PARAMETERS TO BE MEASURED/RECORDED

Transcription

1 CONTENTS INTRODUCTION PARAMETERS TO BE MEASURED/RECORDED TEST EQUIPMENT ACTIVITY PLANNING PEMS DEVICES INSTALLATION INSTRUMENT INSTALLATION VEHICLE DESCRIPTION TEST CYCLE SELECTION & DURATION PEMS TESTS CONCLUSION 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel Loader Turin 10/2012 1

2 INTRODUCTION The EU NRMM Pilot-Program s scope is mainly statistical data collection by testing the vehicle in conditions representative of real life operations; this document is the report of the first test conducted during weeks 40-41/2011 on a Wheel Loader (CE) CNH W190C; next tests on AG vehicles will follow on Summer Participants: Alberto Ruggieri, Massimo Marchetti, Giuseppe Marino (FPT) Gabriele Villa (NHK), Antonio Giaffreda (CNH Lecce) Vehicle: Wheel Loader W190C ZB (S/N NBHE12048) Engine: NEF 6 Cyl. Stage IIIB, rating 169 kw, 0 working hrs Location: New Holland Kobelco (NHK), S. Mauro Torinese Calendar: CW 40 & 41, from 30 th September to 14 th October Instrument: GAS-PEMS (Portable Emission Measurement System) for gaseous pollutant emissions 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel Loader Turin 10/2012 2

3 Parameters Measured/Recorded PEMS Data Concentrations: THC, CO, CO 2, NO, NO 2 [ppm] Exhaust mass flow [kg/h] and temperature [DegK] External data: Ambient temperature [DegK], relative humidity [%] and atmospheric pressure [kpa] Machine position, altitude and ground speed (from GPS). Vehicle Interface to acquire mainly the following CAN data: Engine coolant temperature Engine speed Vehicle speed Reference Engine Torque [DegK] [rpm] [mph] [lb-ft] Percent Engine Torque [%] Percent Friction Torque [%] Engine load [%] Throttle position [%] Fuel rate Intake air manifold temperature (gal/s) [DegK] 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel Loader Turin 10/2012 3

4 Test Equipment Gas-PEMS: Sensors Semtech-DS (picture) (THC, CO, NO, NO 2, CO 2 analyzer) Exhaust Flow MeterSensors: Semtech EFM 4 inches diameter (from 6 to 12 liters engines) Semtech-Sensors EFM Module: (picture) Exhaust flow and temperature acquisition station. Dgtech Dearbone IIIb module: J1939 CAN Data Reader supplied by Semtech GPS and Weather station supplied by Semtech. FID and Span bottles: FID:H 2 -He mix ; Span: NO 2 + gases mix(co, CO 2, NO, THC) Power Supply Unit (picture) Gasoline generator + Inverter Sensors 12V 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel Loader Turin 10/2012 4

5 Activity Planning PEMS INSTALLATION: a. build PEMS support and exhaust connection with the flow-meter. b. install Pems and accessories and secure all the hardware by straps/bolts. c. warm-up the PEMS, connect the vehicle interface to the engine diagnostics connector and verify the correctness of data read by PEMS. d. verify the strip/bolts tightening of the PEMS hardware by functional check on field. TEST EXECUTION: d. pre-test in field for preliminary data acquisition and PEMS installation verification e. PEMS testing session: to collect 3 sets of valid data on a similar duty cycle 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel Loader Turin 10/2012 5

6 PEMS Devices Installation 1/2 Instrument support frame For the safety of the operation/driver we ve chosen to build a support platform to be fixed at the rear of the vehicle Not permanent mounting and no modifications to vehicle parts in this case. Easy to remove and installed again on another similar vehicle. Preparatory works Built by NHK, the best method to fit the support on the vehicle was to use the four rear ballast lifting points and four brackets welded to the upper frame (see picture) The fabrication of the welded structure was completed in one week. 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel Loader Turin 10/2012 6

7 PEMS Devices Installation 2/2 Flow-meter installation Adapter flange is needed to install the 4 EFM to the tale-pipe, (picture above). It must be rigid and physically capable to support the EFM. No permanent exhaust line modifications No sudden diameter discontinuity in the exhaust line. It is preferable to mount the EFM slightly downward to discharge water condensation. Preparatory works FPT built a 90deg elbow flange to be fixed on the engine exhaust pipe. Vehicle smokestack was removed Easy mounting: V-clamps and metallic strip were used To support weight and vibrations of the EFM a rod support is welded on the platform. 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel Loader Turin 10/2012 7

