AVL Jakarta Workshop - 3 - CO2 and Fuel - 2016-09-07a

Daniel Baumann, IT
CO2 & FUEL CONSUMPTION - HYBRID & EV

07.09.2016, Jakarta, Indonesia
Engeljehringer Kurt
AVL List GmbH

Public
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AVL List GmbH, Kurt Engeljehringer
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Engeljehringer Kurt | Emission Test Systems | 07 April 2015 |
CONTENT
Introduction
CO2 / GHG regulations

Gap between Lab testing and real life
Hybrid testing requirements
AVL Test bed solutions
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WE DONT HAVE A PLANET B
Limited Resources of:

We have only one planet
Air volume - 60% of the air is below the summit of mount Everest
Fossil energy
1960
1960:
3 Billion people
200 Million vehicles
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2015
2015:
7 Billion people
1.100 Million vehicles
CO2 AND CLIMATE CHANGE
Al Gore showing the

correlation between CO2
and temperature and is
using a lift do
demonstrate how much
higher CO2 is today.
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ENVIRONMENT and RESOURCES

SUSTAINABILITY and RESPONSIBILITY
CO2 is a global problem

We all are affected. But often
countries much more, which are not
the big emitters.
CO2 emitted per country:

1. China
2. USA
3. India
4. Russia
Climatic change is real.

it is not anymore about avoiding it,
about to limit its effects and to learn
to life with it.
It is men made.
CO2 emitted per person:

1. USA
2. Canada
3. Australia
4. Middle East
97% of all scientific studies say, there

is climatic change and it is men
made. There are only 3% Deniers
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ENVIRONMENT and RESOURCES

SUSTAINABILITY and RESPONSIBILITY
CO2 scenarios for worldwide transport

vs. GHG target as tank to wheel (ttw)
emissions.
The forecast scenarios for the increase

of GHG emissions by the transportation
segment to not match at all the CO2
targets. Even by estimating a large share
of electric passenger cars.
Much more will be needed than fuel
consumption reduction and electrification
of passenger cars.
CO2 neutral fuels (PtG, PtL, Bio fuels
but only generation-2, ...) for
airplanes, ships, trains
reduction of transportation by more
local production (US and EU has
heavily localized production in Asia
and by that exported CO2 emissions
and increased transportation
...
Source: Dr.-Ing. Rolf Leonhard, Robert Bosch GmbH at AVL Exhaust and Particulate Forum,
Ludwigsburg, 2016
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CONTENT
Introduction

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CO2 AND GREEN HOUSE GAS EMISSIONS

[1]
China: gasoline vehicles only. More

stringent targets after consideration of
new energy vehicles awaited.
[2] US: NHTSA fuel economy
standards.
[3] Brazil: all data converted to gasoline
(E00) equivalent.
[4] EU: 95% of the manufacturers fleet
must meet 95 g CO2/km in 2020, 100%
in 2021
EU 2025: 68-78*
EP
*Proposed env.
committee EP
April 2013
Source: ICCT, 12/2014, The state of clean transport policy: A 2014 synthesis of vehicle and fuel policy developments / AVL
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Kurt Engeljehringer | Emission Test Systems | 31 August 2016 |
CO2 LEGISLATION
Application:
Country
Topic
2012
2013
2014
2015
2016
GHG
GHG (2012-2016) 263 -> 225 gCO2/mi
CAFE
Corporate Average Fuel Economy
Fuel
economy
Fuel Consumption Stage-II
Fuel
economy
Fuel Economy Targets
Fuel
economy or
GHG
17 km/l or 140 g GHG/km
Fuel
consumptio
n
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2018
2019
2020
2021
130 g/km CO2
CO2
CO2
2017
2022
2023
2024
95 g/km CO2
2025 Notes
67-78
Meet or Pay
130 and 95g/km targets
based on NEDC
Must meet
GHG (2017-2025) 212 -> 143 gCO2/mi
Meet or Pay
6.9 l/100km (161 gCO2/km)
Fuel Economy Targets 2015
Fuel Consumption 5l/100km (117 gCO2/km)
Fuel Economy Targets 2020
24.3 km/l or 97 g GHG/km
Average fuel consumption
km/l related to vehicle weight
Fleet average
135g CO2/km
LCGC (Low Cost Green Car) scheme
Government program to push

