HYBRID-PROCEDURES AND CHALLENGES FOR EMISSION MEASUREMENT SYSTEMS

HYBRID-PROCEDURES AND CHALLENGES FOR EMISSION MEASUREMENT SYSTEMS K. Engeljehringer AVL List GmbH, Graz, Austria Prof. Dr. C. Beidl Technische Universität Darmstadt Dr. B. Lenzen Technische Universität Darmstadt P. Weickgenannt Technische Universität Darmstadt

HYBRID EMISSION TESTING Content Introduction Test procedures for Hybrids Legislation, what is a Hybrid? NOVC Not Off Vehicle Charging OVC Off Vehicle Charging Emission Measurement Challenges Hybrid specific measurement challenges Conclusion 2

Impressions from Shanghai in October 2012 Taxi drive from airport to downtown Shanghai. What can you see? 3

Impressions from Shanghai in October 2012 A lot of electricity supplied into the city 4

Impressions from Shanghai in October 2012 Advertisement mounted on a factory chimney for a photovoltaic manufacturer. 5

Impressions from Shanghai in October 2012 Night live in Nanjing Rd. From 53 Scooters 43 hat an electric motor, i.e. 80% 6

THE CHALLENGES Balancing resources with demands Resources are limited Surface, we only have one world Air volume the atmosphere is only a thin layer, 60% of the air is below the summit of mount Everest Fossil energy is limited 1960 2010 Demand is increasing 3 Billion people 200 Million vehicles 7 Billion people 1.100 Million vehicles Therefore we need a much higher efficiency in the usage of our resources! 7

THE CHALLENGES Green-House-Gas emissions and Global Warming CO2 emitted per country: The map shows how much CO2 is emitted per country. 1. China 2. USA 3. India 4. Russia CO2 emitted per person: The map shows how much CO2 is emitted per person. 1. USA 2. Canada 3. Australia 4. Middle East 8

CONTROLLING AIR POLLUTION also CO2 emission become regulated 4 l/100km 25 km/l 65 mpg 9

AVL EMISSION LEGISLATION BOARD Many pages, complex and sometimes confusing In Annex 8 of this Regulation, references to Annex 4 shall be understood as reference to Appendix 4 of Annex I of this Regulation. (Quotation from UN-ECE 101) 4000+ pages of worldwide emission legislations and regulations 11

Functionality HYBRID TECHNOLOGIES Types and Functionalities Overview Technology Naming Conventional Vehicles Micro Hybrid Mild Hybrid Full Hybrid Plug-In Hybrid Range Extender Idle Engine Off Start/Stop Energy Recovery by Breaking Vehicle can drive with E-Motor alone Rechargeable battery from external source Vehicle operate as an EV over a wide range Legislation Naming Conventional Vehicles Hybrid: Non Off Vehicle Charging Hybrid: Off Vehicle Charging 12

EMISSION TESTING Hybrid Vehicle NOVC (Not Off-Vehicle Charging) Energy-Conversion Energy-Storage Energy-Distribution Energy-Production Hybrid Electric Vehicle Not Off-Vehicle Charging 2 engines 2 energy storages 1 energy supply 2,27 kwh 2,06 kwh 3,35 kwh 12,15 kwh 0,75 kwh 13

HYBRID EMISSION TESTING Testbeds Hybrid development in the AVL California Technology Center AVL Battery Simulator AVL AMA i60 Emission Bench AVL Automation System 14

EMISSION TESTING Hybrid Vehicle Not Off-Vehicle Charging Emission Analysis Power Analyzer Ampere Meter Fuel consumption Change in state of charge If the State of Charge (SOC) of the battery does not change significantly between start and end of the test, then the result is valid. If SOC changes, then fuel consumption and CO2 is corrected accordingly to the change of the SOC. SOC 15

EMISSION TESTING Hybrid Vehicle Not Off-Vehicle Charging SUV Hybrid, type approved for EU-4 (2005). Engine was off for 56% of the test Battery was charged from 46 % to 64% 16

EMISSION TESTING Hybrid Vehicle OVC (Off-Vehicle Charging) Fuel consumption and CO2 is included in legislation. Energy and CO2 for production is not included. This fuel consumption and related emissions are not included. FAD Conference 2011, Dresden UBA Presentation With the current mix in electricity production in Germany (coal, nuclear, water, ) there is no significant advantage for electrical cars compared to conventional. CO2 emission from Electrical Vehicles are app. 145 gco2/km. 17

EMISSION TESTING Hybrid Vehicle Off-Vehicle Charging Result A best case Determination of the electrical- or off-vehicle charged range. (Charge depleting tests) Emission Analysis Fuel consumption Test which distance the vehicle can be operated in pure electrical or dominant electrical mode. Repeat tests until certain SOC criteria are fulfilled. The average emissions of these tests are calculated. power analyzer Ampere Meter Change in state of charge 18

EMISSION TESTING Hybrid Vehicle Off-Vehicle Charging Result A best case Determination of the electrical- or off-vehicle charged range. (Charge depleting tests) Result B worst case (Charge sustaining) Weighted Result A B Test which distance the vehicle can be operated in pure electrical or dominant electrical mode. Repeat tests until certain SOC criteria are fulfilled. The average emissions of these tests are calculated. Test emissions with minimum SOC. Calculate a final result by weighting Results A and result B with an Utility Factor. Emission results of all tests must apply with legislation limits. A is weighted with the distance the vehicle can be driven mainly by the battery. B is weighted with the typical distance a vehicle is driven between it will be charged. 19

HYBRID EMISSION TESTING Measurement Challenges Over-Dilution engine rpm during test. Challenges: Hybrid vehicles will run for longer times without the combustion engine on. During these times the Bags of the CVS system are filled with dilution air only. That will result in a significant over-dilution over the whole test, which will lead to very low emission concentrations in the bags. Needed Solutions (for EU Legislation): Use Super Low Emission Vehicle measurement system configurations Heated CVS and dried dilution air to allow lower overall dilution ratios 21

HYBRID EMISSION TESTING Possible negative influences by the measurement systems Challenges: CVS tailpipe de-pressure could suck air through the engine, that may result in cooling the catalytic converter to charge it with O2, which disables NOx reduction. Possible Solutions: Ensure low tailpipe de-pressure conditions. Like with an Active Tailpipe Pressure control system. A blower compensates for pressure losses over the dilution air filter and tubing of the CVS 23

HYBRID EMISSION TESTING Conclusion Hybrid technology changes faster than emission legislation can be adjusted. Legislations will continue to change and may not be clear in all details Hybrid emission testing is more complex and time consuming. Especially hard for non-oem Labors, which do not have an inside view about the hybrid control strategies. Worldwide further CO2 reduction targets will come, like 95g/km in 2020 in EU will further change technology and test procedures. 25

Outlook for Automotive Industry Conclusion Further shift of sales and production to BRIC markets. (9% of world production in 2000, 33% in 2010, 47% in 2025) BRIC markets emission limits will become similar to Triad BRIC customer requirements will be different. Higher share of lowbudget cars and different functionalities. (In 2025, 25% of Chinese drivers will be < 30 years and 10% above 60. In Germany 10 % will be < 30 and 33% above 60.) Complexity of automotive engineering will reach unprecedented levels but have to deliver more at the same cost and time levels. Engineering and testing needs to improve effectiveness and efficiency. 26

AVL EMISSION TESTING for a cleaner Environmental 27