AVL PLU131 Flow Measurement Systems - Fuel mass flow

AVL PLU131 Flow Measurement Systems
AVL Approach
AVL provides a large spectrum of flow sensors and system solutions for these tasks with either continuous flow rate metering or injection quantity measurement.
R&D
R&D applications focus on component characterization and validation under a wide range of operation conditions.
Injection quantity measurement and injection rate analysis on component and system test benches. The most prominent group of test objects is fuel injectors (CR, GDI, Port Fuel Injectors, Unit Injectors, SCR Injectors etc.; solenoid and piezo) and fuel injection systems.
Injector testing includes injection quantity characterization versus parameters as energizing time, pressure or temperature (Q(ti,p,T). But it also comprises analysis of needle movement and timing (open and closing) as well as injection rate shaping etc.
Injection system testing investigates multiple injector interaction in a complete engine injection system. Pressure wave compensation, for instance, investigates mutual influence on flow characteristics depending on pressure and engine speed.
Production
Component manufacturing requires quality control, adjustment or calibration of mass products like injectors, pumps, control valves etc. Sample checking or 100% control of flow characteristics is mostly realized via continuous flow measurement where short measurement time and high reliability are the most important features.
Benefits at a Glance
- Test time reduction: higher accuracy reduces averaging time
- Process acceleration in R&D : reliable characterization and fast verification of progress
- Cost reduction in application: engine map pre-calibration reduces engine test bed time
- High reliability: robust sensors and extreme long-term stability of the calibration due to PLU measurement principle
Market Requirements
Production testing for diesel and gasoline fuel injectors includes a variety of integrated measurement solutions ranging from random inspection on semi-automated test benches to 100% control on fully automated production lines. Similar manufacturing test requirements apply to fuel pumps and control valves. R&D and engine applications add further tasks as flow characteristic verification, injector timing map calibration or combustion development.
Technical Data
AVL PLU 131 Flow Sensor Specifications
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STS PLU 131 Fuel |
STS PLU 131 Urea |
PLU 131F |
PLU 131S |
Sensor type |
Injection rate and quantity measurement sensor including high-speed data acquisition system |
Average flow rate |
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Typical applications |
High pressure direct fuel injection component and |
SCR injector and dosing system testing in R&D |
Low pressure fuel injector and fuel pump production |
High temperature or high |
Standard |
Downstream or Upstream |
Upstream |
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Measurement parameters |
Flow rate, injection rate and quantity with up to 12 partial injections, injector current, injector opening and closing delays, pressure, temperature |
Momentary flow rate, total consumption and statistical data in combination with data acquisition system |
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Measurement range |
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Flow rate |
0.01 ... 10 l/h |
0.01 ... 10 l/h |
0.05 ... 10 l/h |
0.05 -10 l/h |
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0.02 ... 20 l/h |
0.02 ... 20 l/h |
0.05 ... 20 l/h |
0.05 - 20 l/h |
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0.04 ... 40 l/h |
0.04 ... 40 l/h |
0.1 ... 40 l/h |
0.1 - 40 l/h |
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0.15 ... 75 l/h |
0.2 - 80 l/h |
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0.3 ... 150 l/h |
0.3 - 150 l/h |
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0.8 ... 300 l/h |
0.8 - 300 l/h |
Injection |
0.1 ... 600 mm³ |
0.1 ... 600 mm³ |
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Measurement uncertainty |
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Flow rate*) |
0.1 % |
0.1 % |
0.1 % |
0.1 % |
Total |
1 % at > 2 mm³ |
1 % at > 10 mm³ shot volume and 4 Hz cycle rate |
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Cycle rate |
10 ... 180 Hz |
1 ... 10 Hz |
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Dynamic response time acc. DIN 19226 |
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<100 ms |
<100 ms |
Media |
Common gasoline and |
Aqueous urea solution according to ISO22241 2008/9 (AdBlue®) ***), |
Common gasoline and |
Common gasoline and |
Density |
0.69 ... 0.85 |
0.99 ... 1.19 |
0.69 ... 0.85 |
0.69 ... 0.85 |
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Further media densities upon request |
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Operating temperature |
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Media |
