcycles with regard to the emission of gaseous pollutants,

CO2 emissions and fuel consumption (Adopted 2005)

GTR-03: Motorcycle brake systems (Adopted 2006)

GTR-04: Test procedure for compression-ignition (C.I.) engines and positive-ignition (P.I.) engines fuelled with

natural gas (NG) or liquefied petroleum gas (LPG) with regard to the emission of pollutants (Adopted

2006)

GTR-05: Technical requirements for on-board diagnostic systems (OBD) for road vehicles (Adopted 2006)

GTR-06: Safety glazing materials for motor vehicles (Adopted 2008)

GTR-07: Head restraints (Adopted 2008)

GTR-08: Electronic stability control systems (Adopted 2008)

GTR-09: Pedestrian safety (Adopted 2008)

GTR-10: Off-cycle emissions (OCE) (Adopted 2009)

GTR-11: Engine emissions from agricultural and forestry tractors and from nonroad mobile machinery (Adopted

2009)

GTR-15: Global technical regulation on Worldwide harmonized Light vehicles Test Procedure. (Established in the

Global Registry on 12 March 2014)


CONTENT


Euro-VI




HEAVY DUTY: EU EMISSION LEGISLATION / REGULATION

EU Emission Legislation:

• Euro-VI has started 2013

• Particle Number (PN) limit established in addition to the Particulate

Mass (PM) limit for Diesel engines.

EU and UN-ECE Technical Regulation:

• GTR-4 (Global Test Procedure) from UN-ECE.

• WHSC (World Harmonized Stationary Cycle)

• WHTC (World Harmonized Transient Cycle)

• “Real Driving Emissions” limits by:

• Off Cycle Emissions (OCE) in a stationary engine test cycle, with

15 random modes.

• “In-Service” on-road tests in vehicle with PEMS (Portable Emission

Measurement Systems).

Main issues for development

• Diesel PN limits.

• Engine calibration for a wide range of engine operation conditions

(speed, torque, temperatures, altitudes, …) to meet “Real Driving

Emissions” limits.

EU

http://www.iconarchive.com/show/multipurpose-alphabet-icons-by-hydrattz/Letter-I-blue-icon.html



HEAVY DUTY: EU EMISSION LIMITS

1992 1996 2000 2005 2008 2013

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 4,50 4,00 2,10 1,50 1,50 1,50 THC

NOx

NMHC CH4

PM

PN

g/kW-h

g/kW-h

g/kW-h

g/kW-h

g/kW-h

g/kW-h

#/kWh

NH3 ppm

CO2, FC g/kW-h

NO2 g/kW-h

1,10 1,10 0,66 0,46 0,46 0,13

8,00 7,00 5,00 3,50 2,00 0,40 3,60 0,15 0,10 0,02 0,02 0,01

25 25 10 8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHTC

CO 5,40 4,00 4,00 4,00

THC

NOx

NMHC

CH4

PM

PN

g/kW-h

g/kW-h

g/kW-h

g/kW-h

g/kW-h

g/kW-h

#/kWh

NH3 ppm

CO2, FC g/kW-h

NO2 g/kW-h

0,16

5,00 3,50 2,00 0,46

0,16 0,03 0,03 0,01

25 25 10

no

0,78 0,55 0,55

1,60 1,10 1,10

EU EU-III EU-II EU-I EU-IV EU-V EU-VI Currently there is no relevant discussion

ongoing about Euro-VII Limits Most likely the main issue for Euro-VII will become: • CO2 reporting not only by g/kWh for

the engine, but a whole vehicle approach. Most likely combining engine test data with a vehicle software simulation approach.

• Testing definition for Heavy Duty vehicle Hybrid-powertrains.

• Maybe a NO2 limit, if the NO2 air pollution situation in cities will not improve in the next years. Problem mainly come up with Diesel engines with PDF but no deNOx System (HD Euro-IV,V and LD Euro-4,5)


















HEAVY DUTY: PARTICLE NUMBER

EU-VI Limit 6*1011

less than

intake air


HEAVY DUTY: FUEL CONSUMPTION

CO2 and fuel consumption measurement and reporting

• CO2 reporting over engine test cycle in g/kWh is required

• A provision for a whole vehicle approach will be developed for EU-VII.

Proposal is to combine engine test data with a vehicle software

simulation approach.

• In Heavy Duty fuel consumption is a much more important factor for

truck buyers, therefore reduction is already demanded by the market

itself.

