IEA Workshop green scoring Entwurf EN · § Emission tests, car reviews, crash tests, product tests, total cost of ownership, etc. § What does consumer protection mean? - no commercial

30. April 2013 Prof Dr-Ing Reinhard Kolke 1

Cycle beating:How are OEM’s optimising the vehicle to test cycles?Who does what in the homologation process?

GFEI – Green Global NCAP labelling / green scoring workshop

“Clean Vehicle Scoring System – How to Define What is a Clean Car?”

30th April 2013Prof. Dr.-Ing. Reinhard Kolke, ADAC Technik Zentrum

© www.adac.de


ADAC Technik Zentrum

§ ADAC is the worlds 2nd largest automobile club

with more than 18.4 m members enjoying the

status of a consumer protection organisation

§ ADAC Technik Zentrum:

Test centre of the European FIA clubs

§ Emission tests, car reviews, crash tests, product

tests, total cost of ownership, etc.

§ What does consumer protection mean?

- no commercial interest in products

- neutral publication

- focus on product improvement

Example:European Test Consortiumfor Child Restraint Systems

The players in consumer protection:

FIA partner clubs , EU,Federal Government, ICRT


ADAC emissions lab and low-temperature dynamometer

Emissions lab

§ Temperature range: -10°C to +40°C

§ max. speed 200 kph

§ Simulation of uphill sections (up to 20%)

§ CO, HC, CH4, THC, NMHC, NOx, NO, NO2, PM, PN, CO2

§ official type approval lab

Low-temperature dynamometer

§ Temperature range: -25°C to +30°C

§ Horsepower up to 2 x 260 kW (2 x 350 hp)

§ max. speed up to 260 kph

§ OBD data interface

§ Variable wheelbase: between 2.36 and 3.36 m


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The challenge for consumer protection:1. What is manipulation? What is legal?2. Who is responsible: Legislation or manufacturer?

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Agenda

A

B

D

C

Limits and tolerances in fuel efficiency specificationsèManufacturers’ leeway

ADAC EcoTest – Presentationè Real information for end users/consumers

ADAC EcoTest – Resultsè How do manufacturers’ specs hold up to emissions in real driving cycles

Conclusions


Limits and tolerances – the background

§ Discrepancies between manufacturer’s specifications and actual fuel efficiency has been a

frequent reason for litigation between consumers and manufacturers.

§ When it comes to fuel consumption, we must distinguish between

- manufacturer’s specifications based a test cycle (NEDC – New European Driving Cycle) in line with EU

Reg. 715/2007 (type approval)

- the fuel consumption of a specific vehicle in real-life use in traffic

- the fuel consumption of the specific vehicle in cause measured in a test cycle (NEDC – New European

Driving Cycle) in line with EU Reg. 715/2007

§ Whereas manufacturers’ fuel efficiency specifications are verified under defined conditions in a lab,

the fuel consumption observed by the motorist depends on personal driving styles, the speed

profile, weather conditions, vehicle payload etc.

Limits and tolerances in fuel efficiency specifications

The fuel consumption observed in real-life traffic cannot be compared with manufacturers’ fuel

efficiency specifications.


Production tolerances

§ According to EU Reg. 715/2007 with regard to determining fuel consumption and CO2 emissions,

the tolerance for CO2 emissions in production cars must not exceed 4 %

§ CO2 emissions are directly correlated with fuel consumption

ð the 4 % rule also applies to fuel consumption


§ The EU Regulation may be applicable only to the type approval of new models, but in the end it

also sets the max. limit for CO2 emission variation in production cars.

§ If state of the art means anything, the actual discrepancies should be below that limit.


Tolerances for fuel consumption measurements

Reasons

§ Admissible bandwidth in defined measurement conditions, e.g.

