AVL India Private Limited (Head Office)AVL+India+Sem… · All the vehicle manufacturers or vehicle importers selling the motor vehicles in India, as specified in the Tables, shall

Manoj Kusumba

AVL India Private Limited (Head Office)

Confidential

EAS development challengesAVL M Seminar, May 22-25, 2018

Manoj Kusumba | | 20 May 2018 | 2Confidential

Author(s): Manoj Kusumba

Co-Author(s):Josef KoenigNeil Jason KunderAnuj Goel

Approved by:

Project Leader:

Version: 1.0

Release date: 20.05.2018

Security level: Confidential

Customer:

Project:

Task ID:

Department:

Copyright © 2018, AVL India Private Limited (Head Office)


Contents

� BS VI development overview

� EAS Hardware screening, selection and

development

− NH3 uniformity

− Urea deposit testing

� Thermal Management

� Fuel economy norms – overview

� Electrification overview @ AVL ITC


Contents



development

− NH3 uniformity






Development process

� Design, layout simulation

− Design changes (Combustion system, fuel injector, turbo, intake throttle, exhaust flap,….)

− EAS layout simulation

− Sensor layout and specification

− Software gap analysis

� Procurement of new and modified parts

� Test bed development and calibration

− Performance and emission development (Engine Out Emission)

− EAS development

� NH3 Uniformity (UI measurement)

� Deposit formation testing

� EAS hardware checks and screening

− Thermal Management

− EAS (SCR, DPF) Calibration (Tail Pipe Emissions)

� Vehicle level development and calibration

� Design validation (DVP)

� Engine emission certification


Development process

� Design, layout simulation

− Design changes (Combustion system, fuel injector, turbo, intake throttle, exhaust flap,….)

− EAS layout simulation

− Sensor layout and specification

− Software gap analysis

� Procurement of new and modified parts

� Test bed development and calibration

− Performance and emission development (Engine Out Emission)

− EAS development

� NH3 Uniformity (UI measurement)

� Deposit formation testing

� EAS hardware checks and screening

− Thermal Management

− EAS (SCR, DPF) Calibration (Tail Pipe Emissions)

� Vehicle level development and calibration

� Design validation (DVP)

� Engine emission certification


EAS layout overview

CO/HC

PM

NOx

Exhaust Emissions

PN


Contents



development

− NH3 uniformity






NH3 uniformity


BS VI EAS layout overview

CO/HC

PM

NOx

Exhaust Emissio

ns PN


NH3 Uniformity - Introduction


Objective


Installation on the engine test bed


Minimum required instrumentation of EAS


Assessment of uniformity


Deposit formation testing


Objective


Robust dosing areas


Engine test bed installation


Instrumentation of EAS


Contents



development

− NH3 uniformity






BS VI EAS layout overview

CO/HC

PM

NOx

Exhaust Emissions

PN


Thermal management

� Dosing release temperature

� Cold start

− SCR heat up

− Keep warm

� DPF regeneration

� DeSOx


Max S

oot

Loadin

g g

/l

RGN Trigger

DPF Life Cycle

DPF Loading DPF Regeneration

DPF Loading

Regeneration Intervall

DPF regeneration


Temperature [°C]

qu

alita

tive B

urn

-Rate

[-]

~550°C

Active RGNActive RGN

Kin

etic-L

imitation

Lo

w R

GN

-Eff

icie

ncy

NO

2-L

imitation

Typical operating rangefor passive RGN

650°C

Th

erm

al C

rack

Th

erm

al C

rack

Kin

etic-L

imitation

Lo

w R

GN

-Eff

icie

ncy

Typical operating rangefor active RGN

~250°C

Passive RGNPassive RGN

Temperature [°C]N

O2/N

Ox

%]

DOC

DOC 2DOC 2

DOC 1DOC 1

Providing NO2

DOCUnburned Fuel

Providing Heat

DOC 1DOC 1DOC 2DOC 2

C + NO2 → CO + NO C + O2 → CO2

DPF - Active & passive regeneration


WHTC – Thermal management

Without thermal management

With thermal management

Dosing release temp

Dosing release temperature


THERMAL ENGINE MANAGEMENT -AIR PATH

Intake throttle

� State-of-art technology route

� Electronically controlled mainly used for thermal EAS management in light load area and steady

state conditions

� Limited effect due to risk of lube oil sucking (intake valve shaft, TC, oil rings) caused by depression

in intake duct

Exhaust flap

� Electronically controlled in light load area and steady state conditions

� High potential for thermal EAS management w/ penalties in BSFC


THERMAL ENGINE MANAGEMENT–FUEL PATH

Main injection timing

� Injection timing retardation for thermal EAS management by lower engine thermal

efficiency

Post injection

� Early post injection (close to main injection event) with lower effect as main timing

retardation

� Late post injection mainly for HC generation for exothermal reaction in DOC with

risk of lube oil dilution


Intake throttle vs exhaust flap


Contents



development

− NH3 uniformity






Overview – Passenger car applications

Source:- SIAM Website

� Source of information :- Amendment No-7 to MoRTH/CMVR/ TAP-115/116: Issue No.: 4

� The Fuel Efficiency Norms will be applicable on Motor vehicle having at least 4 wheels other than Quadricycles, used for transportation of passengers and there luggage.

� The maximum seating capacity of the vehicle shall not be more than 9 including driver and GVW < 3.5 tons (specified as Motor vehicle) for sale in India.

� Each Manufacturer of the said motor vehicle shall comply with energy consumption standard termed as Average Fuel Consumption Standard .

� In any fiscal year commencing from the 1st Day of April, 2017 onwards, the Average of Actual Fuel Consumption shall be less than or equal to Avg. Fuel Consumption Standard as specified in below slides.

