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K. Engeljehringer AVL List GmbH, Graz, Austria AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

AVL EMISSION TESTING Overview and Trends in Worldwide

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K Engeljehringer ndash AVL List GmbH Graz Austria

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

2 AVL Emission Test Systems K Engeljehringer

AVL EMISSION LEGISLATION Many pages complex and sometimes confusing

4000+ pages of worldwide emission legislations and regulations

In Annex 8 of this Regulation references to

Annex 4 shall be understood as reference

to Appendix 4 of Annex I of this

Regulation (Quotation from UN-ECE 101)

3 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

4 AVL Emission Test Systems K Engeljehringer

AVL EMISSION REGULATION Information

All legislations have 4 main topics bull Emission Limits

bull Test cycles

bull Test and Measurement specifications

bull Result calculation and reporting specification

Separation of legislations in 2 parts bull Standards - main focus on limits and test cycle)

bull Regulation - main focus on measurement test and

calculation specifications

bull Modern legislations have already accepted that and are written in

2 books (like Standard Setting part and Technical Regulations)

Standard

Setting Part Technical regulation

5 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS Complex matrix

Time

EU

Japan

USA

Applications

EU-1 EU II

EU-1 EU III

EU-1 EU IV

EU-1 EU V

EU-1 EU VI

EU-1 EU I

Chassis Dyno Engine Dyno

Global Harmonization

USA Harmonization

6 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS Test-Specifications

EU

EU und UN-ECE Emission Standards

bull GTR-02 Measurement procedure for two-wheeled motorcycles with

regard to the emission of gaseous pollutants CO2 emissions

and fuel consumption (Adopted 2005)

bull GTR-04 Test procedure for compression-ignition (CI) engines and

positive-ignition (PI) engines fuelled with natural gas (NG) or

liquefied petroleum gas (LPG) with regard to the emission of

pollutants (Adopted 2006)

bull GTR-05 Technical requirements for on-board diagnostic systems (OBD)

for road vehicles (Adopted 2006)

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

bull GTR-11 Engine emissions from agricultural and forestry tractors and

from non- road mobile machinery (Adopted 2009)

bull GTR-XY Passenger car emission testing based on WLTP

US-EPA and CARB Standards

bull Engine Test bed Test-Specifications in CFR-1065

bull Chassis dyno Test-Specifications in CFR-1066

ISO Standards

bull Engine Test bed ISO 8178

7 AVL Emission Test Systems K Engeljehringer

US EMISSION LEGISLATION Engine and Vehicle Testing

Standard Setting Part

Engine Testing

CFR-1065

This Technical part is the same for

all engine applications which are

tested on an engine test bed

Technical regulation

CFR-1051 Recreational vehicles

CFR-1048 Nonroad SI gt 19 kW

CFR-1042 Marine CI

CFR-1039 Nonroad CI

CFR-1033 Locomotives

CFR-1054 Nonroad SIlt 19 kW

CFR-1030 Aircraft

CFR-1036 Heavy Duty On-Road

CFR-1043 Marine vessel Marpol

CFR-1045 Marine SI

Vehicle Testing

CFR-1066

CFR-1012 Light Duty vehicles

CFR-1015 Fuel Economy

CFR-1022 Highway Motorcycles

Evaporative Testing

CFR-1060

8 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

9 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

10 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

EU

EU Emission Legislation

bull Euro-6 will start in 2014 with a second phase starting in 2017

bull Emission limits are valid for any ldquonormal driving operationrdquo By that EU can change

drive cycles without the need to change limits

bull Euro-6 requires Particulate mass (PM) and Particle number (PN) for all engines

EU and UN-ECE Emission Regulation

bull Test procedures and drive cycle should be the new WLTP (World Light vehicle Test

Procedure) WLTP (Phase 1) should be finished end of 2013 but is delayed If it

isnrsquot ready Euro-6 will continue with UN-ECE R-83 regulation like Euro-5

bull There will be a ldquoReal Driving Emissionsrdquo requirement which will limit emissions

also during any ldquonormalrdquo driving operation That will be measured by Portable

Emission Measurement System (PEMS) on the road As alternative or as further

extension there may also be a random drive cycles

Main issues for development

bull Gasoline engines will dominantly be GDI since CO2 legislation Main development

effort will be PN for GDI (will a Gasoline Particulate Filter (GPF) be needed)

bull Diesel vehicles development will focus on further NOx reduction

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

11 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS EU Passenger Cars

EU

1992 1996 2000 2005 2009 2011 2014 2017

ECE 1504

ECE 1505

NEDC NEDC NEDC NEDC NEDC WLTP

CO

Positive

Ignition

Engines

(Gasoline)

2720 2200 2300 1000 1000 1000 1000

HC 200 100 100 100 100

NMHC 68 68 68

HC + NOx 970 500

NOx 150 80 60 60 60

PM only GDI 5 45 45

PN 6E12

mgkm

mgkm

mgkm

mgkm

mgkm

mgkm

km

2720 1000 640 500 500 500 500

970 560 300 230 230 170 700

500 250 180 180 80

140 80 50 25 5 45 45

6E11 6E11

CO Compression

Ignition

Engines

(Diesel)

HC + NOx

NOx

PM

PN

mgkm

mgkm

mgkm

mgkm

km

Test Cycle

EU-1 EU-2 EU-3 EU-4 EU-5 EU-5+ EU-6

EU

no change change

EU-6+

6E11

important

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

2 AVL Emission Test Systems K Engeljehringer

AVL EMISSION LEGISLATION Many pages complex and sometimes confusing

4000+ pages of worldwide emission legislations and regulations

In Annex 8 of this Regulation references to

Annex 4 shall be understood as reference

to Appendix 4 of Annex I of this

Regulation (Quotation from UN-ECE 101)

3 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

4 AVL Emission Test Systems K Engeljehringer

AVL EMISSION REGULATION Information

All legislations have 4 main topics bull Emission Limits

bull Test cycles

bull Test and Measurement specifications

bull Result calculation and reporting specification

Separation of legislations in 2 parts bull Standards - main focus on limits and test cycle)

bull Regulation - main focus on measurement test and

calculation specifications

bull Modern legislations have already accepted that and are written in

2 books (like Standard Setting part and Technical Regulations)

Standard

Setting Part Technical regulation

5 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS Complex matrix

Time

EU

Japan

USA

Applications

EU-1 EU II

EU-1 EU III

EU-1 EU IV

EU-1 EU V

EU-1 EU VI

EU-1 EU I

Chassis Dyno Engine Dyno

Global Harmonization

USA Harmonization

6 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS Test-Specifications

EU

EU und UN-ECE Emission Standards

bull GTR-02 Measurement procedure for two-wheeled motorcycles with

regard to the emission of gaseous pollutants CO2 emissions

and fuel consumption (Adopted 2005)

bull GTR-04 Test procedure for compression-ignition (CI) engines and

positive-ignition (PI) engines fuelled with natural gas (NG) or

liquefied petroleum gas (LPG) with regard to the emission of

pollutants (Adopted 2006)

bull GTR-05 Technical requirements for on-board diagnostic systems (OBD)

for road vehicles (Adopted 2006)

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

bull GTR-11 Engine emissions from agricultural and forestry tractors and

from non- road mobile machinery (Adopted 2009)

bull GTR-XY Passenger car emission testing based on WLTP

US-EPA and CARB Standards

bull Engine Test bed Test-Specifications in CFR-1065

bull Chassis dyno Test-Specifications in CFR-1066

ISO Standards

bull Engine Test bed ISO 8178

7 AVL Emission Test Systems K Engeljehringer

US EMISSION LEGISLATION Engine and Vehicle Testing

Standard Setting Part

Engine Testing

CFR-1065

This Technical part is the same for

all engine applications which are

tested on an engine test bed

Technical regulation

CFR-1051 Recreational vehicles

CFR-1048 Nonroad SI gt 19 kW

CFR-1042 Marine CI

CFR-1039 Nonroad CI

CFR-1033 Locomotives

CFR-1054 Nonroad SIlt 19 kW

CFR-1030 Aircraft

CFR-1036 Heavy Duty On-Road

CFR-1043 Marine vessel Marpol

CFR-1045 Marine SI

Vehicle Testing

CFR-1066

CFR-1012 Light Duty vehicles

CFR-1015 Fuel Economy

CFR-1022 Highway Motorcycles

Evaporative Testing

CFR-1060

8 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

9 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

10 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

EU

EU Emission Legislation

bull Euro-6 will start in 2014 with a second phase starting in 2017

bull Emission limits are valid for any ldquonormal driving operationrdquo By that EU can change

drive cycles without the need to change limits

bull Euro-6 requires Particulate mass (PM) and Particle number (PN) for all engines

