Draft test procedure for addressing the durability of replacement pollution control devices

Transcription

1 Draft test procedure for addressing the durability of replacement pollution control devices Bernardo MARTÍNEZ Automotive Industry Unit

2 Regulatory framework Regulation 582/2011 Article 15.5: Replacement pollution control devices shall only be type-approved according to Regulation (EC) No 595/2009 and this Regulation once the specific testing requirements are introduced in Annex XI to this Regulation Annex XI, point : The exhaust aftertreatment system shall be subjected to the durability procedures described in Appendix 3

3 Targets Accurately reproduce equipment ageing Consideration of different ageing effects (thermal, chemical and active regeneration) Consideration of transients Provide a flexible and cost-effective method Possibility of reducing the ageing time to hours or less Possibility of simultaneous ageing of different devices (combined or not combined systems) which had already been validated (DAAAC- Diesel Aftertreatment Accelerated Aging Cycles Consortium), at least to a certain extent

4 Lay-out of the procedure Data collection phase: collection of "real life" temperatures and times at those temperatures Service accumulation schedule: accelerated ageing The service accumulation schedule has to be able to reproduce ageing of the equipment at the end of its useful life Category of vehicle in which Minimum Equivalent Equivalent engine or engine system mileage number of number of will be installed (km) WHTC testcycles hours Category N 1 vehicles Category N 2 vehicles Category N 3 vehicles with a maximum technically permissible mass not exceeding 16 tonnes Category N 3 vehicles with a maximum technically permissible mass exceeding 16 tonnes Category M 1 vehicles Category M 2 vehicles Category M 3 vehicles of classes I, II, A and B as defined in Annex I to Directive 2001/85/EC, with a maximum technically permissible mass not exceeding 7,5 tonnes Category M 3 vehicles of classes III and B as defined in Annex I to Directive 2001/85/EC, with a maximum technically permissible mass exceeding 7,5 tonnes

5 Data collection phase Collection of real-driving temperatures: one cold and nine hot WHTC's and two regenerations (at least) Times at those temperatures extrapolated to useful life Use of the Arrhenius equation to calculate ageing time (AT) at arbitrary reference temperature (T r ), that would provide the same ageing as in real life Oil consumption measured i Calculation t e for each temperature bin: time at T r for achieving the same equivalent i ageing as for t bin seconds at i the temperature T bin AT: time at T r for achieving the equivalent ageing as the one existing in real driving, for the useful life of the device i i t e = t bin AT = n i=1 e t e i R T r R i T bin

6 Sensors setting

7 Engine Speed and Load Thermal Sequence Modes Soot Accumuation Mode Active Regeneration Mode Temperature Service accumulation schedule Conduction of an accelerated ageing test-cycle replicating Accelerated thermal ageing, with or without active regeneration Accelerated ageing due to lubricant consumption Example Service Accumulation Cycle Lubricant Consumption Mode Time Speed Load DPF Inlet Temp

8 Thermal ageing Conduction 11 mode test-cycle (3 thermal sequences) Temperature taking every second and calculation AE at T r t e i = C n c =1 e C R T r R T i AE = t e i time for achieving the same ageing, at temperature T r, as for 1 second at temperature T i AE equivalent ageing time, at the temperature T r, corresponding to 2 thermal sequences Determination of number of thermal sequences N TS = AT/AE p i=1 t e i

9 Flexibilities for accelerating thermal ageing Reduction of the ageing time possible, but not less than 10% of the useful life, by Insulating the exhaust pipe Moving the device closer to the exhaust manifold Artificially heating up the temperature of the exhaust Optimizing the engine settings

10 Two or more devices at the same time The service accumulation schedule must be the same (Same N TS ) Equal N TS may not be possible in combined systems (one-box). In this case, highest N TS shall apply: In the case of an assembly of replacement pollution control devices to be type-approved as a system within the meaning of Article 3(25) of Directive 2007/46/EC, if the assembly is built in such a way that the need of replacement of one of the devices of the assembly would lead to the replacement of the whole assembly, the N TS value to be used in the modified thermal accumulation schedule shall be the one corresponding to the device in the assembly with the highest N TS of those calculated

11 Engine Speed and Load Thermal Sequence Modes Soot Accumuation Mode Active Regeneration Mode Temperature Thermal ageing with active regeneration Addition of an active regeneration mode to the 11-mode cycle Active regeneration may be artificially triggered Same equations as for regular thermal ageing sequence Flexibility: the peak temperature of the active regeneration can be rosen up to 800ºC Limit to the flexibility: the number of active regenerations shall not be less than 50% the number of active regenerations during the useful life Example Service Accumulation Cycle Time Speed Load DPF Inlet Temp Lubricant Consumption Mode

12 Chemical ageing (due to lubricant consumption) Target: same lubricant consumption as in useful life Check whether the calculated number of thermal sequences is enough for achieving the oil consumption Check lubricant consumption during 24 thermal sequences Calculate time that the thermal accumulation schedule would have to be run to achieve the lubricant consumption t TAS = LCR WHTC t WHTC LCR TAS Calculate number of thermal sequences corresponding to t TAS N = t TAS t TS Compare N and N TS. If N > N TS, a lubricant consumption sequence has to be added after each thermal sequence The duration of each lubricant consumption sequence is calculated t LS = LCR WHTC t WHTC LCR TAS N TS t TS LCR LAS N TS

13 Acceleration lubricant consumption Remove Reinstall Flip Ring

14 Other aspects It is allowed to use a different engine for the service accumulation schedule (Euro VI type-approved) It is allowed to conduct data collection phase and accelerated thermal ageing at the same time for different devices It is allowed to perform the data collection phase for different devices at the same time, regardless whether or not such devices are to be type-approved as part of a single system, within the meaning or Article 3(23) of Directive 2007/46/EC It is allowed to perform the service accumulation schedule at the same time for different devices, regardless whether or not such devices are to be type-approved as part of a single system, within the meaning or Article 3(23) of Directive 2007/46/EC. In that case, a single service accumulation schedule shall be set for all the devices (N TS the same)

15 Meetings Two experts meetings (5 July 2013 and 22 January 2014) Next steps MVEG 2nd April A last expert meeting? TCMV (for discussion) 20 May 2014 TCMV (for vote) July 2014