EU




EMISSION LEGISLATION / REGULATION

1990 2000 2010 2020

Limits: EU-I EU-II EU-III EU-IV EU-V EU-VI

Test Cycle: 13 Mode ESC + ETC + ELR WHSC+WHTC+OCE

CI - Diesel: conventional SCR or DPF + EGR SCR + DPF

PI – Gasoline, CNG: conventional

Exhaust

After- Treatment

Regulation: ECE R49 GTR-4 ECE R49 ECE R49 + ISO16183

New test requirements:

CVS for transient

CH4 and NH3 Analyzer

Particle Counter

Continuous increase

of requirements over

time.

Random NOx screening points OCE


HEAVY DUTY: WHTC AND WHSC

World Harmonized Transient Cycle (WHTC):

• 2 Tests one cold and one hot

• „Soak time“ between cold and hot cycle 10 +/- 1 min

• Weighting factors 14% cold test and 86% hot test

World Harmonized Stationary Cycle (WHSC):

• Hot test

• Engine conditioned before the test for 10min in mode 9

• Test execution as Ramped Modal Test, the listed weighting factors are only

for reference but not any more used like in the old stationary cycles.


HEAVY DUTY: OFF CYCLE EMISSIONS

Off Cycle Emissions (OCE):

• OCE is a “Random” 15 Mode stationary engine test

• It is the advanced version of the random 3 NOx screening points, we had

in EU-III up to EU-V.

In-Service Emissions conformity (compliance):

“Real Life” Test on the street with

• PEMS (Portable Emission Measurement System)

• Workload window based emission result calculation


This GTR-10 Off-Cycle Emissions (OCE) includes two components.

• First, it contains provisions that prohibit the use of defeat strategies.

• Second, it introduces the World-harmonized Not-to-Exceed (WNTE) methodology, for limiting off-cycle emissions under a

broad range of engine and ambient operating conditions.


HEAVY DUTY: OFF CYCLE EMISSIONS COMPLIANCE


• Off-Cycle Testing. Euro VI regulation introduced off-cycle emissions

(OCE) testing requirements. OCE measurements, performed during

the type approval testing, follow the NTE (not-to-exceed) limit

approach. A control area is defined on the engine map (there are

two definitions, one for engines with a rated speed < 3000 rpm, and

another for engines with a rated speed ≥ 3000 rpm). The control

area is divided into grid. The testing involves random selection of

three grid cells and emission measurement at 5 points per cell.

• Over a wide applicable range of operating and ambient conditions

• Ramped Modal Test Sequence:



In-Service Emissions conformity (compliance):

• In-Service Conformity Testing. Euro VI regulation also introduced in-

use testing requirements that involve field measurements using

PEMS. The testing is conducted over a mix of urban (0-50 km/h),

rural (50-75 km/h) and motorway (> 75 km/h) conditions, with exact

percentages of these conditions depending on vehicle category.

First in-use test should be conducted at the time of type approval

testing.

• “Real Life” Test on the street with PEMS (Portable Emission

Measurement System)

• Result calculation by “Work based window”

• Over a wide applicable range of operating and ambient conditions



Off Cycle Emissions Compliance over a wide applicable range of

operating and ambient conditions

• Absolute air pressure down to 82.5kPa, which is up to an altitude of

app. 1700m)

• all engine coolant temperatures within a range of 70°C to 100°C

• Ambient temperature less or equal to

• T[K] =< -0.4514 * (101.3 – pb[kPa]) + 311

80kPa

~38°C

105kPa

~28°C

Solution for a transient engine test bed ambient

condition simulation.

• Intake air temperature control

• Intake air Humidity control

• Altitude simulation of engine intake air and tailpipe

pressure adjustment


HEAVY DUTY: OFF CYCLE EMISSIONS STATEMENT

Example of an real US-NTE Statement: ECE/TRANS/180/Add.10

10. STATEMENT OF OFF-CYCLE EMISSION COMPLIANCE

In the application for certification or type approval the

manufacturer shall provide a statement that the engine

family or vehicle complies with the requirements of this

OCE gtr. In addition to this statement, compliance with the

WNTE limits shall be verified through additional tests and

certification procedures defined by the Contracting Parties.

10.1. Example statement of Off-Cycle Emission compliance

The following is an example compliance statement:

"(Name of manufacturer) attests that the engines within this

engine family comply with all requirements of the OCE gtr.

(Name of manufacturer) makes this statement in good faith,

after having performed an appropriate engineering

evaluation of the emissions performance of the engines

within the engine family over the applicable range of

operating and ambient conditions.“

10.2. Basis for Off-Cycle Emission compliance statement

The manufacturer shall maintain records at the

manufacturer's facility which contain all test data,

engineering analyses, and other information which provides

the basis for the OCE compliance statement. The manufacturer

shall provide such information to the Certification or Type

Approval Authority upon request.



