Daniel Baumann, IT

RDE IMPACT IN TESTING AND DEVELOPMENT

07.09.2016, Jakarta, Indonesia

Engeljehringer Kurt
AVL List GmbH
Public
 NOTE:

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AVL List GmbH, Kurt Engeljehringer

Public Engeljehringer Kurt | Emission Test Systems | 07 April 2015 | 2

CONTENT

Intro (Air Pollutions, Emissions and CO2)

Market and Market Drivers

Emission Legislation

Technical Regulations

RDE, VW, ...

...

Public Engeljehringer Kurt | Emission Test Systems | 07 April 2015 | 3

 WORKFLOW – CHANGES R-83 TO GTR-15
up to EU-6b based on R-83
Preconditioning run (CI/PI) Soak Time Emission Test
140 140

120 120 140

100 100
Speed [km/h]

Speed [km/h]

80 80
120

Vehicle
60

40
60

40
100 NEDC

Speed [km/h]
6 ... 36h
20 20

0 0
0 200 400
0 200
600 400
800 600
1000 800
1200 1000 1200 80
time [se c] time [se c]

140
Road Load 140 140
140
60

40

Determination
120 120 120
120

100 100 100

100
Speed [km/h]

Speed [km/h]

Speed [km/h]
Speed [km/h]

80 80 80 80
20
60 60 60 60

40 40 40 40 0
20 20 20 20
0 200 400 600 800 1000 1200
0 0 0 0
0 200 400
0 200
600 0 400
800
0 200
600
200
1000 400
800
1200
400 600
1000
600 800
1200
800 1000
1000 1200
1200
time [sec]
time [se c] time [se c] time
time
[se[s
c]e c]

Prepare
Sample Sample
Phase 1 Phase 2

Analyze Phase 1 Analyze Phase 2

Ambient Bag
Ambient Bag

Exhaust Bag
Exhaust Bag

Span Check
Span Check

Zero Check

Zero Check
Zero Check

Zero Check

Span Set
Span Set

Zero Set
Zero Set

Sniff
Sniff
Per vehicle family: Determine the road load parameter for the representative vehicle and adjust chassis dyno simulation, run the precondition cycles (different for gasoline
and diesel), soak to stabilize temperature, run the NEDC emission cycle, sample exhaust and analyze emissions. If the emission result isn’t 30% below the limit, a 2nd or 3rd
test will be required.

EU-6d based on GTR-15 + RDE

Preconditioning run L Preconditioning run H Soak Time Emission Test Emission Test RDE Test
Determination Low Vehicle High Vehicle
of car option
influences
Road Load
Determination
Road Load
Determination
6 ... 36h

m
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B
B

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Bag 2 Bag 2

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Bag 3 Bag 3

m
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Bag 4 Bag 4

Per vehicle family: Define two vehicles, L with the lowest CO2 emissions and H with the highest CO2 emissions. Determine the road load parameters and adjust chassis dyno
simulation for both vehicles, run the precondition cycles (same for gasoline and diesel), soak to stabilize temperature, run the WLTC emission cycle, sample exhaust and
analyze emissions, for both vehicles. Bag analyze sequence in GTR-15 can be shorter than for R-83. in addition: If the emission result isn’t 10% below the limit, a 2nd or 3rd
test will be required. CO2 emission are still based on NEDC cycle. The manufacturer can decide to calculate it (CO2MPAS tool) or to run additional NEDC cycles. For EU CO2
emission also must be verified at 14°C. For each RDE test also one WLTC test must be performed on the Chassis dyno to validate the PEMS measurement

Public Engeljehringer Kurt | Emission Test Systems | 07 April 2015 | 4

RDE: REAL DRIVING EMISSIONS
Real Driving Emissions
• Emission testing under normal conditions of use in real world driving.
• Portable Emission Measurement System (PEMS)
• CO2, CO, NOx and PN
• Exhaust flow rate, Speed and GPS data.
RDE Test
• 90 to 120 min test time
• 34% City (<60km/h)
• 33% rural (60 ... 90km/h)
• 33% Highway (>90km/h)
• 145km/h max speed (extended range up to 160km/h)
• Realistic vehicle load and AC operated as under normal driving
• Cold start is measured, but not included in result calculation