for the fuel consumption
reduction
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EU CO2 TARGETS
Specific emissions target per OEM
Each manufacturer has its individual annual CO2 target.
That is calculated on the basis of the average vehicle mass of
the manufacturer's fleet and a reference mass, which is
defined on base of the average vehicle mass of the whole EU
fleet.
Niche-Derogations for OEMs selling 10.000 to 300.000 cars
and Derogations for OEMs selling less than 10.000 cars per
year
Credits
Incentives for vehicles with less than 50g/km, by counting it

such a car as 3,5 cars in 2013 and 1,5 in 2015
E85 credits (5% less CO2), for such cars in countries where
at least 30% of the fuel stations offer E85 (only Sweden)
Eco-Innovationen
Innovative technologies, which can not show the CO2
reduction in the type-approval test procedure, like LED lights,
can reduce up to 7gCO2/km if agreed by the authorities.
A manufacturer selling 1 Mil. cars per year

and failing his CO2 target by 1g/km, pays :
95 Mil. per year

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USA: GREEN HOUSE GAS (GHG) EMISSIONS

USA has since 1975 the CAFE (Corporate Average Fuel Efficiency) standard.
which continues to be valid, even after introduction of the GHG standards.

Manufacturer may meet the standard or have to pay a fee.
Test are done with the EPA 2-cycle test (FTP-75 + HWFET)
USA implemented a Green House Gas (GHG) standard
US Supreme court decided that also CO2 is a pollutant under the Clean Air Act.
GHG (Green House Gases) are CO2, CH4 (50 times more GHG potential than
CO2) and N2O (280 times more GHG potential)
Standards must be meet
It is unlikely that EU will also include CH4 and N2O, since EU emission
inventories show that CH4 and NO2 contribution is only 1% GHG emissions
(already as CO2 equivalent, N2O factor 280 and 50 for CH4 already
included).
Diagram: German GHG emissions of road transportation CO2, N2O and
CH4 in Mio t CO2 equivalent. Source: UBA
US labeling information for car buyers
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USA: FUELECONOMY.GOV
The average
US Car
The average
European Car
Plug-In Hybrids
A pure electric
vehicle
Tailpipe GHG emissions:

393 g/mi
246 g/km
286 g/mi
179 g/km
81 g/mi
51 g/km
133 g/mi
83 g/km
0 g/mi
0 g/km
Total GHG emissions:

473 g/mi
296 g/km
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364 g/mi
228 g/km
300 g/mi
188 g/km
240 g/mi
150 g/km
250 g/mi
156 g/km
includes tailpipe- and emissions for

production and distribution of fuel and
electricity. Based on Pylmouth, Michigan
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CONTENT
Introduction

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GAP BETWEEN LAB AND REAL LIFE

Gap between Norm- and real life CO2 emissions over time.
Source:
The impact of the drive cycle is typically over estimated
ICCT International Council on Clean Transportation 2014
CO2 (Fuel consumption) Correlation NEDC versus WLTC

Drive cycle impact:
10 typical diesel and 10 typical gasoline vehicles

driven in the WLTC and NEDC with the same test
procedures did not show difference in the CO2
emissions.
+/- 2%
Test procedure impact:
Driving these vehicle by using the UN-ECE-83 test

procedures and in the GTR-15 (WLTP) test procedures
results in
20-25% higher CO2 emissions in the GTR-15

procedures
no change in test procedure and drive cycle
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MOTIVATION OF NEW EU LEGISLATION?

Measures:
Targets:
RDE
Close the gap between lab and real

life pollutant emission limits
PEMS testing
Euro-6
Limits
130 95
gCO2 / km
GTR-15
Technical Regulation
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Today pollutant emissions are in average app. 7 times

(Diesel NOx) higher on the road than in the lab.
Further reducing NOx and PN

emissions
Further reducing CO2 and fuel

consumption targets
Close the gap between norm and

real life CO2 and fuel consumption
Today CO2 emissions and fuel consumption are in

average app. 40% higher on the road than the declared
norm values.
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CONTENT
Introduction

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HYBRID AND EV VEHICLES

When talking about Hybrid vehicles there are various names used. Especially between technology naming and names used in the emission regulations
are quite different. As example Plug-In is used to describe the technology, while the EU regulation calls it an Off Vehicle Charging (OVC) hybrid.
functional matrix below may help.
Hybrid related naming's