EU and UN-ECE Emission Regulation

bull Test procedures and drive cycle should be the new WLTP (World Light vehicle Test

Procedure) WLTP (Phase 1) should be finished end of 2013 but is delayed If it

isnrsquot ready Euro-6 will continue with UN-ECE R-83 regulation like Euro-5

bull There will be a ldquoReal Driving Emissionsrdquo requirement which will limit emissions

also during any ldquonormalrdquo driving operation That will be measured by Portable

Emission Measurement System (PEMS) on the road As alternative or as further

extension there may also be a random drive cycles

Main issues for development

bull Gasoline engines will dominantly be GDI since CO2 legislation Main development

effort will be PN for GDI (will a Gasoline Particulate Filter (GPF) be needed)

bull Diesel vehicles development will focus on further NOx reduction

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

11 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS EU Passenger Cars

EU

1992 1996 2000 2005 2009 2011 2014 2017

ECE 1504

ECE 1505

NEDC NEDC NEDC NEDC NEDC WLTP

CO

Positive

Ignition

Engines

(Gasoline)

2720 2200 2300 1000 1000 1000 1000

HC 200 100 100 100 100

NMHC 68 68 68

HC + NOx 970 500

NOx 150 80 60 60 60

PM only GDI 5 45 45

PN 6E12

mgkm

mgkm

mgkm

mgkm

mgkm

mgkm

km

2720 1000 640 500 500 500 500

970 560 300 230 230 170 700

500 250 180 180 80

140 80 50 25 5 45 45

6E11 6E11

CO Compression

Ignition

Engines

(Diesel)

HC + NOx

NOx

PM

PN

mgkm

mgkm

mgkm

mgkm

km

Test Cycle

EU-1 EU-2 EU-3 EU-4 EU-5 EU-5+ EU-6

EU

no change change

EU-6+

6E11

important

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

3 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

4 AVL Emission Test Systems K Engeljehringer

AVL EMISSION REGULATION Information

All legislations have 4 main topics bull Emission Limits

bull Test cycles

bull Test and Measurement specifications

bull Result calculation and reporting specification

Separation of legislations in 2 parts bull Standards - main focus on limits and test cycle)

bull Regulation - main focus on measurement test and

calculation specifications

bull Modern legislations have already accepted that and are written in

2 books (like Standard Setting part and Technical Regulations)

Standard

Setting Part Technical regulation

5 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS Complex matrix

Time

EU

Japan

USA

Applications

EU-1 EU II

EU-1 EU III

EU-1 EU IV

EU-1 EU V

EU-1 EU VI

EU-1 EU I

Chassis Dyno Engine Dyno

Global Harmonization

USA Harmonization

6 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS Test-Specifications

EU

EU und UN-ECE Emission Standards

bull GTR-02 Measurement procedure for two-wheeled motorcycles with

regard to the emission of gaseous pollutants CO2 emissions

and fuel consumption (Adopted 2005)

bull GTR-04 Test procedure for compression-ignition (CI) engines and

positive-ignition (PI) engines fuelled with natural gas (NG) or

liquefied petroleum gas (LPG) with regard to the emission of

pollutants (Adopted 2006)

bull GTR-05 Technical requirements for on-board diagnostic systems (OBD)

for road vehicles (Adopted 2006)

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

bull GTR-11 Engine emissions from agricultural and forestry tractors and

from non- road mobile machinery (Adopted 2009)

bull GTR-XY Passenger car emission testing based on WLTP

US-EPA and CARB Standards

bull Engine Test bed Test-Specifications in CFR-1065

bull Chassis dyno Test-Specifications in CFR-1066

ISO Standards

bull Engine Test bed ISO 8178

7 AVL Emission Test Systems K Engeljehringer

US EMISSION LEGISLATION Engine and Vehicle Testing

Standard Setting Part

Engine Testing

CFR-1065

This Technical part is the same for

all engine applications which are

tested on an engine test bed

Technical regulation

CFR-1051 Recreational vehicles

CFR-1048 Nonroad SI gt 19 kW

CFR-1042 Marine CI

CFR-1039 Nonroad CI

CFR-1033 Locomotives

CFR-1054 Nonroad SIlt 19 kW

CFR-1030 Aircraft

CFR-1036 Heavy Duty On-Road

CFR-1043 Marine vessel Marpol

CFR-1045 Marine SI

Vehicle Testing

CFR-1066

CFR-1012 Light Duty vehicles

CFR-1015 Fuel Economy

CFR-1022 Highway Motorcycles

Evaporative Testing

CFR-1060

8 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

9 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

10 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

EU

EU Emission Legislation

bull Euro-6 will start in 2014 with a second phase starting in 2017

bull Emission limits are valid for any ldquonormal driving operationrdquo By that EU can change

drive cycles without the need to change limits

bull Euro-6 requires Particulate mass (PM) and Particle number (PN) for all engines

EU and UN-ECE Emission Regulation

bull Test procedures and drive cycle should be the new WLTP (World Light vehicle Test

Procedure) WLTP (Phase 1) should be finished end of 2013 but is delayed If it

isnrsquot ready Euro-6 will continue with UN-ECE R-83 regulation like Euro-5

bull There will be a ldquoReal Driving Emissionsrdquo requirement which will limit emissions

also during any ldquonormalrdquo driving operation That will be measured by Portable

Emission Measurement System (PEMS) on the road As alternative or as further

extension there may also be a random drive cycles

Main issues for development

bull Gasoline engines will dominantly be GDI since CO2 legislation Main development

effort will be PN for GDI (will a Gasoline Particulate Filter (GPF) be needed)

bull Diesel vehicles development will focus on further NOx reduction

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

11 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS EU Passenger Cars

EU

1992 1996 2000 2005 2009 2011 2014 2017

ECE 1504

ECE 1505

NEDC NEDC NEDC NEDC NEDC WLTP

CO

Positive

Ignition

Engines

(Gasoline)

2720 2200 2300 1000 1000 1000 1000

HC 200 100 100 100 100

NMHC 68 68 68

HC + NOx 970 500

NOx 150 80 60 60 60

PM only GDI 5 45 45

PN 6E12

mgkm

mgkm

mgkm

mgkm

mgkm

mgkm

km

2720 1000 640 500 500 500 500

970 560 300 230 230 170 700

500 250 180 180 80

140 80 50 25 5 45 45

6E11 6E11

CO Compression

Ignition

Engines

(Diesel)

HC + NOx

NOx

PM

PN

mgkm

mgkm

mgkm

mgkm

km

Test Cycle

EU-1 EU-2 EU-3 EU-4 EU-5 EU-5+ EU-6

EU

no change change

EU-6+

6E11

important

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

4 AVL Emission Test Systems K Engeljehringer

AVL EMISSION REGULATION Information

All legislations have 4 main topics bull Emission Limits

bull Test cycles

bull Test and Measurement specifications

bull Result calculation and reporting specification

Separation of legislations in 2 parts bull Standards - main focus on limits and test cycle)

bull Regulation - main focus on measurement test and

calculation specifications

bull Modern legislations have already accepted that and are written in

2 books (like Standard Setting part and Technical Regulations)