- Test bench temperature (between 20 and 30 °C)

- Air humidity (altitude of test bench)

- Position and specification of the wind machine

- Level of discharge of the battery before and after the test

§ Rolling resistance curve (data table instead of deceleration test data)

§ Driver impact within the predefined limits

§ Technical condition of vehicle, mass, tyres, standstill/idle periods

§ Fuel quality, type of drum, measurement equipment (level of maintenance)

Limits and tolerances in horsepower and fuel efficiency specs

Many years of experience with the ADAC test bench have shown that

§ Tolerances for tests under conditions in line with the type approval do not exceed ±2 %, as long

as the testing conditions are not changed between tests (à repeatability)


§ The New European Driving Cycle (NEDC) has been in force since 1 January 1996; it consists of an urban and extra-urban component with a max. speed of 120 kph

§ EU Reg. 715/2007: aims at verifying fuel consumption and CO2 emissions

§ Fuel consumption calculated from the amount of hydrocarbon emissions (CO, HC, CO2)

§ Certified EU testing labs ensure uniform and legally binding measurements

§ In Germany, testing labs are accredited by the Federal Motor Transport Authority

Mandatory test procedure (NEDC)


0

20

40

60

80

100

120

140

0 200 400 600 800 1000 1200

Time [s]

Sp

ee

d

[kp

h]

v [kph] Idle 1st gear 2nd gear 3rd gear 4th gear 5th gear

Urban Extra-urbanNEDC cycle

Cycle 1 Cycle 2 Cycle 3 Cycle 4 Cycle 5

§ NEDC was developed to determine the amount of emissions.

§ It is adequate for the comparative assessment of cars.


Results:

§ Mindful driving can beat manufacturer’s

specifications

§ Fuel efficiency can be 20 % better than

manufacturer’s specifications

§ It is easier to drive fuel-efficiently with

larger cars

Empiric fuel consumption data –EcoTour 2008: 42 vehicles – 9 countries – 2,800 km


3,50

4,00

4,50

5,00

5,50

6,00

6,50

3,50 4,00 4,50 5,00 5,50 6,00 6,50 7,00 7,50 8,00

NEDC manufacturer data [l/100km]

Ec

oT

ou

r d

ata

[l/1

00

km

]

small gasoline

small diesel

small family gasoline

small family diesel

family gasoline

family diesel


§ The EcoTour driving profile

resembles the extra-urban

section of the NEDC

§ Hardly any vehicle was able to

beat manufacturer’s specs for

extra-urban driving even where

the drivers employed extreme

eco-driving techniques

§ The values of the NEDC extra-

urban cycle can hardly be

matched

§ Calls for revising the NEDC

extra-urban cycle

Source:

3.00

3.50

4.00

4.50

5.00

5.50

6.00

6.50

3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 8.00

EUDC manufacturer data [l/100 km]

Ec

oT

ou

r d

ata

[l/1

00

km

]

small petrol

small diesel

small family petrol

small family diesel

small family petrol

small family diesel

VW Passat 1.9 TDI Blue Motion

EcoTour consumption =

= extra urban consumption


Empiric fuel consumption data –EcoTour 2008: 42 vehicles – 9 countries – 2,800 km


Summary

§ Where all the leeway granted under the type approval and the admissible tolerances are

taken advantage of to the fullest, discrepancies in fuel efficiency of up to 20 % are possible.

- ADAC metering conducted under the Autotest car review and the EcoTest programmes have shown that

discrepancies of this magnitude are not unheard of.

§ The technical possibilities of state-of-the-art test benches allow us to define test conditions much

more precisely.

- The procedure defined in the EU regulation concerning the verification of pollutant emissions is inadequate

since the leeway it grants defeat the purpose of comparative verification of fuel consumption.

- In litigation, the test conditions of the initial test must be matched exactly to ensure comparability.



ADAC EcoTest

§ Has provided comprehensive consumer information regarding the eco-friendliness of vehicles since 2003.

§ Assessment of fuel consumption (CO2 emissions) and pollutant emissions.

§ Based on specially developed real-life driving cycles, which go beyond the mandatory type approval test cycles.

§ Objective: innovation, light-weight design and fuel efficiency across all vehicle classes

§ Manufacturers use EcoTest as a standard and include the test label in their advertising

§ All consumer tests, like EcoTest, needs to be adjusted regularly. Moving target!