Technology
name
Micro - Hybrid
Mild - Hybrid
Full - Hybrid
Plug-In - Hybrid
Range Extender
Pure Electric
Vehicle
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EU related emission
regulation naming
US related emission
regulation naming
Electrification Functionality
Engine
Start/Stop
E-Boost
Systems
Regenerati
ve braking
Drive with
E-Motor
only
External
Battery
charging
Pure
electric
driving
Electric
driving
only
Conventional vehicle for Conventional vehicle for

emission standards and emission standards and
not a hybrid.
not a hybrid.
NOVC Hybrid
Hybrid electric vehicle
Not off vehicle charging
OVC Hybrid
Off vehicle charging
Plug-In Hybrid,
Grid connected electric
vehicle
BEV Battery Electrical

Vehicle
Grid connected electric

vehicle
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FULL HYBRID (NOVC)

Technology
name
Full - Hybrid
EU related emission
regulation naming
US related emission
regulation naming
Engine
Start/Stop
E-Boost
Systems
Regenerati
ve braking
Drive with
E-Motor
only
External
Battery
charging
Pure
electric
driving
Electric
driving
only
NOVC Hybrid
Hybrid electric vehicle
Not off vehicle charging
Emission
Analysis
Fuel
consumption
SOC
Power
Analyzer
Ampere
Meter
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Change in
state of charge
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PLUG-IN FULL HYBRID (OVC)

Technology
name
Plug-In - Hybrid
EU related emission
regulation naming
US related emission
regulation naming
OVC Hybrid
Off vehicle charging
Plug-In Hybrid,
Grid connected EV
Result A
CHARGE DEPLETING
Engine
Start/Stop
E-Boost
Systems
Regenerati
ve braking
Result B
CHARGE SUSTAINING
Drive with
E-Motor
only
External
Battery
charging
Pure
electric
driving
Electric
driving
only
Weighted Result
OVC - PHEV- Measurements :
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RANGE - Electric range / OVC range

ELECTRICITY - Power consumed from main to reach this range.
FUEL CONSUMPTION Charge DEPLETING and Charge SUSTAINING
POLLUTANTS EMISSIONS must be within the limits on each test cycle
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PHEV HYBRID WORKFLOWS TIME

16:00
18:00
20:00
22:00
18:00
20:00
22:00
14:00
12:00
10:00
08:00
06:00
22:00
20:00
18:00
Day 5
16:00
14:00
12:00
10:00
08:00
06:00
22:00
20:00
18:00
Day 4
16:00
14:00
12:00
10:00
08:00
06:00
22:00
20:00
18:00
Day 3
16:00
14:00
12:00
10:00
08:00
06:00
18:00
20:00
22:00
16:00
14:00
hours
1
12
5
5
1
0.5
12
5.5
12
1
12
1
5
1
5
3.3 Days
Day 2
16:00
Discharge
Soak 6-36h & charge
x-NEDC (Dovc)
charge
Discharge
Precon
Soak 6-36h
x-NEDC (Emissions)
Soak 6-36h charge
Discharge
Soak 6-36h
NEDC 1 Ph
Charge
Discharge
Charge
Minimum
12:00
Day 1
app. 1 week to get 1 result
Discharge
Soak 6h
2 x UDDS
Soak 12-36h charge
x-UDDS
Soak 12-36h
2 x UDDS
Soak 12-36h charge
x-HFET
charge
Discharge
Soak 12-36h
1 + 3 HFEDS
1+1 US06
1+1 SC03
Minimum
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14:00
12:00
10:00
08:00
06:00
22:00
20:00
18:00
Day 5
16:00
14:00
12:00
10:00
08:00
06:00
22:00
20:00
18:00
Day 4
16:00
14:00
12:00
10:00
08:00
06:00
22:00
20:00
18:00
Day 3
16:00
14:00
12:00
10:00
08:00
06:00
18:00
20:00
22:00
Day 2
16:00
hours
1
6
1.5
12
5
12
1.5
12
3
5
1
12
2
1
1
3.2 Days
14:00
Day 1
12:00
US
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SOAK AREA PLUG-IN HYBRID VEHICLES