Standard

Setting Part Technical regulation

5 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS Complex matrix

Time

EU

Japan

USA

Applications

EU-1 EU II

EU-1 EU III

EU-1 EU IV

EU-1 EU V

EU-1 EU VI

EU-1 EU I

Chassis Dyno Engine Dyno

Global Harmonization

USA Harmonization

6 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS Test-Specifications

EU

EU und UN-ECE Emission Standards

bull GTR-02 Measurement procedure for two-wheeled motorcycles with

regard to the emission of gaseous pollutants CO2 emissions

and fuel consumption (Adopted 2005)

bull GTR-04 Test procedure for compression-ignition (CI) engines and

positive-ignition (PI) engines fuelled with natural gas (NG) or

liquefied petroleum gas (LPG) with regard to the emission of

pollutants (Adopted 2006)

bull GTR-05 Technical requirements for on-board diagnostic systems (OBD)

for road vehicles (Adopted 2006)

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

bull GTR-11 Engine emissions from agricultural and forestry tractors and

from non- road mobile machinery (Adopted 2009)

bull GTR-XY Passenger car emission testing based on WLTP

US-EPA and CARB Standards

bull Engine Test bed Test-Specifications in CFR-1065

bull Chassis dyno Test-Specifications in CFR-1066

ISO Standards

bull Engine Test bed ISO 8178

7 AVL Emission Test Systems K Engeljehringer

US EMISSION LEGISLATION Engine and Vehicle Testing

Standard Setting Part

Engine Testing

CFR-1065

This Technical part is the same for

all engine applications which are

tested on an engine test bed

Technical regulation

CFR-1051 Recreational vehicles

CFR-1048 Nonroad SI gt 19 kW

CFR-1042 Marine CI

CFR-1039 Nonroad CI

CFR-1033 Locomotives

CFR-1054 Nonroad SIlt 19 kW

CFR-1030 Aircraft

CFR-1036 Heavy Duty On-Road

CFR-1043 Marine vessel Marpol

CFR-1045 Marine SI

Vehicle Testing

CFR-1066

CFR-1012 Light Duty vehicles

CFR-1015 Fuel Economy

CFR-1022 Highway Motorcycles

Evaporative Testing

CFR-1060

8 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

9 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

10 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

EU

EU Emission Legislation

bull Euro-6 will start in 2014 with a second phase starting in 2017

bull Emission limits are valid for any ldquonormal driving operationrdquo By that EU can change

drive cycles without the need to change limits

bull Euro-6 requires Particulate mass (PM) and Particle number (PN) for all engines

EU and UN-ECE Emission Regulation

bull Test procedures and drive cycle should be the new WLTP (World Light vehicle Test

Procedure) WLTP (Phase 1) should be finished end of 2013 but is delayed If it

isnrsquot ready Euro-6 will continue with UN-ECE R-83 regulation like Euro-5

bull There will be a ldquoReal Driving Emissionsrdquo requirement which will limit emissions

also during any ldquonormalrdquo driving operation That will be measured by Portable

Emission Measurement System (PEMS) on the road As alternative or as further

extension there may also be a random drive cycles

Main issues for development

bull Gasoline engines will dominantly be GDI since CO2 legislation Main development

effort will be PN for GDI (will a Gasoline Particulate Filter (GPF) be needed)

bull Diesel vehicles development will focus on further NOx reduction

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

11 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS EU Passenger Cars

EU

1992 1996 2000 2005 2009 2011 2014 2017

ECE 1504

ECE 1505

NEDC NEDC NEDC NEDC NEDC WLTP

CO

Positive

Ignition

Engines

(Gasoline)

2720 2200 2300 1000 1000 1000 1000

HC 200 100 100 100 100

NMHC 68 68 68

HC + NOx 970 500

NOx 150 80 60 60 60

PM only GDI 5 45 45

PN 6E12

mgkm

mgkm

mgkm

mgkm

mgkm

mgkm

km

2720 1000 640 500 500 500 500

970 560 300 230 230 170 700

500 250 180 180 80

140 80 50 25 5 45 45

6E11 6E11

CO Compression

Ignition

Engines

(Diesel)

HC + NOx

NOx

PM

PN

mgkm

mgkm

mgkm

mgkm

km

Test Cycle

EU-1 EU-2 EU-3 EU-4 EU-5 EU-5+ EU-6

EU

no change change

EU-6+

6E11

important

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

5 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS Complex matrix

Time

EU

Japan

USA

Applications

EU-1 EU II

EU-1 EU III

EU-1 EU IV

EU-1 EU V

EU-1 EU VI

EU-1 EU I

Chassis Dyno Engine Dyno

Global Harmonization

USA Harmonization

6 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS Test-Specifications

EU

EU und UN-ECE Emission Standards

bull GTR-02 Measurement procedure for two-wheeled motorcycles with

regard to the emission of gaseous pollutants CO2 emissions

and fuel consumption (Adopted 2005)

bull GTR-04 Test procedure for compression-ignition (CI) engines and

positive-ignition (PI) engines fuelled with natural gas (NG) or

liquefied petroleum gas (LPG) with regard to the emission of

pollutants (Adopted 2006)

bull GTR-05 Technical requirements for on-board diagnostic systems (OBD)

for road vehicles (Adopted 2006)

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

bull GTR-11 Engine emissions from agricultural and forestry tractors and

from non- road mobile machinery (Adopted 2009)

bull GTR-XY Passenger car emission testing based on WLTP

US-EPA and CARB Standards

bull Engine Test bed Test-Specifications in CFR-1065

bull Chassis dyno Test-Specifications in CFR-1066

ISO Standards

bull Engine Test bed ISO 8178

7 AVL Emission Test Systems K Engeljehringer

US EMISSION LEGISLATION Engine and Vehicle Testing

Standard Setting Part

Engine Testing

CFR-1065

This Technical part is the same for

all engine applications which are

tested on an engine test bed

Technical regulation

CFR-1051 Recreational vehicles

CFR-1048 Nonroad SI gt 19 kW

CFR-1042 Marine CI

CFR-1039 Nonroad CI

CFR-1033 Locomotives

CFR-1054 Nonroad SIlt 19 kW

CFR-1030 Aircraft

CFR-1036 Heavy Duty On-Road

CFR-1043 Marine vessel Marpol

CFR-1045 Marine SI

Vehicle Testing

CFR-1066

CFR-1012 Light Duty vehicles

CFR-1015 Fuel Economy

CFR-1022 Highway Motorcycles

Evaporative Testing

CFR-1060

8 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

9 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

10 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

EU

EU Emission Legislation

bull Euro-6 will start in 2014 with a second phase starting in 2017

bull Emission limits are valid for any ldquonormal driving operationrdquo By that EU can change

drive cycles without the need to change limits

bull Euro-6 requires Particulate mass (PM) and Particle number (PN) for all engines

EU and UN-ECE Emission Regulation

bull Test procedures and drive cycle should be the new WLTP (World Light vehicle Test

Procedure) WLTP (Phase 1) should be finished end of 2013 but is delayed If it

isnrsquot ready Euro-6 will continue with UN-ECE R-83 regulation like Euro-5

bull There will be a ldquoReal Driving Emissionsrdquo requirement which will limit emissions

also during any ldquonormalrdquo driving operation That will be measured by Portable

Emission Measurement System (PEMS) on the road As alternative or as further

extension there may also be a random drive cycles

Main issues for development

bull Gasoline engines will dominantly be GDI since CO2 legislation Main development

effort will be PN for GDI (will a Gasoline Particulate Filter (GPF) be needed)

bull Diesel vehicles development will focus on further NOx reduction

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

11 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS EU Passenger Cars

EU

1992 1996 2000 2005 2009 2011 2014 2017

ECE 1504

ECE 1505

NEDC NEDC NEDC NEDC NEDC WLTP

CO

Positive

Ignition

Engines

(Gasoline)

2720 2200 2300 1000 1000 1000 1000

HC 200 100 100 100 100

NMHC 68 68 68

HC + NOx 970 500

NOx 150 80 60 60 60

PM only GDI 5 45 45

PN 6E12

mgkm

mgkm

mgkm

mgkm

mgkm

mgkm

km

2720 1000 640 500 500 500 500

970 560 300 230 230 170 700

500 250 180 180 80

140 80 50 25 5 45 45

6E11 6E11

CO Compression

Ignition

Engines

(Diesel)