Solution for a transient engine test bed ambient

condition simulation.

• Intake air temperature control

• Intake air Humidity control

• Altitude simulation of engine intake air and tailpipe

pressure adjustment

pre

ssu

re [

mb

ar]

tem

pera

ture

[°C

]

po

wer

[kW

] h

um

idit

y [

% r

el]

sp

eed

[rp

m]

power

engine

speed

pressure

intake air temperature

humidity


CONTENT


Euro-VI




HEAVY DUTY: USA EMISSION LEGISLATION / REGULATION

US Emission Legislation:

• Harmonization between EPA and CARB regulations

• GHC (Green-House-Gases) CO2, CH4 and N2O must be

measured and reported.

US Technical Regulation:

• Test procedure is based on CFR-1065, which is very different to

old CFR-86 or EU. Examples:

• All Calculations are based on mol.

• Test system performance specs related to emission

standard and not to device range

• Continuous Analyzer w/o analog gains switch

• Low quench CLD analyzers required.

• NTE (Not to Exceed) emission limits measured in the vehicle on-

road with PEMS (Portable Emission Measurement Systems).

Main issues for development

• Engine calibration for a wide range of engine operation conditions

(speed, torque, temperatures, altitudes, …) to meet NTE limits.


TECHNICAL REGULATIONS

(40 CFR 86 SubPt. B – Light-duty vehicles)

40 CFR 1039 – Nonroad CI engines

40 CFR 1048 – Large Non-Road SI engines (>19 kW)

40 CFR 1054 – Small Non-Road SI engines (<19 kW)

40 CFR 1045 – Marine SI engines and vessels

40 CFR 1042 – Marine CI engines and vessels

40 CFR 1043 – Marine engines and vessels (Marpol)

40 CFR 1033 – Locomotives

40 CFR 1051 – Recreational engines and vehicles

40 CFR 1036 – Heavy-duty highway engines

40 CFR 1037 – Heavy-duty motor vehicles

Standard Setting Parts: Applications:

CFR-1066 – Vehicle Testing

CFR-1065 – Engine testing

Technical Regulations:

| AVL Emission Test Systems | Engeljehringer | 2014 23

40 CFR 1065 BASIC UNDERSTANDING REQUIRED

Emission Applications

• 40 CFR 1065 is not only a new legislation, with a certain delta list, when

compared to older legislations or compared to European legislations.

• It is a new way to specify emission testing.

• This new way is definitely better from a measurement quality point of

view. But it is very much different as in the past.

40 CFR 1065 is

a new way to specify emission testing


LD US AND EU REGULATION

OLD SPECIFICATIONS BASED ON DEVICE SPECIFICATIONS


• Old US legislations and European regulation

defines requirements device by device.

• Therefore it is possible to clearly say, a device is

conform with legislation independent of the other

systems on the test bed.

Measurement device

specifications


40 CFR 1065/1066 – A NEW WAY OF SPECIFICATIONS


Specification of

measurement chain

• 40 CFR 1065/1066 specifies requirements based

on the total measurement chain. From a point of

view for the result quality, that is the best way.

• But, by that it is not possible to clearly say, that a

device is conform with legislation independent of

the other systems on the test bed. A system may

be conform in one type of test bed and not

conform in another.

• Example: If an analyzer can not pass certain

performance criteria it might still be conform. But

the bench supplier expects that the HOST system

will do some compensation calculations to fix it.



EU und UN-ECE Emission Standards:

• Limits also for engines with over 560kW.

• Global Technical regulation GTR-11 will be implemented.

• Transient testing for most engine applications

• Agricultural and forestry tractors will be covered also by Non-Road

Mobile Machinery legislation. (before a separate legislation))

• “Real Driving Emissions” measurement with PEMS under evaluation.

• Discussions for Stage V (2020?) to implement also a PN limit. Currently

Non-Road Stage IV engines are often using open filter systems. EU

wants to have best available technology (closed filters).

US-EPA and CARB Standards:

• Test procedure is based on CFR-1065, which is quite

different compared to old US or European legislation.

• Transient testing for most engine applications

• Not to Exceed (Real Driving Emissions) measurement with

PEMS under evaluation.

