F O C U S 2 9 In fall 2015, AVL was awarded the contract for NVFEL‘s latest showcase project: a test cell to be newly equipped for measuring the smallest concentrations of vehicle emissions in accordance with the newest EPA testing procedures. A key criterion for selecting AVL as technology partner was its ability to meet the technical demands placed on the measuring equipment and the automation system. The capability to test hybrid and pure electric vehicles apart from conventionally powered vehicles, and to design and evaluate test runs in a flexible manner were further reasons for awarding AVL the project. CUSTOMIZED HIGH-END MEASURING TECHNOLOGY To achieve optimal test bed operation, the complete test cell was equipped with high-end measuring technology. And this is where the iGENERATION Series II comes into play. Its heated exhaust gas measurement system with stainless steel tubing allows measuring super ultra-low concentrations of carbon monoxide (CO), total hydrocarbons (THC) and nitrogen oxides (NOx). To fulfill the latest US greenhouse gas regulations, the system is equipped with gas chromatography technology for measuring methane (CH4), and with a quantum cascade laser (QCL i60) for detecting nitrous oxide (N2O). As the new test bed is also intended for testing SUVs and vans, AVL is also supplying the CVS i60 SII MD exhaust dilution system, featuring a flow rate of up to 60m³/min and four switchable venturis, as well as a FlowSonix, a dilution air flow measurement system with pressurecontrolled mixing point. Particulate measurement in diesel and GDI vehicles is accomplished with the AVL PSS i60 SII DD particulate sampler (double dilution). Test bed automation is based on the innovative AVL iGEM Vehicle automation system for emission testing, which meets the EPA testing requirements thanks to its 1066 test cycle package. To achieve realistic measuring results, drive cycle metrics and two further test cycles were added to the 1066 package. To ensure the accurate testing of hybrid vehicles, the AVL iGEM Vehicle is equipped with a unique hybrid package with patented smart, intermittent bag filling procedure. This enables the analysis of large sample volumes. To complement the hybrid application, AVL uses startstop monitoring (AVL 389) and a Hioki Power Analyzer. MODEL TECHNOLOGY The new chassis dynamometer with AVL exhaust emission measurement technology at the NVFEL will support the following testing procedures in accordance with EPA 40 CFR (Code of Federal Regulations) Part 1066: the Greenhouse Gas Regulations and Tier 3 Regulations, as well as the general emission compliance activities and Clean Vehicle Assessment programs for gasoline, diesel, naturalgas powered and hybrid vehicles. As the EPA also welcomes representatives of various industries and countries on a regular basis, the agency was especially interested in obtaining a test cell that can be regarded as ‚best in class‘ from a functional point of view, which underlines the exceptional position of AVL even further. > James Williamson, Regional Business Manager AVL North America INTERVIEW WITH JAMES WILLIAMSON, REGIONAL BUSINESS MANAGER AVL NORTH AMERICA What is so special about this project compared to other, similar projects? “The upgrade project at the EPA cell D329 is primarily focused on the testing of cleanest new vehicles only. This means EPA will only do new vehicle certification for Tier 3. In addition to testing new clean vehicles the system will be capable of HEV, PHEV, and EV testing.” What is the biggest challenge AVL has to overcome? “In this project it’s hard to tell which aspect poses the biggest challenge. Every customer has different requirements. For us, every order is a special task, which we tackle with expertise and experience.” To what extent do AVL’s emissions solutions satisfy the customer’s needs also in terms of aesthetics? “The EPA is very satisfied with the flexibility AVL iGEM Vehicle offers. From an aesthetics point of view we designed three layouts for the EPA in our proposal. This attention to detail and our ability to have all the emissions equipment laid out in the optimum arrangement in the control room was key in the decision for selecting AVL.” <
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