HC + NOx

NOx

PM

PN

mgkm

mgkm

mgkm

mgkm

km

Test Cycle

EU-1 EU-2 EU-3 EU-4 EU-5 EU-5+ EU-6

EU

no change change

EU-6+

6E11

important

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

6 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS Test-Specifications

EU

EU und UN-ECE Emission Standards

bull GTR-02 Measurement procedure for two-wheeled motorcycles with

regard to the emission of gaseous pollutants CO2 emissions

and fuel consumption (Adopted 2005)

bull GTR-04 Test procedure for compression-ignition (CI) engines and

positive-ignition (PI) engines fuelled with natural gas (NG) or

liquefied petroleum gas (LPG) with regard to the emission of

pollutants (Adopted 2006)

bull GTR-05 Technical requirements for on-board diagnostic systems (OBD)

for road vehicles (Adopted 2006)

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

bull GTR-11 Engine emissions from agricultural and forestry tractors and

from non- road mobile machinery (Adopted 2009)

bull GTR-XY Passenger car emission testing based on WLTP

US-EPA and CARB Standards

bull Engine Test bed Test-Specifications in CFR-1065

bull Chassis dyno Test-Specifications in CFR-1066

ISO Standards

bull Engine Test bed ISO 8178

7 AVL Emission Test Systems K Engeljehringer

US EMISSION LEGISLATION Engine and Vehicle Testing

Standard Setting Part

Engine Testing

CFR-1065

This Technical part is the same for

all engine applications which are

tested on an engine test bed

Technical regulation

CFR-1051 Recreational vehicles

CFR-1048 Nonroad SI gt 19 kW

CFR-1042 Marine CI

CFR-1039 Nonroad CI

CFR-1033 Locomotives

CFR-1054 Nonroad SIlt 19 kW

CFR-1030 Aircraft

CFR-1036 Heavy Duty On-Road

CFR-1043 Marine vessel Marpol

CFR-1045 Marine SI

Vehicle Testing

CFR-1066

CFR-1012 Light Duty vehicles

CFR-1015 Fuel Economy

CFR-1022 Highway Motorcycles

Evaporative Testing

CFR-1060

8 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

9 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

10 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

EU

EU Emission Legislation

bull Euro-6 will start in 2014 with a second phase starting in 2017

bull Emission limits are valid for any ldquonormal driving operationrdquo By that EU can change

drive cycles without the need to change limits

bull Euro-6 requires Particulate mass (PM) and Particle number (PN) for all engines

EU and UN-ECE Emission Regulation

bull Test procedures and drive cycle should be the new WLTP (World Light vehicle Test

Procedure) WLTP (Phase 1) should be finished end of 2013 but is delayed If it

isnrsquot ready Euro-6 will continue with UN-ECE R-83 regulation like Euro-5

bull There will be a ldquoReal Driving Emissionsrdquo requirement which will limit emissions

also during any ldquonormalrdquo driving operation That will be measured by Portable

Emission Measurement System (PEMS) on the road As alternative or as further

extension there may also be a random drive cycles

Main issues for development

bull Gasoline engines will dominantly be GDI since CO2 legislation Main development

effort will be PN for GDI (will a Gasoline Particulate Filter (GPF) be needed)

bull Diesel vehicles development will focus on further NOx reduction

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

11 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS EU Passenger Cars

EU

1992 1996 2000 2005 2009 2011 2014 2017

ECE 1504

ECE 1505

NEDC NEDC NEDC NEDC NEDC WLTP

CO

Positive

Ignition

Engines

(Gasoline)

2720 2200 2300 1000 1000 1000 1000

HC 200 100 100 100 100

NMHC 68 68 68

HC + NOx 970 500

NOx 150 80 60 60 60

PM only GDI 5 45 45

PN 6E12

mgkm

mgkm

mgkm

mgkm

mgkm

mgkm

km

2720 1000 640 500 500 500 500

970 560 300 230 230 170 700

500 250 180 180 80

140 80 50 25 5 45 45

6E11 6E11

CO Compression

Ignition

Engines

(Diesel)

HC + NOx

NOx

PM

PN

mgkm

mgkm

mgkm

mgkm

km

Test Cycle

EU-1 EU-2 EU-3 EU-4 EU-5 EU-5+ EU-6

EU

no change change

EU-6+

6E11

important

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

7 AVL Emission Test Systems K Engeljehringer

US EMISSION LEGISLATION Engine and Vehicle Testing

Standard Setting Part

Engine Testing

CFR-1065

This Technical part is the same for

all engine applications which are

tested on an engine test bed

Technical regulation

CFR-1051 Recreational vehicles

CFR-1048 Nonroad SI gt 19 kW

CFR-1042 Marine CI

CFR-1039 Nonroad CI

CFR-1033 Locomotives

CFR-1054 Nonroad SIlt 19 kW

CFR-1030 Aircraft

CFR-1036 Heavy Duty On-Road

CFR-1043 Marine vessel Marpol

CFR-1045 Marine SI

Vehicle Testing

CFR-1066

CFR-1012 Light Duty vehicles

CFR-1015 Fuel Economy

CFR-1022 Highway Motorcycles

Evaporative Testing

CFR-1060

8 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

9 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

10 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

EU

EU Emission Legislation

bull Euro-6 will start in 2014 with a second phase starting in 2017

bull Emission limits are valid for any ldquonormal driving operationrdquo By that EU can change

drive cycles without the need to change limits

bull Euro-6 requires Particulate mass (PM) and Particle number (PN) for all engines

EU and UN-ECE Emission Regulation

bull Test procedures and drive cycle should be the new WLTP (World Light vehicle Test

Procedure) WLTP (Phase 1) should be finished end of 2013 but is delayed If it

isnrsquot ready Euro-6 will continue with UN-ECE R-83 regulation like Euro-5

bull There will be a ldquoReal Driving Emissionsrdquo requirement which will limit emissions

also during any ldquonormalrdquo driving operation That will be measured by Portable

Emission Measurement System (PEMS) on the road As alternative or as further

extension there may also be a random drive cycles

Main issues for development

bull Gasoline engines will dominantly be GDI since CO2 legislation Main development

effort will be PN for GDI (will a Gasoline Particulate Filter (GPF) be needed)

bull Diesel vehicles development will focus on further NOx reduction

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

11 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS EU Passenger Cars

EU

1992 1996 2000 2005 2009 2011 2014 2017

ECE 1504

ECE 1505

NEDC NEDC NEDC NEDC NEDC WLTP

CO

Positive

Ignition

Engines

(Gasoline)

2720 2200 2300 1000 1000 1000 1000

HC 200 100 100 100 100

NMHC 68 68 68

HC + NOx 970 500

NOx 150 80 60 60 60

PM only GDI 5 45 45

PN 6E12

mgkm

mgkm

mgkm

mgkm

mgkm

mgkm

km

2720 1000 640 500 500 500 500

970 560 300 230 230 170 700

500 250 180 180 80

140 80 50 25 5 45 45

6E11 6E11

CO Compression

Ignition

Engines

(Diesel)

HC + NOx

NOx

PM

PN

mgkm

mgkm

mgkm

mgkm

km

Test Cycle

EU-1 EU-2 EU-3 EU-4 EU-5 EU-5+ EU-6

EU

no change change

EU-6+

6E11

important

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

8 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

9 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

10 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

EU

EU Emission Legislation

bull Euro-6 will start in 2014 with a second phase starting in 2017

bull Emission limits are valid for any ldquonormal driving operationrdquo By that EU can change

drive cycles without the need to change limits

bull Euro-6 requires Particulate mass (PM) and Particle number (PN) for all engines

EU and UN-ECE Emission Regulation

bull Test procedures and drive cycle should be the new WLTP (World Light vehicle Test

