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HYBRID-PROCEDURES AND CHALLENGES FOR EMISSION MEASUREMENT SYSTEMS

K. Engeljehringer – AVL List GmbH, Graz, Austria Prof. Dr. C. Beidl – Technische Universität Darmstadt Dr. B. Lenzen – Technische Universität Darmstadt P. Weickgenannt – Technische Universität Darmstadt

2 AVL Emission Test Systems, K. Engeljehringer

HYBRID EMISSION TESTING Content

• Introduction

• Test procedures for Hybrids

• Legislation, what is a Hybrid?

• NOVC – Not Off Vehicle Charging

• OVC – Off Vehicle Charging

• Emission Measurement Challenges

• Hybrid specific measurement

challenges

• Conclusion


Impressions from Shanghai in October 2012

Taxi drive from airport to downtown Shanghai. What can you see?



A lot of electricity supplied into the city



Advertisement mounted on a factory chimney for a photovoltaic manufacturer.



Night live in Nanjing Rd.

From 53 Scooters 43 hat an electric motor, i.e. 80%


2010

7 Billion people

1.100 Million vehicles

THE CHALLENGES Balancing resources with demands

1960

3 Billion people

200 Million vehicles

Therefore we need a much higher efficiency

in the usage of our resources!

• Surface, we only have one world

• Air volume – the atmosphere is only a thin layer, 60% of the

air is below the summit of mount Everest

• Fossil energy is limited

Resources

are limited

Demand

is increasing


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


CONTROLLING AIR POLLUTION also CO2 emission become regulated

4 l/100km

25 km/l

65 mpg



• Introduction







challenges

• Conclusion


AVL EMISSION LEGISLATION BOARD 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)


HYBRID TECHNOLOGIES Types and Functionalities Overview

Functionalit

y

Legislation

Naming

Idle Engine Off

Start/Stop

Energy Recovery

by Breaking

Vehicle can drive

with E-Motor

alone

Rechargeable

battery from

external source

Vehicle operate

as an EV over a

wide range

Conventional

Vehicles Micro

Hybrid

Mild

Hybrid

Full

Hybrid

Plug-In

Hybrid

Range

Extender

Conventional Vehicles Hybrid:

Off Vehicle Charging

Technology Naming

Hybrid:

Non Off Vehicle Charging


Energy-Production Energy-Distribution Energy-Storage Energy-Conversion

Hybrid Electric Vehicle

Not Off-Vehicle Charging

2 engines

2 energy storages

1 energy supply

EMISSION TESTING Hybrid Vehicle NOVC (Not Off-Vehicle Charging)

12,15 kWh

3,35 kWh

0,75 kWh

2,27 kWh

2,06 kWh


HYBRID EMISSION TESTING Testbeds

Hybrid development in the AVL California Technology Center

AVL AMA i60 Emission Bench AVL Battery Simulator AVL Automation System


EMISSION TESTING Hybrid Vehicle “Not Off-Vehicle Charging”

Fuel

consumption

Emission

Analysis

Ampere

Meter

Power

Analyzer

If the State of Charge

(SOC) of the battery

does not change

significantly between

start and end of the test,

then the result is valid.

If SOC changes, then

fuel consumption and

CO2 is corrected

accordingly to the

change of the SOC. Change in

state of charge

∆ SOC


EMISSION TESTING Hybrid Vehicle “Not Off-Vehicle Charging”

SUV Hybrid, type approved for EU-4 (2005).

Battery was charged from 46 % to 64%

Engine was off for 56% of the test


EMISSION TESTING Hybrid Vehicle OVC (Off-Vehicle Charging)

Fuel consumption and CO2 is

included in legislation. This “fuel”

consumption and

related emissions

are not included.

Energy and CO2 for production is

not included.

FAD Conference 2011, Dresden – UBA Presentation

“With the current mix in electricity production in Germany (coal,

nuclear, water, …) there is no significant advantage for electrical

cars compared to conventional.

CO2 emission from Electrical Vehicles are app. 145 gCO2/km.


EMISSION TESTING Hybrid Vehicle “Off-Vehicle Charging

Result A “best case”

Determination of the electrical- or off-vehicle charged

range. (Charge depleting tests)

Test which distance the vehicle can be operated in

pure electrical or dominant electrical mode.

Repeat tests until certain SOC criteria are fulfilled.

The average emissions of these tests are calculated.

Fuel

consumption

Emission

Analysis

Ampere

Meter

power

analyzer Change in

state of charge


Result B

“worst case”

(Charge sustaining)

Test emissions with

minimum SOC.

EMISSION TESTING Hybrid Vehicle “Off-Vehicle Charging

Weighted

Result

Result A “best case”

Determination of the electrical- or off-vehicle charged

range. (Charge depleting tests)

Test which distance the vehicle can be operated in

pure electrical or dominant electrical mode.

Repeat tests until certain SOC criteria are fulfilled.

The average emissions of these tests are calculated.

Calculate a final result by

weighting Results A and

result B with an Utility

Factor.

A is weighted with the

distance the vehicle can be

driven mainly by the

battery.

B is weighted with the

typical distance a vehicle is

driven between it will be

charged.

A B

Emission results of all tests must apply with legislation limits.



• Introduction







challenges

• Conclusion


HYBRID EMISSION TESTING Measurement Challenges – Over-Dilution

Challenges:

• Hybrid vehicles will run for longer times without the combustion engine on.

• During these times the Bags of the CVS system are filled with dilution air only.

• That will result in a significant over-dilution over the whole test, which will lead to very low emission

concentrations in the bags.

engine rpm during test.

Needed Solutions (for EU Legislation):

• Use Super Low Emission Vehicle measurement system configurations

• Heated CVS and dried dilution air to allow lower overall dilution ratios


HYBRID EMISSION TESTING Possible negative influences by the measurement systems

Challenges:

• CVS tailpipe de-pressure could suck air through the engine, that may result in cooling the catalytic

converter to charge it with O2, which disables NOx reduction.


HYBRID EMISSION TESTING Possible negative influences by the measurement systems

Challenges:

• CVS tailpipe de-pressure could suck air through the engine, that may result in cooling the catalytic

converter to charge it with O2, which disables NOx reduction.

Possible Solutions:

• Ensure low tailpipe de-pressure conditions. Like with an Active Tailpipe Pressure control system. A

blower compensates for pressure losses over the dilution air filter and tubing of the CVS



• Introduction







challenges

• Conclusion


HYBRID EMISSION TESTING Conclusion

• Hybrid technology changes faster than emission legislation can be adjusted.

Legislations will continue to change and may not be clear in all details

• Hybrid emission testing is more complex and time consuming.

Especially hard for non-OEM Labors, which do not have an inside view

about the hybrid control strategies.

• Worldwide further CO2 reduction targets will come, like 95g/km in 2020 in EU

will further change technology and test procedures.


Outlook for Automotive Industry Conclusion

• Further shift of sales and production to BRIC markets.

(9% of world production in 2000, 33% in 2010, 47% in 2025)

• BRIC markets emission limits will become similar to Triad

• BRIC customer requirements will be different. Higher share of low-

budget cars and different functionalities. (In 2025, 25% of Chinese

drivers will be < 30 years and 10% above 60. In Germany 10 % will be

< 30 and 33% above 60.)

• Complexity of automotive engineering will reach unprecedented levels

but have to deliver more at the same cost and time levels. Engineering

and testing needs to improve effectiveness and efficiency.


AVL EMISSION TESTING for a cleaner Environmental

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