Ambient conditions
• Temperature between 0°C to 30°C (extended range -7°C to 35°C)
• Altitude up to 700m (extended range up to 1300m)
• Humidity as it is, but no NOx humidity correction like in lab-tests

Limits and Result calculation

• Limits are based on the laboratory limits multiplied by the so called
„Conformity Factor CF“. CF for NOx phase in from 2.1 to 1.5 and CF for PN
under discussion
• 2 Complex result calculation options, EMROAD (JRC) or CLEAR (TU-Graz)
Public Kurt Engeljehringer | Emission Test Systems | 02 September 2016 | 5
 RDE DEVELOPMENT:

What is the key

element of RDE ?
Randomness

Make RDE reproducible

What is the base of
all development work ? Reproduction
Different Use Cases

Different user groups Defeat Devices

Authorities
have different targets Emission factors
Reproduction of road tests
...

Manufacturers Concept decisions

Front loading
Robustness evaluation of
calibration
...

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 6

RDE DEVELOPMENT: ANALOGY
Being in the hospital Going to the doctor Sick at home

Development Solving the problem Type Approval

Analyzing  Production andValidation
the problem COP  In-Use Conformity
Indicating  ...
a problem

All types of testbeds (Engine-, Powertrain-, Cassis Dyno testbeds) Chassis Dyno On the street

Laboratory Emission Systems

• Reproducibility of tests
• highest emission measurement accuracy
• Advanced emission testing systems, like Pre- and Post-Cat, FTIR Systems, ...
• Full automation and data handling systems, ...

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 7

 RDE USE CASES
UC-2: “Conventional Drive Cycles”

• Chassis Dyno
Type In Service Compliance
• Powertrain- and Approval (Verification, Benchmark)
• Engine testbed

Development Type Approval COP In-Service Compliance

Chassis Dyno RDE Chassis Dyno RDE

UC-3: Virtual Development

UC-1: Reproduction of individual RDE tests
• HIL Front Loading
• Chassis Dyno

• Traffic Simulation on • Powertrain- and

HIL or on test bed • Engine test bed

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 8

USE CASE 1: “REPRODUCTION UND ANALYSIS”

Euro-5 Diesel passenger car with DOC, SCR and DPF

α, v signal
These data were measured during preliminary tests of a new test
brake signal methodology under develop. It can not be expected that the here shown
good correlation, like 0,1% can always be achieved or guarantied. However
Automatic in several tests deviations were within 5%.

CO2 mass [g/s] CO2 mass

Road 178,1 g/km

Lab. 177,9 g/km
Deviation -0,1 %

NOx mass [g/s] NOx mass

Road 0,633 g/km
Lab. 0,692 g/km
Deviation +9,3 %

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 9

USE CASE 2: “CONVENTIONAL DRIVE CYCLES”
Conventional drive cycle testing but with RDE “Reference” cycles:
• The current development methodology , which is mostly based on standard reference
cycles, is extended by already known or newly developed “RDE Reference Cycles”.
• These include variations of velocity, road gradient, curve radius, ambient conditions, …

Drive Cycle based development:

• Beside the well known emission cycles, like WLTC, NEDC or FTP75 also other known
cycles will be used. Like
• Artimis (also known as CADC), which was used in the past mainly for emission
modeling and emission inventory estimations
• Standardized Random Test Sequence, like RTS95 ("aggressive”)
• Specific “RDE Reference cycles” which are generated by an OEM specifically for
its vehicle and customer “DNA”.
• Drive cycles generated by a “Random Cycle Generator”, like the one from TNO
• or specific drive cycle maneuver elements combined to a test sequence like a
“finite element approach”.