Procedure) WLTP (Phase 1) should be finished end of 2013 but is delayed If it

isnrsquot ready Euro-6 will continue with UN-ECE R-83 regulation like Euro-5

bull There will be a ldquoReal Driving Emissionsrdquo requirement which will limit emissions

also during any ldquonormalrdquo driving operation That will be measured by Portable

Emission Measurement System (PEMS) on the road As alternative or as further

extension there may also be a random drive cycles

Main issues for development

bull Gasoline engines will dominantly be GDI since CO2 legislation Main development

effort will be PN for GDI (will a Gasoline Particulate Filter (GPF) be needed)

bull Diesel vehicles development will focus on further NOx reduction

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

11 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS EU Passenger Cars

EU

1992 1996 2000 2005 2009 2011 2014 2017

ECE 1504

ECE 1505

NEDC NEDC NEDC NEDC NEDC WLTP

CO

Positive

Ignition

Engines

(Gasoline)

2720 2200 2300 1000 1000 1000 1000

HC 200 100 100 100 100

NMHC 68 68 68

HC + NOx 970 500

NOx 150 80 60 60 60

PM only GDI 5 45 45

PN 6E12

mgkm

mgkm

mgkm

mgkm

mgkm

mgkm

km

2720 1000 640 500 500 500 500

970 560 300 230 230 170 700

500 250 180 180 80

140 80 50 25 5 45 45

6E11 6E11

CO Compression

Ignition

Engines

(Diesel)

HC + NOx

NOx

PM

PN

mgkm

mgkm

mgkm

mgkm

km

Test Cycle

EU-1 EU-2 EU-3 EU-4 EU-5 EU-5+ EU-6

EU

no change change

EU-6+

6E11

important

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

9 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

10 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

EU

EU Emission Legislation

bull Euro-6 will start in 2014 with a second phase starting in 2017

bull Emission limits are valid for any ldquonormal driving operationrdquo By that EU can change

drive cycles without the need to change limits

bull Euro-6 requires Particulate mass (PM) and Particle number (PN) for all engines

EU and UN-ECE Emission Regulation

bull Test procedures and drive cycle should be the new WLTP (World Light vehicle Test

Procedure) WLTP (Phase 1) should be finished end of 2013 but is delayed If it

isnrsquot ready Euro-6 will continue with UN-ECE R-83 regulation like Euro-5

bull There will be a ldquoReal Driving Emissionsrdquo requirement which will limit emissions

also during any ldquonormalrdquo driving operation That will be measured by Portable

Emission Measurement System (PEMS) on the road As alternative or as further

extension there may also be a random drive cycles

Main issues for development

bull Gasoline engines will dominantly be GDI since CO2 legislation Main development

effort will be PN for GDI (will a Gasoline Particulate Filter (GPF) be needed)

bull Diesel vehicles development will focus on further NOx reduction

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

11 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS EU Passenger Cars

EU

1992 1996 2000 2005 2009 2011 2014 2017

ECE 1504

ECE 1505

NEDC NEDC NEDC NEDC NEDC WLTP

CO

Positive

Ignition

Engines

(Gasoline)

2720 2200 2300 1000 1000 1000 1000

HC 200 100 100 100 100

NMHC 68 68 68

HC + NOx 970 500

NOx 150 80 60 60 60

PM only GDI 5 45 45

PN 6E12

mgkm

mgkm

mgkm

mgkm

mgkm

mgkm

km

2720 1000 640 500 500 500 500

970 560 300 230 230 170 700

500 250 180 180 80

140 80 50 25 5 45 45

6E11 6E11

CO Compression

Ignition

Engines

(Diesel)

HC + NOx

NOx

PM

PN

mgkm

mgkm

mgkm

mgkm

km

Test Cycle

EU-1 EU-2 EU-3 EU-4 EU-5 EU-5+ EU-6

EU

no change change

EU-6+

6E11

important

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

10 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

EU

EU Emission Legislation

bull Euro-6 will start in 2014 with a second phase starting in 2017

bull Emission limits are valid for any ldquonormal driving operationrdquo By that EU can change

drive cycles without the need to change limits

bull Euro-6 requires Particulate mass (PM) and Particle number (PN) for all engines

EU and UN-ECE Emission Regulation

bull Test procedures and drive cycle should be the new WLTP (World Light vehicle Test

Procedure) WLTP (Phase 1) should be finished end of 2013 but is delayed If it

isnrsquot ready Euro-6 will continue with UN-ECE R-83 regulation like Euro-5

bull There will be a ldquoReal Driving Emissionsrdquo requirement which will limit emissions

also during any ldquonormalrdquo driving operation That will be measured by Portable

Emission Measurement System (PEMS) on the road As alternative or as further

extension there may also be a random drive cycles

Main issues for development

bull Gasoline engines will dominantly be GDI since CO2 legislation Main development

effort will be PN for GDI (will a Gasoline Particulate Filter (GPF) be needed)

bull Diesel vehicles development will focus on further NOx reduction

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

11 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS EU Passenger Cars

EU

1992 1996 2000 2005 2009 2011 2014 2017

ECE 1504

ECE 1505

NEDC NEDC NEDC NEDC NEDC WLTP

CO

Positive

Ignition

Engines

(Gasoline)

2720 2200 2300 1000 1000 1000 1000

HC 200 100 100 100 100

NMHC 68 68 68

HC + NOx 970 500

NOx 150 80 60 60 60

PM only GDI 5 45 45

PN 6E12

mgkm

mgkm

mgkm

mgkm

mgkm

mgkm

km

2720 1000 640 500 500 500 500

970 560 300 230 230 170 700

500 250 180 180 80

140 80 50 25 5 45 45

6E11 6E11

CO Compression

Ignition

Engines

(Diesel)

HC + NOx

NOx

PM

PN

mgkm

mgkm

mgkm

mgkm

km

Test Cycle

EU-1 EU-2 EU-3 EU-4 EU-5 EU-5+ EU-6

EU

no change change

EU-6+

6E11

important

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

11 AVL Emission Test Systems K Engeljehringer

EMISSION LEGISLATIONS EU Passenger Cars

EU

1992 1996 2000 2005 2009 2011 2014 2017

ECE 1504

ECE 1505

NEDC NEDC NEDC NEDC NEDC WLTP

CO

Positive

Ignition

Engines

(Gasoline)

2720 2200 2300 1000 1000 1000 1000

HC 200 100 100 100 100

NMHC 68 68 68

HC + NOx 970 500

NOx 150 80 60 60 60

PM only GDI 5 45 45

PN 6E12

mgkm

mgkm

mgkm

mgkm

mgkm

mgkm

km

2720 1000 640 500 500 500 500

970 560 300 230 230 170 700

500 250 180 180 80

140 80 50 25 5 45 45

6E11 6E11

CO Compression

Ignition

Engines

(Diesel)

HC + NOx

NOx

PM

PN

mgkm

mgkm

mgkm

mgkm

km

Test Cycle

EU-1 EU-2 EU-3 EU-4 EU-5 EU-5+ EU-6

EU

no change change

EU-6+

6E11

important

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

12 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

bull Project is set up accordingly to UNECE 1998 world harmonization

agreement

bull Sponsored by EU and Japan USA has withdrawn sponsoring in

June 2010

Project and objective

bull DHC Development of a drive cycle - average world wide driving behavior

bull DTP Development of the test procedures (parameter definition equipment specifications

fuels hellip) for better reproducibility and better representativeness like road load determination

bull It will result in a Global Technical Regulation (GTR) how to test emissions

bull It will NOT define which emissions will be limited and what the limits shall be

Project plan

bull Phase-1 Drive cycle and test procedures should be finished Nov 2013

bull Phase-2 Off-Cycle emissions Low ambient temperature High altitude In-Service conformity

Durability hellip

Euro 6 is planed for 2014 WLTP will be implemented if and as far it will be available

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

13 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION WLTP (World Light vehicle Test Procedure) and Euro 67