� Compilation and Enforcement :- All Manufacturer and Importers shall comply with the said standards.

� The Ministry of Road Transport and Highway will enforce the same under the Central Motor Vehicle Rule, 1989.


The Average Fuel Consumption standard

Formula for calculation of Limits of Avg. Fuel Consumption = a X (W-b) + c

Where as,

a = Constant Multiplier

b = Fixed Constant

C = Fixed Constant

W = Weighted Average Unladen mass of the Vehicle in Kg.

Average Fuel Consumption standard (Limit) of the manufacturer in Petrol Equivalent Liter per 100 Kilometer.

Where weighted average unladen mass of the manufacturer shall be calculated as follows

W = ∑ Ni Wi / ∑Ni , Where

Ni = Number of Vehicle manufactured or imported in India of a model ‘i’ in the respective fiscal year. Ni

Wi = Unladen mass in kg of Vehicle ‘i’ in the respective fiscal year.

Source:- Gazette Notification S.O 1072(E) Dated : - 23rd April, 2015 issues by MoP


Table for Constant multiplier and Fixed constant

a 0.0024

b 1037

c 5.4922

Avg. Fuel ConsumptionStandard

= 0.0024 x (W – 1037) + 5.4922

Table 1.1 (for Fiscal Year 2017-18 to 2022-23)

a 0.002

b 1145

c 4.7694

Avg. Fuel ConsumptionStandard

= 0.002 x (W – 1145) + 4.7694

Table 1.2 (for Fiscal Year 2022-23 onwards)

Source:- Gazette Notification S.O 1072(E) Dated : - 23rd April, 2015 issues by MoP


Summary

� From 1st April, 2017, Fuel Efficiency Norm is mandatory for M1 Category vehicle whose GVW is Less than 3.5 Tons.

� The FE will be measured at the time of TA as well as during COP.

� The same vehicle can be used for both Emission as well as FE Measurement.

During Test the system will measure the CO2

emitted by the vehicle during the test in grams/km. Using the CO2 Emission value, FE will be further calculated in liters/100 kms by dividing the CO2

Values by a constant factor 23.7135.

� The Manufacturer will have to keep record CO2 emitted by each model and its variant and maintain the data in an “Annual Fuel Consumption Report”.

� The Manufacturer will have to maintain “Fuel Consumption Integrated Passbook” also.


Overview – HD Commercial Vehicle

� On and from 1st April, 2018, diesel vehicles of category M3 and N3 with gross vehicle

weight of twelve tonnes and above, complying with BS-IV emission norms, shall be tested

for constant speed fuel consumption as specified by the Ministry of Road Transport and

Highways, till the time Bureau of Indian Standards notify corresponding standards:

� Phase 01 norms effective from 1st April, 2018 and Phase 02 norms effective from 1st April,

2021.

� All other four wheel drive vehicles which are not covered in the norms shall be treated as

two wheel drive vehicles and shall conform to the norms of their two wheel drive category.

� In any fiscal year commencing on and from the 1st day of April, 2018, the fuel consumption

of each vehicle of a particular category shall be less than the fuel consumption value

derived from the equation of that category as specified in the preceding tables.

� The norms shall apply only for vehicles complying with BS-IV emission norms and for the

vehicles complying with BS-VI emission norms, the competent authority shall derive a

suitable correction factor to be used on above mentioned BS-IV norm values.Source :Draft notification dated 16 August 2017


Overview – HD Commercial Vehicle

Compliance and enforcement

� All the vehicle manufacturers or vehicle importers selling the motor vehicles in India, as

specified in the Tables, shall comply with the energy consumption standards specified

� The Ministry of Road Transport and Highways shall implement the conformity of production

by constant speed fuel consumption method which shall be conducted once in every two

years;

� At least one conformity of production for the vehicle has to be conducted latest by 1st April,

2020

� The Ministry of Road Transport and Highways, shall enforce the norms along with provisions

relating to testing and calculation methodologies, reporting, consequence of non-

compliance and equivalent vehicle credits for electricity driven motor vehicles under the

Central Motor Vehicle Rules, 1989, in consultation with Ministries concerned.

Source :Draft notification dated 16 August 2017


N3 vehicle category


M3 vehicle category


Suggested emission roadmap beyond BS VI

Draft National Auto Policy – Feb 2018


Suggested emission roadmap beyond BS VI

Draft National Auto Policy – Feb 2018


Contents


� EAS Hardware screening, selection and development

− NH3 uniformity




� Electrification overview @ AVL India Technical Centre


AVL ITC: ElectrificationRoadmap

Ju

ly 2

01

8

• HV Battery Emulation• E-Vehicle Tests• E-Powertrain Tests• Durability Tests• Vibration Analysis

• Systems and Requirements Engineering

• Mechanical Design• Structural Simulations• Software Development

INDIA TECHNICAL CENTER

Dec. 2

01

8

• Calibration• Thermal Simulations• Vehicle Integration• Vehicle and Fleet Validation• End-of-Line Component

Testing• EV & E-PWT Benchmarking

DC Fast Charging Stations


AVL ITC: Electrification Infrastructure Roadmap

� 160kW 800V Battery Emulator� Emulation on Chassis Dynamometer and Powertrain Testbeds� High level safety systems� Automation to enable efficiency and performance tests� Benchmarking capabilities

� DC Fast Chargers with CCS and ChaDeMo

Amit Arora

Associate Vice President - PTE Sales

[email protected]

Ph. No +91 98110 55044


AVL ITC, Gurgaon

AVL-Graz

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We design, simulate, develop and validate new ideas and products

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Documents

AVL India Private Limited (Head Office)AVL+India+Sem… · All the vehicle manufacturers or vehicle importers selling the motor vehicles in India, as specified in the Tables, shall