8 Instrument Installation Analyser and Generator were attached to the frame with straps; the frame is properly trimmed to allow secure straps Smaller devices (Inverter and FM/vehicle interfaces) were fixed with plastic strips. Gas Cylinder were strictly kept to the frame by appropriate brackets. All cables were fixed to the platform with plastic strips. 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel Loader Turin 10/2012 8

9 Vehicle description VEHICLE ENGINE ENGINE DISPLACEMENT Wheel Loader mod. WLO W190C NEF 6 CYL. 4V COMMON RAIL SCR cc. NUMBER OF CYLINDERS 6 ENGINE RATED POWER ENGINE PEAK TORQUE EMISSION LEVEL GROSS VEHICLE WEIGHT RATING GVW IN TEST 1800rpm 1300rpm Stage IIIB / TIER 4A 17433Kg ~18000Kg 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel loader Turin 10/2011 9

10 PEMS test cycle selection & duration To define the vehicle s test duration for PEMS vehicle measurement, it s necessary to know the reference work (W ref ), which is the work produced during the NRTC bench test. The sum of the «y» and of the «load and carry» tests work have to be at least 5 times the reference work. Typical working cycles defined for WL validation: Y Cycle 35% Load&Carry Cycle 30% Grizzly Charging 15% Stockpiling 10% Face Digging 5% Miscellaneous 5% Project Testing Protocol: Data amount required - At least 3 records on a similar duty cycle - In each test run the cumulated work shall be at least 5 times the work produced in the NRTC bench cycle. DEFINED 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel loader Turin 10/2011 Duty Cycle combination selected for PEMS Test to be representative of real service: 1. Y Cycle 62,5 % time (moving soil for short distance) 2. Load & Carry Cycle 37,5 % time (60mt carrying & moving soil) For estimation of the Mean Cycle Power has been performed a preliminary test of 1hr for data acquisition by data logger only (values strongly variables depending on operator attitude): Y Cycle 65 % of Rated Power L&C Cycle 50 % of Rated Power Calculated PEMS-TEST Duty Cycle : 50min Effective test duration (to collect data and accumulate experience) : 1. Y Cycle 43 min 2. Load & Carry Cycle 22 min Total time 65 min 10

11 PEMS TEST: «Y» cycle: Test time:~43min Y cycle video 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel loader Turin 10/

12 NOx vs Exhaust Temperatures: with exhaust temperature under 230DegC, NOx emissions increase. During the entire Y cycle: high temperature, so good performance. Variation in engine power due to difficulty in repeatibility of every single cycles (operator feeling, soil, sand quantity, etc..) are variables to keep in count during the test definition 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel loader Turin 10/

13 PEMS TEST: «Load & Carry» Test time: ~22min Load & Carry video 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel loader Turin 10/

14 Shorter and less «hard» test = colder exhaust temperature and higher NOx emissions Engine load more «stable» vs. «Y» cycle due to the alternation between digging and roading phase. 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel loader Turin 10/

15 Y cycle High exhaust temperatures are the best conditions for to maintain low NOx emission level «Load&Carry» and «Y» cycles show different behaviour in engine load, exhaust gas temperatures and consequent NOx emissions. 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel loader Turin 10/

16 CONCLUSIONS Y Cycle Emissions result to have generally better results than L&C Cycle: more load/exhaust temperatures and less idling time = better performance. Technical problems may prevent from picking up a minimum amount of data to ensure the repeatability of the test and therefore invalidate the test The installation can take up to a week, in order to ensure safety during the maneuvers and reliability of the measurement. Before starting to move hardware, it s necessary to meet the customer on where the test will be performed and discuss about every aspect of the activity, from safety documents that has to be exchanged to the skill of the driver needed, through a site/field inspection to determine the duration of the test. It is necessary to determine with the customer that the vehicles concerned to the ISC may need changes more or less heavy to safely mount the PEMS and that the customer's downtime (machine stop) might reach working days. Wi-fi connection is necessary in case of lack of space in the cabin (most cases of CE vehicles); but, if the wi-fi transmissions does not guarantee a reliable link, it s not possible (or it s very uncomfortable and sometimes dangerous), to directly follow the acquisition in the cab if a cable connection is used. 10/2011 FPT CNH NRMM EU - Pilot Program Tests on Wheel loader Turin 10/