WLTP Drive Cycle consists of 4 Phases bull Low Phase

bull Middle Phase

bull High Phase

bull Extra-High Phase

Objective

bull Test-cycle accepted worldwide to increasing harmonization for the automotive sector at a

global level

bull Shall reflect in average the world wide driving behavior of passenger cars and light duty

vehicles (based on driving data from main Contracting parties including India China hellip)

bull Different gear shift points for PC and LDCV

4 Phases

1800 sec long

46 kmh average velocity

125 kmh max velocity

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

14 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Light Duty - Passenger Cars

USA Emission Legislation

bull US-EPA and CARB will harmonize their standards

bull Low Emission Vehicle program III (LEV-III) starts in 2014

bull PM limits will be reduced by a factor 10

bull PM measured for all engine- and fuel types

bull Medium Duty Vehicle (MDV) are tested on chassis dynos

USA Emission Regulation

bull Test specifications accordingly CFR-1066 and CFR-1065 replacing the current

Part-40 CFR-86

Main issues for development

bull Fleet averages equivalent to current SULEV by 2022

bull New emissions categories and combined NMOG and NOx standards

bull New E-85 fuel requirements and limit changes

bull Eliminate 50000 mile intermediate useful life standards and increased durability

requirement from 120000 miles to 150000 miles

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

15 AVL Emission Test Systems K Engeljehringer

LIGHT DUTY VEHICLE Chassis Test Bed (with Hybrid add-ons)

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

16 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

17 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

EU

EU Emission Legislation

bull Euro-VI has started 2013

bull In addition to Particulate Mass (PM) also Particle Number (PN) limits for Diesel

bull Euro-VII isnrsquot defined yet CO2 and fuel consumption requirements will come next

EU and UN-ECE Emission Regulation

bull Euro-VI test procedure is based on Global Test Procedure GTR-04 from UN-ECE

bull New World Harmonized Stationary Cycle (WHSC) and World Harmonized

Transient Cycle (WHTC) is used

bull ldquoReal Driving Emissionsrdquo requirements limit emissions also during any ldquonormalrdquo

driving operation That is done by

bull an Off Cycle Emissions (OCE) stationary engine test cycle with 15 random

engine speedtorque points

bull and with the vehicle on the road by Portable Emission Measurement

Systems (PEMS)

Main issues for development

bull Diesel PN limits

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

18 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

1992 1996 2000 2005 2008 2013

Moderate Reduction (lt30) Large Reduction (gt30)

Test cycles

EU-I+II

13-Mode

EU-III+IV

ESC

EU-VI

WHSC

CO 450 400 210 150 150 150

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

110 110 066 046 046 013

800 700 500 350 200 040

360 015 010 002 002 001

25 25 10

8 E11

no

6 E11

Test cycles

EU-III+IV

ETC

EU-VI

WHSC

CO 540 400 400 400

THC

NOx

NMHC

CH4

PM

PN

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

gkW-h

kWh

NH3 ppm

CO2 FC gkW-h

NO2 gkW-h

016

500 350 200 046

016 003 003 001

25 25 10

no

078 055 055

160 110 110

Tbd

Tbd

I EU

II III IV V VI

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

19 AVL Emission Test Systems K Engeljehringer

EU EMISSION LEGISLATION TRENDS Heavy Duty ndash On-Road Engines

USA Emission Legislation

bull Harmonization of EPA and CARB regulations

bull In addition to CO2 also CH4 and N2O must be measured and reported for Green-

House-Gas (GHC) legislation

USA Emission Regulation

bull Test procedure is based on CFR-1065 (very different to old CFR-86 or EU)

bull All Calculations are based on mol or CFR-86

bull Performance specifications are based on statistical evaluations and limits

are not anymore related to measurement ranges but on the actual

emissions of the engine tested and the emission limit

bull Analyzer must not switch analog gains for continuous measurement

bull CLD analyzers must meet very small CO2 and H2O quenching specs

bull ldquoReal Driving Emissionsrdquo limit emissions during normal driving operation That is

done with the vehicle on the road by Portable Emission Measurement Systems

(PEMS)

Main issues for development

bull Engine calibration for a wide range of engine operation conditions (speed torque

temperatures altitudes hellip) to meet real driving emission requirements

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

20 AVL Emission Test Systems K Engeljehringer

HEAVY DUTY ON-ROAD ENGINE Engine Test Bed

NH3 NH3

Emission Engine Test Bed with CVS

bull Automation system iGEM Engine

bull Full Flow Dilution with CVS i60

bull Diluted gaseous emission bench AMA i60

bull Particulate Sampler PSS i60 with integrated particle

counter APC

bull NH3 Analyzer SESAM i60 FT or LDD

Emission Engine Test Bed with SPC

bull Automation system iGEM Engine

bull Partial flow Dilution with SPC

bull Raw gaseous emission bench AMA i60

bull Particle counter APC connected to SPC

bull NH3 Analyzer SESAM i60 FT or LDD

Also US-EPA is now accepting partial flow dilution and raw gaseous emission measurement

for stationary and transient testing

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

21 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

22 AVL Emission Test Systems K Engeljehringer

Off-Road - ABGASGESETZGEBUNG Herausforderungen

EU

EU und UN-ECE Emission Standards

bull Limits also for engines with over 560kW

bull Global Technical regulation GTR-11 will be implemented

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

Machinery legislation (before a separate legislation))

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

bull Discussions for Stage V (2020) to implement also a PN limit Currently Non-

Road Stage IV engines are often using open filter systems

US-EPA and CARB Standards

bull Test procedure is based on CFR-1065 which is quite different compared to

old US or European legislation

bull ldquoReal Driving Emissionsrdquo measurement with PEMS under evaluation

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

23 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Pollution Control

Off-Road engine applications are the last combustion engine

application which gets effected by emission legislation

App 2000 the fist emission legislations came up for Off-Road

App 2011 most of the off-road applications are effected by emission

legislation

In order to fulfill most off-road legislation emission limits more and

more engines will require the use of an exhaust aftertreatment

technology

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

24 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Transienter Pruumlflauf NRTC (Non Road Transient Cycle)

Transient

Test Cycle

Stationary

Test Cycle

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

25 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Space limitations

bull Most off-road applications have a limited space available Like on a

tractor it is important that the driver can see the front wheels

bull To mount additionally an exhaust aftertreatment systems is

challenging especially since these devices get very hot

Load profile and exhaust temperature

bull Often the average engine load is very for most of the operation

times Only for a short period of time the maximum engine power is

used Which results in low average exhaust temperatures

bull With such low exhaust temperatures exhaust aftertreatment

systems will not work or can not be properly regenerated

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

26 AVL Emission Test Systems K Engeljehringer

OFF-HIGHWAY ANWENDUNGEN Herausforderung Abgasnachbehandlung

100 150 200 250 300 350 400

Exhaust Temperature [degC]

Amount of time when exhaust temperature is suitable for

Exhaust after treatment systems (T ge T Abgas)

SCR Continuous Regenerating DPF (NO2)

20

40

60

80

100

NRTC

20

40

60

80

100

20

40

60

80

100

Traktor beim

Saumlen

Traktor

beim Fahren

NRTC

Non Road

Transient Cycle

NRTC

20

40

60

80

100

Gabelstapler

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

27 AVL Emission Test Systems K Engeljehringer

OFF-ROAD EMISSIONS Exhaust Aftertreatment - Challenges

Exhaust aftertreatment technology

bull The basic technologies from light- and heavy-duty engine applications

can be transferred to off-road applications

bull However there are additional challenges like space limitations costs

too low exhaust temperatures and shared responsibilities

Shared responsibility

bull Very often the machinery manufacturer and the engine manufacturer are two different companies

The machinery manufacturer buys an engine from the engine manufacturer The engine

manufacturer is responsible for the emission type approval of the engine

bull When the engine needs an exhaust aftertreatment system to fulfill the limit which is very much

integrated in the machinery who will supply the exhaust aftertreatment system and who is finally

responsible for the emissions

USA

US Engine manufacturer penalized for Clean Air Act violations

US EPA announced a settlement with two US engine manufacturer to resolve alleged Clean Air