§ Assessments of over 1,200 tested cars are available. 150 vehicles are tested annually.

§ Adjustment of the test and rating criteria as from April 2012:

- Inclusion of the WLTP cycle (the coming world-wide test cycle)

- Well-to-wheel assessment for better comparability of electric vehicles

- Electric cars are assessed on the basis of the energy consumed (kWh) incl. self-discharge and the CO2 emissions from power

plants based on the German (D) electricity mix (Source: Federal Environment Agency, UBA) and renewable energies

- Stricter CO2 limits

- Adjustment of pollutant assessment to Euro 6 (petrol engines)

- Measurement and assessment of the particle number


EcoTest test cycles

§ NEDC cold

Initial assessment; testing for pollutants such as HC, CO, NOx,

particulate matter and NEW! the particle number of diesel and

direct-injection petrol engines; NEW! daytime running lights (if

present) or low beams are on during test; CO2 testing

§ WLTP

“World cycle” replaces NEDC hot; with air conditioning on and

NEW! daytime running lights (if present) or low beams are on

during test; CO2 testing

§ ADAC Motorway test

With air conditioning on and NEW! and daytime running lights (if

present) or low beams on during test; testing for pollutants such

as HC, CO, NOx, particulate mass; CO2 testing

Phase 1 Phase 2

0

20

40

60

80

100

120

140

0 200 400 600 800 1000 1200

Time [s]

Sp

eed

[k

ph

]

v [kph] Idle 1st gear 2nd gear 3rd gear 4th gear 5th gear

0

20

40

60

80

100

120

140

1 201 401 601 801 1001 1201 1401 1601

t [sec]

v [

kp

h]

Speed [kph]

Phase 1 - low -0 - 589 sec. [589 sec.]

Phase 2 - middle -590-1022 sec. [433 sec.]

Phase 3 - high -1023-1477 sec. [455 sec.]

Phase 4 -extra high -1478-1800 sec. [323 sec.]

0

20

40

60

80

100

120

140

3 34

63

94

124

155

185

216

247

277

308

338

369

400

428

459

489

520

550

581

612

642

673

703

734

765

793

Time [s]

Sp

eed

[kp

h]

Preconditioning Phase 1 Phase 2

4th gear 4th gear4th gear

Highest gear Highest gear


EcoTest test cycles

§ Petrol and diesel vehicles

No special sequence

§ LPG/CNG vehicles

NEW! EcoTest is run only on LPG/CNG drive

§ Hybrids

Battery state of charge (SOC) 60-70 %

§ Plug-In-hybrids

Measurement of full battery and measurement

of empty battery – standard averaging;

measurement of the charge (energy input ) in

kWh and calculation of CO2 emissions (1 kWh= 563 g/kWh; Source: UBA; this value is corrected as

needed)

§ Electric vehicles

Measurement in electric vehicle cycle (all three cycles back to back) until SOC < 50 %; measurement

of the charge (energy input ) in kWh and calculation of CO2 emissions (1 kWh= 563 g/kWh; Source:

UBA; this value is updated as needed); power plant emissions are not relevant

v [kph]

0

20

40

60

80

100

120

140

0 500 1000 1500 2000 2500 3000

Time [s]

Sp

ee

d [

kp

h]


EcoTest rating

Pollutant rating

(absolute)

CO2 rating

(well-to-wheel, class-

dependent scale)

Additional information

provided:

Fuel consumption


EcoTest rating – 5-star rating system

Small ecological footprint

<30

30...49

50...69

70...89

≥90

Large ecological footprint


Pollutants rating

30%

ADAC Motorway

NEDC cold

HCNOxCO

PM

HCNOxCO

50%Worst Case

70%

50%

50%Worst Case

50%Worst Case

PMPN

Phase 1 Phase 2

0

20

40

60

80

100

120

140

0 200 400 600 800 1000 1200

Zeit [s]

Ges

ch

win

dig

ke

it [

km

/h]

v [km/h] Leerlauf 1. Gang 2. Gang 3. Gang 4. Gang 5. Gang

0

20

40

60

80

100

120

140

3

34

63

94

12

4

15

5

18

5

21

6

24

7

27

7

30

8

33

8

36

9

40

0

42

8

45

9

48

9

52

0

55

0

58

1

61

2

64

2

67

3

70

3

73

4

76

5

79

3

Zeit [s]

Ges

ch

win

dig

keit

[k

m/h

]


4. Gang 4. Gang4. Gang

max. Gang max. Gang

Pollutant rating

(absolute)


Pollutants rating – thresholds

§ All types of drives or fuels are equal in ADAC EcoTest.