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 10

 USE CASE 2: EXAMPLE BMW
Source: RDE – First experiences with diesel powertrains, Brüne, BMW, 9th International Exhaust Gas and Particulate Emissions Forum, 2016, Ludwigsburg, Germany

Drive cycle versus Engine Map BMW RDE Route Chassis Cycle Development RDE Borderline Drive Cycle

• NEDC 1. Road data from 20 cars, 30 drivers, 25.000km in BMW Chassis Dyno RDE Drive cycle
• WLTC Europe • 45 min
• RTS-95 • 43 km
2. classified into over 10.000 short trip events
• (FTP-75) • max. 158 km/h
3. Creation of 300 drive cycles • avg. 59 km/h
• (Artemis)
4. Cycle selection by drive attributes and pre- • 1100m/100km altitude gain
selection by CO2 and NOx simulation
5. Validation on chassis dyno

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 11

USE CASE 3: VIRTUAL DEVELOPMENT
Virtual Integration and Front-Loading Calibration:
• Virtual simulation of random driving maneuvers with full variability of ambient conditions,
driver types, vehicle variants, connected powertrain, …
• Evaluation of powertrain and vehicle concepts, definition of solutions and engineering
targets, calibration in non standard ambient conditions
• Front loading of ECU calibration

Advanced Testbed:
• Advanced engine- powertrain- or chassis dyno test beds with “Real Driving” and vehicle
variants simulation capabilities.

Hardware in the Loop (HIL) Testbed:

• Only few hardware parts (ECU, injection nozzles, ...) and rest is simulated for full
variability of ambient conditions, driver types, vehicle variants, powertrain, …
• Same AVL user interface and functionalities as AVL conventional test beds
Pure software simulation:
• Virtual simulation of random driving maneuvers with full variability of ambient conditions,
driver types, vehicle variants, connected powertrain, …

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 12

TOOL CHAIN VIDEO: ROAD 2 LABOR

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 13

 ROAD 2 LABOR
SEMA Specialty Equipment Market Association Test of “Road 2 Lab”
Tests:
1. Validation of PEMS versus laboratory emission
measurement system
2. Road test with PEMS
3. Chassis dyno tests with PEMS und Lab-Emission system

SEMA Garage, California, USA
Boundary conditions:
• Modern chassis dyno, but not especially configured for RDE
• PEMS with RDE-Export and Automation with RDE-Import
PEMS Validation with CVS • Test were done to present the “Tool-Chain”, only. No activities
were done to improve simulation or result quality.
• „Snap-Shoot“ results and „Work would start now“

Systems:
• Vehicle: Ford Mustang, Gasoline 6Cyl EcoBoost
• Chassis Dyno: 48“ Einachs Rolle AVL Zöllner
• PEMS: AVL M.O.V.E iS
• Emission test systems: AVL CVS i60, AMA i60, PSS i60
• Automation AVL iGEM Vehicle

Road-Test Laboratory-Test
Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 14
 RDE: LAB2ROAD
AMA + PSS + APC + CVS Automation PEMS Chassis Dyno PEMS Validation
1 D NP

.S.M.A.D
Correlations requirements (10 March 2016):
• CO2 +/- 10 g/km or +/- 10% of Lab-Result, what ever is larger
• NOx +/- 15 mg/km or +/- 15% of Lab-Result, what ever is larger
R ETN UO C EL C I TR A P L V A

• CO +/- 150 mg/km or +/- 15% of Lab-Result, what ever is larger

• THC +/- 15 mg/km or +/- 15% of Lab-Result, what ever is larger

Correlation Validation CO2 CO NOx FE

g/mi g/mi g/mi mpg
WLTC WLTP_20160311_08_TC1
PEMS Raw-Modal 307,2 0,0133 0,0196 28,
06i SV C LVA TEN IBA C GAB 06i LVA TEN IBA C GAB 06i LVA 06i SSP LVA 06i AMA LVA
Reference Lab System CVS-Bag 325,8 0,0061 0,0171 27,
PEMS versus Lab % -5,7% 118,1% 14,5% 2,7%

US06 US06_20160308_07_TC1
+/-10% +/-15% +/-15% +/-15% tbd PEMS Raw-Modal 333,4 0,2417 0,0498 26,1
Reference Lab System CVS-Bag 352,6 0,2503 0,0450 24,5
100% PEMS versus Lab % -5,4% -3,4% 10,8% 6,4%
Result (EU Limits) pass pass pass

CARB RDE route (section) RDE_1phase_20160311_10_TC1

PEMS Raw-Modal 530,2 0,3493 0,0424 16,4
Reference Lab System CVS-Bag 514,9 0,3847 0,0504 16,8
PEMS versus Lab % 3,0% -9,2% -15,9% -2,2%
CO2 NOx CO THC PN Result (EU Limits) pass pass pass
Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 16
ROAD 2 LAB