Act violations In one case the engine manufacturer shipped more than 590000 highway and

non-road diesel engines to the vehicle assemblers without the aftertreatment devices andor with

improperly configured fuel injector and map settings

One manufacturer has to pay a $255 million penalty and continue a recall of noncompliant

engines

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

28 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Stage IIIB

Tier 4

CO2

GHG

Fuel Consumption

Emission Diagnostics

In-use Testing

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

29 AVL Emission Test Systems K Engeljehringer

OFF-ROAD Emission Testing ndash Information Legislation Regulation

Alternative Fuels

NESHAPNSPS Air Quality Requirements

Tier 4

Gothenburg Protocol

World Bank

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

30 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

31 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Emissions

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

32 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

International Maritime Organization (IMO) Regulation

IMO is the United Nations specialized agency responsible for the safety

security and prevention of marine pollution by ships

IMO publishes the Marine Pollution (MARPOL) regulation which affects all

ocean going vessels and can be applied as emissions standards to domestic-

and foreign-flagged vessels

MARPOL covers all kinds and sources of pollutions caused by vessels not only

the engine emissions Engine emissions are regulated by Annex-VI of MARPOL

and has a NOx limit It also enables local regions to restrict the use of fuels with

high sulfur content (Heavy Fuel Oil HFO) as a measure against SOx emissions

In pollution sensitive areas geographically-based limits will focus to reduce NOx

SOx and PM emissions To achieve air quality benefits at reasonable costs it

allows different options better fuel or the use of exhaust aftertreatment systems

IMO will also add a Not to Exceed (NTE) requirement for ships

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

33 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Standards and Regulations

USA Regulation bull In the USA marine diesel engines must also fulfill the IMO emission standard

bull 2004 in addition US Environmental Protection Agency (EPA) mandated a

reduction in PM and NOx

bull 2012 EPA Tier-3 has further reduce PM by 50 and NOx by 20 and will require

the use of 15ppm Ultra-Low Sulfur Diesel (ULSD)

bull In 2014 EPA Tier-4 will further reduce PM by 90 and NOx by 80 for commercial

engines with more than 600 kW compared to Tier-2 in certain local areas

bull USA will also implement a Not to Exceed (NTE) requirement for ships

bull Testing procedures and measurement equipment must follow CFR-1065 regulation

EU Regulation In Europe marine engines must also fulfill the IMO emission standard

For inland water ways ships also must fulfill the Directive 200426EC amended by

201026EU This is the same Directive which applies for all Non-Road Mobile

Machineries in Europe

For certain locale water ways also additional requirements exist like the river Rhine or

Lake Constance

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

34 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Test Cycles

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

35 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

36 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Fuel and Sulfur Oxides

1 Liter Heavy Fuel Oil

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

37 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Exhaust Aftertreatment

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

38 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Engine test bed certification All propulsion engines - small large and very large engines must show its

compliance with the emission standards on an engine test bed These tests

are done in the same way as for most other engine applications like non

road mobile machinery engines The test bed tests have also to be done

nevertheless if the engine gets modified when it is installed on board

Large ships also have auxiliary engines for example to produce electricity

on board Also these engines have to be certified on an engine test bed

Since these engines are not used for the ship propulsion other engine test

cycles apply like the ISO 8178 C1 or D2 cycle

Additional on-board certification Such engines will often be modified or fine-tuned after the test bed

certification was done and the engine is installed into the ship

Then the test bed certification is seen as a pre-certification which must be

followed by an on-board emission verification

A ship propeller has a certain correlation between speed and torque the so

called propeller law Since the test cycles follow this propeller law it is

possible to repeat the test bed test also on -board

Most engine parameters and especially emissions are measured on-board

Engine parameters which canrsquot be measured on-board can be copied from

the test bed test

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

39 AVL Emission Test Systems K Engeljehringer

MARINE APPLICATIONS Testing and Certification

Not to Exceed requirements

IMO and US-EPA will also add a Not to Exceed (NTE) requirement

There the emission under realistic in-use operation conditions will be

verified

IM requirements Regular inspection and maintenance verification is done during the whole

life-time This can be done by one out of three methods

bull An engine parameter check which verifies certain engines

components settings and operating values which could affect the

emissions (is typically a time consuming work)

bull A simplified verification of the emission on board like the on board

certification test

bull A direct monitoring method which is using fixed installed on board

emission measurement system

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

40 AVL Emission Test Systems K Engeljehringer

EMISSION TESTING Marine Applications

Notes

Higher potential of corrosion

and contamination because

of high SO2 in exhaust

bull Back-flush and

after sample purge

bull more frequent

maintenance and

service

Consider sample boost

pumps because of long

sample line length since the

engines are very large

Large diversity of fuel types

and fuel parameters

especially in case of FTIR

evaluation packages

SCR and SOx Scrubber

issues

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

41 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

42 AVL Emission Test Systems K Engeljehringer

ZERO EMISSIONS VERSUS CO2 A local versus a global problem

Pollutant Emission is a local problem

Even when some emission components may be transported

over some 100 kilometers like particulates Mostly only the

people and environment of this region or especially of a city is

effected by pollution problems

Green House Gas Emissions is a global problem

Green House Gas (GHG) emissions will effect the climatic

conditions of the entire world and change the climate Often the

region which might be effected by the weather catastrophes

are not emitting large amounts of GHG emissions but will

suffer

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

43 AVL Emission Test Systems K Engeljehringer

THE CHALLENGES Green-House-Gas emissions and Global Warming

CO2 emitted per country

The map shows how much CO2 is emitted

per country

1 China

2 USA

3 India

4 Russia

CO2 emitted per person

The map shows how much CO2 is emitted

per person

1 USA

2 Canada

3 Australia

4 Middle East

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

44 AVL Emission Test Systems K Engeljehringer

GREEN HOUSE GAS EMISSIONS (GHG) Achievements and targets

SIAM BEE

Proposals

2015 121 ndash 155 gkm

2020 104 ndash 136 gkm

Source ICAT 2012

4 l100km

25 kml

65 mpg

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

45 AVL Emission Test Systems K Engeljehringer

EMISSION TRENDS Green ndash House ndash Gas (GHG) Reduction

USA

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

46 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS What is it

Naming

bull There is no commonly aligned naming of testing methods or procedures in

all discussions and regulations There are words like

bull ldquoReal Driving Emissionsrdquo

bull bdquoNot-to-Exceedldquo

bull bdquoOff-Cycle Emissionldquo

bull bdquoReal World Emissionldquo

bull bdquoIn-Use Complianceldquo

bull bdquoIn Service Conformityldquo

bull In principle there are two different approaches for Real Driving Emissions

bull Random cycles in the test bed

bull Mobile testing on the road

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

47 AVL Emission Test Systems K Engeljehringer

THR PROBLEM of old and current emission legislation procedures

Older technology was not flexible like

carburetors mechanical or electronic engine

control Reducing emissions in any cycle

reduced emission under most operation

conditions

Modern engine control units (Computer)

are flexible and fine tuned for the known

cycle Reducing emission will not reduce

emission under normal operation

conditions

Therefore modern legislations are changing the procedures and add random cycles or in

use requirements or both

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

48 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

USA

Source wwwepagovcomplianceresourcespoliciescivilcaamobilevehicleengine-penalty-policypdf wwwcertreformorgaboutgeorge-lawrences-

note wwwepagovotaqimports420b10027pdf wwwepagovcomplianceresourcesnewsletterscivilenfalert