EU

Will require advanced exhaust aftertreatment systems





USA

Caterpillar penalized for Clean Air Act violations

US EPA and the Department of Justice (DOJ) announced a settlement with Caterpillar Inc. to resolve alleged

Clean Air Act violations for shipping more than 590,000 highway and non-road diesel engines without the correct

emissions controls (Exhaust aftertreatment systems and ECU control) . California Air Resources Board (CARB),

is also settling its claims for violations from the sale of improperly configured engines in California.

Caterpillar will pay a $2.55 million penalty (EPA) and $510,000 (CARB) and recall of all noncompliant

engines and .

In addition to the recall, Caterpillar will mitigate the effects of the excess emissions from its engines through

permanent retirement of banked emission credits.

Source: http://yosemite.epa.gov/opa/admpress.nsf/0/684d1a6f813f6811852578db0059148e?openDocument

Engine Manufacturer and Machinery Manufacturer: Who is responsible for Emissions

Shipping engines without aftertreatment devices had been a common practice in the heavy-duty engine and vehicle

industry. As the ATDs are typically integrated with the vehicle's exhaust system rather than with the engine, the

practice of shipping them from the exhaust system manufacturer directly to the engine buyer simplified the logistics.

http://yosemite.epa.gov/opa/admpress.nsf/0/684d1a6f813f6811852578db0059148e?openDocument

http://yosemite.epa.gov/opa/admpress.nsf/0/684d1a6f813f6811852578db0059148e?openDocument


EMISSION REGULATION

How to measure emissions ?

Possible Emission Measurement Methods


EMISSION MEASUREMENT METHODS

Sensors

Exh.

Air

Fuel

Smoke

Test Bed Undiluted

Analytics Test Bed

UUT Load

Unit

Exhaust

Flow Smoke

Raw

Bench Blower

Undiluted measurement for gaseous Emissions

Partial Flow Dilution for Particulate Mass and Particle Number

Exhaust flow determination is mandatory for undiluted measurement:

In order to calculate the total mass emissions of an engine by undiluted emission

measurement it is mandatory to measure or determine the total exhaust flow of the

engine.

Partial Flow

Dilution

SPC

PN


EMISSION REGULATION

Sensors

Exh.

Air

Fuel

Smoke

PN

Test Bed Undiluted

Analytics

Full Flow Dilution

(CVS)

Diluted

Analytics Test Bed

CLD FID

UUT Load

Unit

Exhaust

Flow Smoke

Raw

Bench

Mixing

Chamber

Dilution

Tunnel

Tunnel

CLD

Tunnel

FID

Particle

Counter

Particulate

Sampler

CVS

Bags

CVS Heat

Exchanger

CVS Flow

Control

Diluted

Bench Blower

Full Flow Dilution System – CVS (Constant Volume Sampler):

A CVS simplifiers mass emission measurement very much. There is no exhaust flow

measurement needed, it avoids condensation of the water from the combustion and it

simulates somehow the effects taking place in the ambient. It consist of:

• Blower plus flow measurement and control (typical critical flow ventury nozzles

CFV).

• Mixing chamber and dilution air filter

• Bag Sampler to collect samples of diluted exhaust and dilution air.

• Optional a heat exchanger


CERTIFICATION: HEAVY DUTY ON-ROAD ENGINES

Sensors

Exh.

Air

Fuel

Smoke

Alcohol

Sampler

or Innova

Aldehyde

Cartridge

Sampler

PN

Test Bed Undiluted

Analytics

Partial Flow

Dilution

Full Flow Dilution

(CVS)

Diluted

Analytics Special Analytics Test Bed

CLD FID

Engine Engine

Dyno Air+Fuel (9) (9) Global

EU

UUT Load

Unit

Exhaust

Flow Smoke

Raw

Bench BMD SPC

Mixing

Chamber

Dilution

Tunnel

Tunnel

CLD

Tunnel

FID

Particle

Counter

Particulate

Sampler

CVS

Bags

CVS Heat

Exchanger

CVS Flow

Control

Diluted

Bench Impinger Cartridges Blower

(4) Alternative a configuration with a full flow CVS system is possible, actually it is the reference solution in the legislation, but since cost and space issue it is not the preferred solution.

(5) USA: CVS is seen as the preferred solution for the USA, since a specific market preference coming from the historical large installed base of CVS systems.

(9) Alcohol and Aldehyde measurement is required, but often it is replaced by other means (like using factors or using manually chemistry laboratory sampling and analysis)

Engine Engine

Dyno Air+Fuel

(4)

USA Engine

Engine

Dyno Air+Fuel

(9) (9)

(9) (9)

(5)

Japan Engine

Engine

Dyno Air+Fuel

(4)


CONTENT


Measuring emissions for HD and OF engines

AVL Emission Testing Solutions and Products

Conclusion

AVL Emission Testing Solutions and Products


COMPETENCY

AVL-PTE is an Engine and Powertrain development company with over 3000 engineers. All types of engines and fuels and for all worldwide emission standards.