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 20

CORRELATION: ROAD-2-LAB
CVS + AMA + PSS + APC Automation PEMS Chassis Dyno Road

11
DNDPNP
.S.M.A.D .S.M.A.D

R ETN UO C EL C I TR A P L V A

R ETN UO C EL C I TR A P L V A

06i SV C LVA TEN IBA C GAB 06i LVA TEN IBA C GAB 06i LVA 06i SSP LVA 06i AMA LVA

06i SV C LVA TEN IBA C GAB 06i LVA TEN IBA C GAB 06i LVA 06i SSP LVA 06i AMA LVA

Rolle mit Rolle mit Strasse mit

CVS & Co PEMS PEMS

CO2 433 g/mi -1 % 428 g/mi +11 % 387 g/mi +12 %

NOx 0,147 g/mi -17 % 0,122 g/mi +9 % 0,112 g/mi +31 %

CO 0,152 g/mi +28 % 0,194 g/mi +24 % 0,156 g/mi -3 %

In-Lab Correlation PEMS to CVS-Bag Correlation Road to Lab Correlation with PEMS to PEMS Over all correlation

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 22

CORRELATION: ROAD-2-LAB

140
Speed
120

100

V_ACT [km/h]
80

60

40
RDE “Re-Run on” Chassis Dyno Road Test
20

40 -20

35

30 CO2 g/mi

mdot_CO2 DC [g/s]
Emission Emission Emission 25
measured measured measured
by CVS by PEMS by PEMS 20

15

10

0
0 500 1000 1500 2000 2500 3000 3500 4000
Time [s]

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 23

CORRELATION: ROAD-2-LAB
140

120

100

V_ACT [km/h]
80

60

40

20

40 -20

35

30

mdot_CO2 DC [g/s]
25

20

15

10

0
0 500 1000 1500 2000 2500 3000 3500 4000
Ti m e [s ]

140

120
RDE “Re-Run on” Chassis Dyno Road Test
100

V_ACT [km/h]
80

60

40

20

0
Emission Emission Emission 40 -20
measured measured measured
35
by CVS by PEMS by PEMS
30
mdot_CO2 DC [g/s] 25

20

15

10

0
100 200 300 400 500 600 700 800 900
Time [s]

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 24

LESSONS LEARNED
RDE Diving is more demanding than emission cycles
• 1/3 of energy consumed must be absorbed by the dyno
• 1/3 of energy consumed is in the exhaust as heat and pressure
• 1/3 of energy consumed is released as heat and needs do be cooled
• Test bed infrastructure like air-conditioning must be able to handle the additional heat.

Additional environmental simulation requirements

• Temperature and humidity
• Pressure for altitude simulation

Dyno and Driving Style

• Higher load, especially for high power heavy vehicles, will require larger dynos and cooling fan.
• Better vehicle restrain systems on chassis dynos, to hold the vehicle.
• Drivers aid location must enable longer driving times
• Simulating the individual road load and not only “norm” road loads, like for emission cycles.
• Different drive style on chassis dynos, since on the street you follow the traffic while in the lab you follow a
set curve. That often results in different pedal movements, even with the same driver.
• Drivers aid location must enable longer driving times

Emission test systems

• Larger exhaust gas flow rates and heat will need larger CVS flow rates.
• PEMS validation on Chassis Dyno has to be possible:
• Restrain systems and PEMS mounted at the same time
• Connection of PEMS outlet to CVS inlet
• Check influences of CVS tubing and de-pressure on PEMS flow meter
Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 25
 CONCLUSION
Legislations need to close the gap between Lab and Road:
• Technology moves much faster than legislation will
ever be able to move.
• Legislation must have an excellent overview about
up-coming technologies
• Must consider that vehicles get smarter and
smarter

RDE development is a tool chain over all test bed types:

• RDE means to except randomness in testing
Hardware Chassis • Development needs reproducibility
Dyno
in the Loop • “Lab2Road” and “Road2Lab” is a continuous loop
during vehicle development and validation
• Simulation needed for the unlimited number of
variations in RDE

RDE means moving forward ...

• to all time clean cars
• to modern development procedures and tools
• to a better air quality

Public Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 | 26

THANK YOU

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