Explanation and Validation of the Flat Belt Method ENTWURF Fahrzeugtechnik Fahrleistung und Verbrauch EGNT/2

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1 Explanation and Validation of the Flat Belt Method ENTWURF

2 Why? Why VW want to use the flat belt as new method for determination of the road load. The weather conditions in Germany allows at most 100 days per year for measurements on the street. Today and in future the possibilities for optimizations of the drive train get smaller and more expensive. The coast down on the street cannot image in detail such optimizations. The different influences on the street are often higher than the optimizations. The Flat Belt method allows measurements of the physical vehicle drag without any corrections and calculations over the speed, time, weight and atmospheric influences. Better repeatability of the measurements Seite 2

3 The Flat belt dyno Realistic measurements of the hole mechanical drag of a car under defined climate terms and conditions Seite 3 F mechanical F air = measured = measured and calculated

4 The Flat belt dyno, measure principle Each belt unit is mounted drag free against the environment by air bearings. The reaction forces of the car is measured over the hole unit against the environment. Cooling fan Vehicle fixing F v M mv F h M mh Hydraulic stabilising of the belt Seite 4 Force measurement Air bearing Dyno unit Air bearing cross vertical

5 The Flat belt dyno, technical specifications Technical specifications: Engine output per unit* : 75 kw Wheel load per unit* 1000 kg Measurement specifications maximum range accuracy Speed* : 200 kp/h km/h +/- 0,01km/h Drag force (unit)* : 2400 N N +/- 0,05 % Acceleration* : 0 +/- 0,5 g 0,002 m/s² Seite 5 adjustment specifications range accuracy Speed* : km/h +/- 0,1km/h Drag force (unit)* : N +/- 0,1 % : * Manufacturers instructions from his flyer.

6 Pro and contra Pro: Quick measurements, up to 4 measurements per day. Small optimizations in the drive train are measurably. No atmospheric influences. No traffic influences. No significant weight, tire and weather corrections necessary. Fast identification of defects in the drive train. Good repeatability Seite 6 Open points: Two different measurements with two tolerances are necessary. A reference is needed for both measurements (in progress). The validation by a technical service like the TÜV is projected for summer 2013.

7 Explanation of the method Flat belt and wind tunnel method. Same terms and conditions for both measurements as used on the street. Especially weight, tires, rims, body parts Aerodynamic drag: Measurement of the aerodynamic drag with the coast down vehicle. 3 measurements at the speed points of 80, 100, 120, 140 km/h. 1 measurement of the frontal area Seite 7 Mechanical drag: Measurement of the mechanical drag on each wheel / axle: Warm up the 140km/h for 1200s Step down the vehicle in 10km/h steps and measurement of the force for each step. The air drag is added by calculation to the measured mechanical drag of the vehicle. Calculation of the F0, F1, F2 value from this measured road load curve.

8 Explanation of the procedure Dyno and vehicle Speed Measured force Measurement of the road load on the flat belt. Step 1: Step 2: Warm 140km/h Measurement v :10km/h; t :10 s 1 2 A: Vehicle is already warm up with a tolerance from +/- 2,5N. A Seite 8

9 Explanation of the used formula Used calculation: Seite 9

10 Validation vehicle 1 Polo, stability and reproducability The tested vehicle was a Polo Blue Motion. At all measurements we don`t change something at the vehicle. The Measurement_street_4 were measured with the TÜV Nord in The flat belt measurements are nearly constant (+- 2,5 N). We see higher derivations between the coast down tests on the street (+- 20N). This vehicle was very sensitive for ambient circumstances like wind. 600 Measurement_flat_belt_1 Fahrwiderstand [N] Measurement_street_1 Measurement_street_2 Measurement_street_3 Measurement_street_4 Measurement_street_ Seite Geschwindigkeit [km/h]

11 Validation vehicle 2 Beetle Seite 11 Road load [N] Street measurement flat belt t mean f mean F0 96,1 99,4 105,8 F1 0,66 0,58 0,50 F2 0,0354 0,0354 0, Measurement_flat_belt 100 Measurement_street_time_mean Measurement_street_force_mean Delta ( Flat belt - Street (time mean)) in % 0 Delta ( Flat belt - Street (force mean)) in % Speed [km/h] Derivation (Flat belt - street) [%] Mass: Start weight Milage : 1494 kg : km Conditions street measurement: Air temp. : 21,3 C Air preassure : 1004 hpa Wind speed : 1 m/s Time: 19:25 21:45 Calculated as described in 70/220 EWG

12 Validation vehicle 3 Tiguan Street measurement flat belt t mean f mean F0 126,9 128,6 135,6 F1 0,68 0,30 0,21 F2 0,0397 0,0440 0,0444 Mass: Start weight Milage : 1762 kg : km Conditions street measurement: Air temp.. : 21,5 C Air preassure : 1002 hpa Wind speed : 1,6 m/s Time: 19:30 21:45 Calculated as described in 70/220 EWG Seite 12

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