Unlike under current legislation, no bonus for diesel engines applies in ADAC EcoTest.

HC 0.10 a) 0.20 d) 0.10 a) 0.20 d)

CO 0.50 b) 1.00 e) 0.50 b) 7.00 c)

NOx 0.06 a) 0.25 f) 0.06 a) 0.70 c)

PM 0.003 c) 0.015 c) 0.003 c) 0.015 c)

PN 6E+10 c) 6E+12 g)

NEDC ADAC Motorway

50 points for [g/km]




a) Euro 6 petrol

d) Euro 3 petrol

b) Euro 6b diesel

c) ADAC EcoTest

f) Euro 4 diesel

g) possibly OBD GW

e) Euro 4 petrol


CO2 rating

50%

50%

70%

30%

ADAC Motorway

WLTP

CO2 rating

(well-to-wheel, class-dependent)

Phase 1 Phase 2

0

20

40

60

80

100

120

140

0 200 400 600 800 1000 1200

Zeit [s]

Ges

ch

win

dig

ke

it [

km

/h]

v [km/h] Leerlauf 1. Gang 2. Gang 3. Gang 4. Gang 5. Gang

NEDC cold

0

20

40

60

80

100

120

140

3

34

63

94

12

4

15

5

18

5

21

6

24

7

27

7

30

8

33

8

36

9

40

0

42

8

45

9

48

9

52

0

55

0

58

1

61

2

64

2

67

3

70

3

73

4

76

5

79

3

Zeit [s]

Ges

ch

win

dig

keit

[k

m/h

]


4. Gang 4. Gang4. Gang

max. Gang max. Gang

0

20

40

60

80

100

120

140

1 201 401 601 801 1001 1201 1401 1601

t [sec]

v [

km

/h]

Speed [kph]

Phase 1 - low -0 - 589 sec. [589 sec.]

Phase 2 - middle -590-1022 sec. [433 sec.]

Phase 3 - high -1023-1477 sec. [455 sec.]

Phase 4 -extra high -1478-1800 sec. [323 sec.]


CO2 emissions in energy generation per unit of energyC

O2

pe

r u

nit

of

en

erg

y (

well-t

o-t

an

k)

[g/M

J]

-20

0

20

40

60

80

100

120

140

160

180

Petr

ol

Die

sel

Bio

eth

an

ol

85

% LP

G

CN

G(H

gas)

D e

lectr

icit

ym

ix

Ele

ctr

icit

yfr

om

reg

en

era

tive

so

urc

es


CO2 rating – thresholds, well-to-wheel

§ CO2 ratings are based on a system of relative class-dependent scales.

The ADAC EcoTest offers consumers useful information for comparing vehicles of the same size and vehicle class.

50 points

for [g/km]

10 points

for [g/km]

1 80 180

2 80 180

3 90 195

4 100 215

5 115 240

6 130 270

7 145 300

Vehicleclass

0

10

20

30

40

50

60

0 50 100 150 200 250 300 350 400

CO2 (g/km) WTW

Sc

ore

Class 1

Class 2Class 3

Class 4

Class 5

Class 6Class 7


CO2 rating – vehicle classes and sample cars

Audi A8, 7-series BMW, Mercedes S-ClassLuxury7

Audi A6, 5-series BMW, Mercedes E-Class, Volvo V70

Executive6

3-series BMW, Mazda 6, Opel/Vauxhall Insignia, Toyota Avensis

Family 5

Mercedes A-Class, Toyota Auris, VW GolfSmall family 4

Ford Fiesta, Peugeot 208, VW Polo, Audi A1 Supermini3

Fiat 500, Peugeot 107, VW up!City2

SmartMicrocar1

ExamplesVehicle class

No.