AVL operates worldwide 228 test beds for in-house and customer powertrain development.

• 116 Engine test beds • 11 Powertrain Test beds • 20 Chassis Dynos • 81 Special test beds for

transmission, components

AVL-ITS is the worldwide largest manufacturer of engine, powertrain and vehicle test and measurement systems.


INVOLVEMENT

AVL

• is not involved in

definition of limits

and test cycles

AVL

is strongly involved in

definition of procedures

and test and

measurement

specification

Examples:

Involvement in UN-ECE Groups (Example WLTP-DTP) there are app. 100 persons registered at WLTP 20% from Government

5% from Technical Services

64% from Industry

11% from Test system suppliers, 6% by AVL

AVL Emission Regulation Service (EmRep)

AVL maintains its own Emission Regulation online service

Consulting in all emission legislation and certification topics

other assignment examples Austrian Standardization Institute, Committee 038 member „On Road

vehicle “

ISO/TC 70/SC 8 Exhaust gas emission measurement committee

(official representative of Austria)

FAD “Förderkreis Abgasnachbehandlungstechnologien für

Dieselmotoren”, Committee chair for emission measurement.

….

….


CUSTOMER PROJECTS: TÜV HESSEN, GERMANY

TÜV Hessen Test Center:

• Focus on alternative powertrain, alternative fuel

and Real Driving Emissions Testing

• Chassis Dyno Emission Test Cell for Certification

and R&D with additional “Real Driving Emission”

Simulation capabilities.

• Engine Test Cell

• Portable Emission Measurement System


CUSTOMER PROJECTS: USA EPA IN AN ARBOR, USA

USA Environmental Produktion Agency:

• 2 complete chassis dyno emission test cells for light duty cars up to

medium duty commercial vehicles.

• The test cells are fully capable to meet all current regulations and future

new emission regulations, like CFR-1065 and CFR-1066.

• Medium Duty CVS

• Dual Dilution Tunnels, heated

• Dilution Air Flow Meter

• PM measurement Diesel and Gasoline GDI

• 2nd Bag Sampler for additional Photo Acoustic and/or FTIR Analyzer

• NMOG measurement

• Alcohol sampling

• GHG measurement

• Raw and dilute gaseous measurements

• Automation system

• These test cells will also be used for development of the USA future

regulation methodology (1065 and 1066) for the LEV-III and Tier-III

program.


CUSTOMER PROJECTS: VIETNAM REGISTER, HANOI

Vietnam Register, Hanoi, Vietnam:

A complete AVL turn-key emission test center by AVL.

• It is the most modern emission center in South East Asia.

• It is fully certified by German TÜV (picture 5)

Test cells for:

• Passenger cars and light duty trucks (picture 1)

• Motorcycles and small 3- and 4 wheelers (picture 2)

• Heavy duty engines (picture 3)

• Evaporative emission testing (picture 4)

Timing:

• In 12 month from rice field to building and facility infrastructure.

• In 8 month from start of installation to a fully German TÜV certificated

emission test center.

• 200 motorcycle and 40 passenger car homologations in the first year of

full operation


AVL EMISSION TESTING PRODUCT PORTFOLIO

AVL has the largest and most complete emission testing and

measurement product portfolio on the market.


AVL iGENERATION EMISSION TEST SYSTEMS

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

AVL iGeneration Emission Systems

AVL has launched a totally new innovative

and intuitive emission measurement system

generation, covering all standard emission

systems.

Highest possible accuracy, repeatability and

atomization

Compliant with all current and future

legislations (by current drafts)

Highest availability and lowest TCO

One emission automization platform

One hardware platform

One software platform

One platform of highly integrated and

atomized calibration and validation devices.

iGEM Vehicle

iGEM Engine


AVL EMISSION TESTING PRODUCTS

over 2000 installed iGeneration emission systems

over 1000 installed AMA i60 emission benches


AVL EMISSION TESTING PRODUCTS

Gas Analyzers

Particulate and Smoke

Exhaust Gas Analyzers

Dilution Systems

Automation Systems

Every working hour a Gas Analyzer is shipped to a customer

Every 3rd working hour a Particulate measurement Instrument

Every working day a large Emission System

Every 2nd working day a Dilution- or PM sampling system

Every 3rd working day an Emission Automation System

emission: heavy duty and off-road

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