-30 - +70 °C |
+10 - +60 °C |
-20 - +70 °C |
-30 - +70 °C |
Environment |
-30 - +60 °C |
+10 - +60 °C |
-20 - +60 °C |
-30 - +60 °C |
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Up to 150 °C with optional cooling flange |
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Up to 150 °C with optional cooling flange |
Operating pressure |
0.01 - 200 bar |
0.01 - 10 bar |
0.1 - 10 bar |
0.01 - 200 bar |
Differential |
ΔP=0 (PLU measurement principle) |
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Back |
No minimum back pressure required |
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Interfaces |
Frequency |
Frequency |
Frequency |
Frequency (max.150 kHz) |
Power supply |
100 - 240 V AC |
100 - 240 V AC |
24 V - 40 V DC |
24 V - 40 V DC |
Power consumption |
Max. 50 W |
Max. 50 W |
Max. 40 Watt |
Max. 40 Watt |
Sensor dimensions |
335 x 216 x 140mm |
335 x 216 x 140mm |
340 x 216 x 133 mm |
335 x 216 x 140mm |
Sensor weight |
16 kg |
15 kg |
10 kg |
14 kg |
Protection |
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Ex II 2G EEx d IIB T6 |
Ex II 2 G EEx d IIB T6 acc. EN 50 018:1994, EN 50 014:1997 |
Safety |
CE |
CE |
CE |
CE |
Calibration |
Traceable back to German national standard (PTB) |
*) Measurement uncertainty of flow meter calibration factors under repeatable conditions with medium HAKU at 20 °C and 1 bar
**) Total measuring uncertainty acc. GUM ( Guide to the Expression of Uncertainty in Measurement ) for an optimized injection system
***) AdBlue® is a trademark of the VDA for the official name Urea AUS 32 according to ISO 22241 2008/9
****) De-ionized water solution with 1% P3-Prevox 7400 (99/1 vol%) or with 50% ethylene glycol (50/50 vol%)
System Scope
Continuous Fuel Flow Measurement
Fuel pumps, control valves and diesel and gasoline low pressure injectors are typically tested in operation as a final step in the production process. Average fuel flow quantity examination over a characteristic flow range is used as performance check for the devices.
For this purpose AVL offers the PLU131 flow sensor family with the following features:
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High-accuracy continuous fuel flow meters for a wide temperature and pressure range
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Large measuring range up to 1:500 at high resolution provide for short measurement time
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Extreme sensor robustness and long-term stability of calibration
Fuel Injection Quantity Measurement
High pressure systems for direct fuel injection like common rail diesel or GDI require cycle-resolved shot quantity measurement for performance examination as well as for production quality check, featuring:
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Shortest measurement time for flow characteristic verification in end-of-line testing
R&D applications include further tasks in injector and system characterization, such as:
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Crank-angle resolved injection rate analysis for combustion development
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Precise shot measurement of multiple injections for injection system pressure wave compensation and injection timing map calibration
With the Shot-to-Shot™, PLU131 AVL provides a state-of-the-art shot measurement system compliant with the most extreme requirements of OEMs and component suppliers.
Aqueous media (AdBlue®) and extremely low flow rate
Low pressure injection systems are used for diesel engine exhaust aftertreatment in SCR systems for NOx reduction and HC dosers for DPF regeneration. Extremely low flow rates and small dosing quantities are particular challenges for characterization and performance testing of these dosing systems. AVL offers system solutions that are well adapted to these special requirements.
System Integration Service
AVL provides integration support to system integrators as well as end users for the full range of flow sensors and system solutions and for a variety of measurement tasks.
Measuring Principle
PLU Measurement Principle
AVL PLU sensors combine the most suitable measurement technology for these specific applications with high reliability and extreme long-term stability of the calibration.
The PLU measurement principle offers a number of advantages:
- Extremely large measuring range of up to 1:1000
- High accuracy even at very low flow rates <10g/h
- No pressure drop (Δp=0) and consequently no influence on the dosing system
- No leakage over the gear counter due to (Δp=0)
The PLU measurement principle, with two independent positive displacement sensors, combines the highly dynamic sensitivity of a piston sensor with the extremely robust accuracy of a servo-controlled gear meter. It prevents any interference of the flow meter with the hydraulic system to be measured. The sensor cancels out the pressure difference (ΔP=0) between inlet and outlet, avoiding leakage alongside the gears.