Overall EcoTest results

The first cars tested to 5-star ratings in ADAC EcoTest:

Toyota Prius 1.8 hybrids & 1.8 Plug-In hybrids; BMW 320d ede BluePerf. & 520d ede BluePerf.

0

10

20

30

40

50

60

0 10 20 30 40 50 60

Schadstoffbewertung

Ko

hle

nd

iox

idb

ew

ert

un

g

DieselElektroHybrid-BenzinerOttoLPGCNGHybrid-Diesel

Punkte

Punkte

CO

2ra

tin

g

Pollutant rating

PetrolHybrid-Petrol Electric

Score

Score


NOx emissions in EcoTest: NEDC vs. BAB motorway cycle

EcoTest ensures that vehicles meet emission standards not only in the mandatory type approval test cycle but also in real-life traffic conditions.

Eu

ro5/6

Ott

o

Euro

6 D

iese

l

Eu

ro5 D

iesel

Euro

4

Die

sel

0

0,2

0,4

0,6

0,8

1

1,2

1,4

1,6

1,8

2

0 0,05 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,45

NOx im NEFZ [g/km]

NO

x im

AD

AC

Au

tob

ah

nzy

klu

s [

g/k

m]

Diesel

Diesel-Hybrid

Otto

Hybrid-Benziner

LPG

CNG

EcoTest Grenzwert 10 Punkte

EcoTest Grenzwert 50 Punkte

BMW 320d ede BluePerf.

BMW 520d ede BluePerf.

NO

Xin

BA

B m

oto

rway c

ycle

[g

/km

]

NOX in NEDC [g/km]

EcoTest limit 10 points

EcoTest limit 50 points

Hybrid-Petrol

Petrol


NOx emissions in EcoTest:Performance of various exhaust after-treatment systems

Outside the NEDC parameters NOx emissions are clearly higher. Some exhaust after-treatment systems also work better under these conditions.

0

0,05

0,1

0,15

0,2

0,25

0,3

0,35

0,4

0,45

0,5

Me

rce

de

s G

LK

25

0C

DI

Blu

eT

EC

4M

atic

7G

-Tro

nic

Plu

s (

DP

F)

BM

W 3

20

dE

ffic

ien

tDyn

am

ics

Ed

itio

nB

lue

Pe

rform

ance

(DP

F)

BM

W 3

20d

To

uri

ng

Blu

eP

erf

orm

ance

Sp

ort

Lin

eA

uto

ma

tic (

DP

F)

BM

W 5

20

dE

ffic

ien

tDyn

am

ics

Ed

itio

nB

lue

Pe

rform

ance

(DP

F)

BM

W 7

50d

Blu

eP

erf

orm

an

cexD

rive

Au

tom

atic

(DP

F)

BM

W M

55

0d

Blu

eP

erf

orm

an

cexD

rive

Au

tom

atic

(DP

F)

Ma

zda

6 K

om

bi 2.2

SK

YA

CT

IV-D

Ce

nte

r-Lin

e

Ma

zda C

X-5

2.2

SK

YA

CT

IV-D

Cen

ter-

Lin

e (

DP

F)

NO

x (

Die

se

l) [

g/k

m]

NEFZ

BAB

EcoTest 50 Punkte = Euro6 Otto

Euro6 Diesel

NOx - Speicherkat innermot.SCR

NO

x(D

iesel)

[g

/km

]NEDC

EcoTest 50 points = Euro6 Petrol

SCR NOx-DeNOx-Catalyst Engine Tech


Test results for particle numbers of DI petrol engines in NEDC, WLTP and ADAC BAB motorway cycle

1,0E+10

1,0E+11

1,0E+12

1,0E+13

Audi A3 1.8 TFSI VW CC 1.8 TSI

Pa

rtik

ela

nza

hl

NEFZ

BAB130

WLTP

Part

icle

nu

mb

er

NEDC


Fuel consumption in EcoTest vs. manufacturer’s specifications

With the exception of EcoTest, all popular eco-friendliness car ratings are based on manufacturer’s specifications and thus do not reflect actual fuel consumption.