httpjoongangdailyjoinscomarticleviewaspaid=2935973

bull $267 Mil spend by Honda and $78 Mil by Ford to settle charges for

using ldquoDefeat Devicesrdquo which are forbidden by the Clean Air Act

bull $83 million penalties plus $1000 million to resolve claims against seven

major diesel engine manufacturers for violation of environmental law The

companies sold 13 million diesel engines containing illegal defeat

devices which allow an engine to pass the emissions test but modified

emission controls during real driving

South-Korean Ministry of Environment

bull The National Institute of Environmental Research (NIER) tested 5 diesel-

engine SUV models

bull All 5 models passed the legal test but serious problems arose when the

air conditioning was turned on While most cars showed a 10 to 20

increase in nitrogen oxide (NOx) emissions these five SUVs had 6 to 11

times more NOx emissions than the legal limit

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

49 AVL Emission Test Systems K Engeljehringer

THE PROBLEM of old and current emission legislation procedures

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

50 AVL Emission Test Systems K Engeljehringer

REAL DRIVING EMISSIONS Variants

Real Driving

Emission testing

and

Standard Test Bed Emission Systems

AVL iGENERATION PRODUCT LINE

Portable Emission Systems

AVL MOVE Mobile Testing Platform

bull Test bed test

bull Random and unknown

test cycle

bull Can be reproduced which

is important for RampD

bull Mobile in use

measurement

bull Unknown driving

conditions

bull Can not be repeated

Random

Cycle

Mobile

PEMS

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

51 AVL Emission Test Systems K Engeljehringer

Emission Testing mobile and in the Lab A combination of both

Test bed

bull Environmental relevance rarr limited (Standard cycle)

bull Standardization rarr Results can be compared

bull Reproducibility rarr yes (most important for development)

bull Driving conditions rarr bdquostraight and without hillsldquo

bull Ambient conditions rarr standardized and konstant

Mobile Testing

bull Environmental relevance rarr high (realer world)

bull Not standardized rarr Results can not be compared

bull Reproducibility rarr not possible

bull Driving conditions rarr bdquowith turns and hillsldquo

bull Ambient conditions rarr variable in defined limits

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

52 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Overview and Trends in Worldwide Emission Legislations

Content

bull Legislation and Harmonization

bull Emission Applications

bull Light Duty Passenger Cars

bull Heavy Duty On-Road Engines

bull Off-Road Engines

bull Special Topics

bull Green-House-Gas emissions

bull Real Driving Emissions

bull AVL Emission Solutions

bull Product Portfolio

bull Reference Examples

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

53 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

iGEM Engine

GEM301 EC

Heavy Duty

Engine

GEM301 EC

Off-Road

Engine

TFMS

Test Field

Management

iGEM

Vehicle

LD + HD

Chassis Cell

SORE GEM

Small

Engine

iGEM Offline

PUCConcerto

Emission Data

Evaluation

iGEM Engine

Light Duty

Engine

Testing Tools - Automation Systems

SHED

Automation

Pre-Filters

Sample-

selection

Calibration-

and Check

Devices

Analyzers

Accessories and Calibration

AVL DiX

High End

DiGas 2200

Motor Cycle

DiGas 4000

DiSmoke

Workshop Instruments

Visiolution

In-Cylinder

Simulation

AST

Advanced Emissions

Visiolution

In-Cylinder

Help Desk

Support

e-spares

Service

Maintenance

Ramp-up

Support

CARE

SW + HW

Residence

Service

Customer Service

Training

Products

Training

Applications

AMA i60

High End

AMA i60

Stand Alone

AMA i60

Remote

SESAM i60FT Multi Component

SESAM-i60FT Multi Component

+ Analyzers

AMA i60

NH3 hellip

Exhaust Gas Analyzers

EmRep

Online

Legislation

Consulting

Emission

Testing

Clean Air

Support

Programs

Consulting

CVS i60

Light Duty

CVS

CVS i60

Heavy Duty

CVS

PSS i60

Particulate

Sampler

SPC

Partial Flow

Dilution

Dilution Systems

Micro Soot

Onboard

PM PEMS

MOVE

Gas PEMS

in 2011

Portable Systems

Opacity

Onboard

SHED

VTVV

SHED

Automation

Canister

Loading

Fuel

Cart

SHED-FID

Evaporative Emission Systems

Smoke

Meter

Opacity

Meter

Micro Soot

Sensor

Particle

Counter

Particulate and Smoke

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

54 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

55 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Performance

Highest possible accuracy and repeatability

Compliant with all current and future

legislations (by current drafts)

Highest availability

Benefits

Identical HW architecture

Same components wherever possible

Common spare part stock

Common maintenance procedures

Less training effort

Lowest total cost of ownership

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

56 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Same software platform

Intuitive operation

Best integration and interfacing

Aligned upgrades like for new legislations

Benefits

Easier operation

Less operator mistakes

High automated procedures and functions

Integration of several GUIs on one operator

monitor

iGEM FT

iGEM PSS

iGEM CVS

iGEM AMA

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

57 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS iGeneration Emission Test Systems

AVL has launched a totally new innovative and

intuitive emission measurement system

generation covering all standard emission

systems

Calibration devices and Accessories

All required calibration validation devices

needed for emission testing

Fully automated operation

Benefits

One device can be used for different

measurement systems

Fully integrated with systems for automated

procedures for efficient workflow and

highest accuracy and repeatability

tailored also for the challenges of new

engine concepts

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

58 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

59 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TEST SYSTEMS Emission Test Automation Systems

Puma Open Platform

Engine and Powertrain Vehicle Testing

iGEM Vehicle iGEM Engine

iGEM-Engine and iGEM-Vehicle emission automation is harmonizing vehicle and

engine testing on base of the Puma Open automation platform

Exchange of test procedures and data between Engine- and Chassis Dyno tests

Same operation software modules error handling and look and feel

other devices

actuators and

sensors

other devices

actuators and

sensors

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

60 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING AVL Powertrain Test Centers

India

Ann ArborMI

Plymouth MI

Headquarters Graz UK

China

France

Lake Forest CA

Korea

Germany

Turkey

Sweden Haninge

Soumldertalje

Remscheid Muumlnchen Stuttgart Regensburg Neuenstadt Ingolstadt

Nagoya

Tokio

Moscow

Sao Paulo

AVL worldwide 110+ in-House Emission Test Cells bull 94 Engine- and Powertrain Test cells bull 16 Chassis Dyno Test Cells bull 2 SHEDs bull 24 Special test cells

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

61 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING EPA has selected AVL

US-EPA Ann Arbor USA

US Environmental Protection Agency

AVL selected to supply 2 complete Chassis

Dyno Emission Test Cell for developing and

testing of the next generation of US

emission legislation including

Fulfilling CFR-1065 and CFR-1066

specifications

PM sampling for diesel and gasoline

NMOG sampling

Green-House-Gas emission

measurement

Pre- and Post-Cat emission

measurement

AVL ldquoHeated CVSrdquo concept for low

emission testing (SULEV)

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

62 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING TUumlV Hessen selected AVL

TUumlV Hessen Germany

Technology und Environmental Center

AVL selected to supply test and emission

measurement systems There is also a

special focus on the challenges of new

powertrain concepts like hybrids electrical

vehicles and alternative fuels

Chassis Dyno Emission Test Cell

ldquoAdvancedrdquo Which can simulate real

driving conditions trafic up- and

down-hill driving as well as turns by

using 4 independent rollers

Engine Emission Test Cell

Portable Emission Measurement

Systems (PEMS)

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

63 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Vietnam Register (VR) selected AVL as Turn-Key Supplier

VR Vietnam Register Vietnam

National vehicle emission certification

laboratory of Vietnam

AVL selected as ldquoTurn key solutionrdquo supplier

for the national emission laboratory AVL

responsible for planning building design test

laboratory configuration test and

measurement systems and system and

application training Final EU and UN-ECE

laboratory approval done by German TUumlV

Chassis Dyno Emission Test Cell for

passenger cars (1)

Chassis Dyno Emission Test Cell for

motorcycles (2)

Heavy Duty Engine Emission Test Cell (3)

Evaporative emission systems (4)

1

2 3

4

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems

64 AVL Emission Test Systems K Engeljehringer

AVL EMISSION TESTING Emission Test Product Portfolio

AVL delivers a Gas Analyzer

every working hour

Gas Analyzers

hellip a Particulate Instrument

every 3rd working hour

Particulate and Smoke

hellip an Emission System

every working day

Exhaust Gas Analyzers

hellip a Dilution- or Particulate system

every 2nd working day

Dilution Systems

hellip an emission automation system

every 3rd working day

Automation Systems