3

3,5

4

4,5

5

5,5

6

6,5

7

7,5

8

8,5

9

9,5

10

10,5

3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 8 8,5 9 9,5 10 10,5

FC EcoTest [g/km]

FC

He

rste

lle

ran

ga

be

[g

/km

]Dieselgleich10% Mehrverbrauch20% Mehrverbrauch30% MehrverbrauchBenzinerHybrid

FC

man

ufa

ctu

rer‘

s s

pecif

icati

on

[l/1

00km

]

FC EcoTest [l/100km]

Same10% less fuel efficient

20% less fuel efficient30% less fuel efficientPetrol


Fuel consumption in EcoTest vs. manufacturer’s specifications – hybrid vs. diesel

0

0,5

1

1,5

2

2,5

3

3,5

4

4,5

5

1 2 3

Kra

fts

toff

ve

rbra

uc

h [

g/k

m]

Hybrid EcoTest Hybrid Herstellerangabe

Diesel EcoTest Diesel Herstellerangabe

To

yota

Pri

us 1

,8 H

yb

rid

Hyu

nd

ai i3

0 1

.6 C

RD

i

Ho

nd

a I

nsi

gh

t 1

.3 H

ybri

d

Ho

nd

a C

ivic

2.2

i-D

TE

C

Pe

ug

eo

t 5

08

RX

H

Re

na

ult

Scé

nic

EN

ER

GY

Fu

el co

nsu

mp

tio

n [

l/100km

]

manufacturer’s spec

manufacturer’s spec


CO2 emissions in EcoTest: NEDC vs. BAB motorway cycle

Usually, CO2 emissions outside the NEDC are clearly higher.

100

150

200

250

300

350

400

100 150 200 250 300 350 400

CO2 im NEFZ [g/km]

CO

2 i

m B

AB

[g

/km

]

Klasse2

Klasse3

Klasse4Klasse5

Klasse6

Klasse7

gleich

10% Mehrverbrauch20% Mehrverbrauch

30% Mehrverbrauch

40% Mehrverbrauch

CO

2em

issio

ns in

BA

B [

g/k

m]

CO2 emissions in NEDC [g/km]

Same

Class 2

Class 3 Class 4 Class 5 Class 6 Class 7

10% less efficient 20% less efficient 30% less efficient 40% less efficient


145

159

0

20

40

60

80

100

120

140

160

180

Renault Fluence Z.E. Expression Volvo C30 Electric

CO

2 (

g/k

m)

Manufacturer

EcoTest

CO2 emissions in EcoTest vs. manufacturer’s specifications

The EcoTest CO2 results of electric cars may considerably depart from manufacturers’ specifications due to energy generation and driving cycles.

Manufacturers’specifications

0 g/km

Manufacturers’specifications

0 g/km


§ Due to variables in production, there are discrepancies between the type approval/manufacturer’s

fuel consumption specifications and the actual fuel consumption of production cars.

§ The state of the art in bench testing ensures that under the same test conditions tolerances are

within a 2 % margin.

§ Discrepancies of up to 20 % are possible if all the leeway granted under the Directive and the

admissible tolerances are taken advantage of to the fullest.

Conclusions

§ We cannot allow that the leeway afforded by regulation be used to the detriment of the

consumers.

§ The new driving cycle known as Worldwide Harmonized Light Vehicles Test Procedure (WLTP),

which is currently under development by the United Nations Economic Commission for Europe

(UNECE), should be implemented as soon as possible.

§ The ADAC EcoTest offers more realistic emission and fuel consumption data for consumers.


Thank you very much for your attention!

Documents

IEA Workshop green scoring Entwurf EN · § Emission tests, car reviews, crash tests, product tests, total cost of ownership, etc. § What does consumer protection mean? - no commercial