For Plug-In Hybrid vehicles (OVC) the hybrid batteries will be
charged and discharged during soak times.
Soak
Soak
That requires to:

measure SOC and
Energy flow
record data
link the data to the test
vehicle data base
integrate this data in the
final emission test report
of the vehicle
do it for more than one
vehicle in parallel
Charge
Soak
Soak
Charge
Charge
Discharge
Soak
AVL iGEM Charge Meter

Example: EPA / CARB SAE J1711 Workflow
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CONTENT
Introduction

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AVL EMISSION PRODUCT PORTFOLIO

AVL has the largest and most complete emission testing and
measurement product portfolio on the market.
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Kurt Engeljehringer | Emission Test Systems | 18 Februar 2016 |
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AVL iGeneration Emission Test Systems

AVL has launched a totally new innovative and intuitive emission
measurement system generation, covering all standard emission systems.
Hardware Platform
Performance:
Highest possible accuracy and repeatability
Compliant with all current and future legislations (by current drafts)
Highest availability
Benefits:
Identical HW architecture
Same components wherever possible
Common spare part stock
Common maintenance procedures
Less training effort
Lowest total cost of ownership
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Software Platform
iGEM FT
Performance:
Intuitive operation
Best integration and interfacing
iGEM PSS
Aligned upgrades, like for new legislations

Benefits:
iGEM CVS
Easier operation
Less operator mistakes
iGEM AMA
High automated procedures and functions

Integration of several GUIs on one operator monitor
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Calibration devices and Accessories

iGEM FT
Performance:
All required calibration validation devices needed for emission testing
Fully automated operation
iGEM PSS
Benefits:
One device can be used for different measurement systems
iGEM CVS
Fully integrated with systems for automated procedures for efficient

workflow and highest accuracy and repeatability
tailored also for the challenges of new engine concepts
iGEM AMA
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AVL Emission Automation Systems

AVL iGEM Vehicle
Features:
Fully automated operation of test bed and all systems
All legislations implemented, for a vehicle- and fuels-types
One man operation possible
All required test, calibration and validation functions
One platform from engine, powertrain and vehicle testing

Test bed automation system of the US-EPA, TV Hessen, ...
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BASIC EMISSION TESTING SOLUTION

Basic Solution
Basic cost efficient solution
Mainly for certification and certification
type of development
Including NOVC hybrid vehicles
Fulfilling all legislation requirements
The most important Topics

Easily upgradable
Gasoline/Diesel
Low Emission capable
Particulate mass and particle number
measurement for all vehicles
4 sample phases for WLTC
LV & HV battery SOC measurement
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HYBRID TESTING - CERTIFICATION

Hybrid Basic Solution
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Engine Start/Stop Detection

Current Clamp and analyzer
CVS valve matrix for repeating cycles
Automation system with hybrid
functionality
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HYBRID TESTING - ADVANCED

Hybrid Basic Solution
Engine Start/Stop Detection

Current Clamp and analyzer
CVS valve matrix for repeating cycles
Automation system with hybrid
functionality
Hybrid Advanced Solution Add Ons
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Heated CVS system configuration

Tail pipe pressure control
Dilution air flow sensor
Power Analyzer
Pre- and Post Cat emission bench
2nd Chassis Roller 4WD
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AVL - CHASSIS DYNO - SOLUTION

Maximized availability of test cell (Efficiency)
Fastest test cell and pre-test and post-test device preparation

Minimized maintenance downtime
One man test operation capability
Parallelized/Unmanned maintenance and quality assurance test
Customer example: 3 shift, 6 days a week, 6 testcells 32,000 valid
tests per year
Future-proof solution
future powertrain concepts considered

Modularity and upgradability, prepared for future needs
Compliant to current and future regulations (up to app. 2025)
Tailored to customer needs
Pre-engineered solution - 3D layout

Modularity
Optimized for customer needs and existing customer facility
fast adaptation to development needs and technology changes
Hybrid Testing
All types of Hybrid- and EV vehicle testing
Unique RDE tool chain (RDE ready)
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Road2Lab and Lab2Road functionality (aligned with PEMS AVL M.O.V.E)

Simulation (InMotion) integration
45
AVL EMISSION Test Systems
Mastering Emissions

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Daniel Baumann, IT

CO2 & FUEL CONSUMPTION - HYBRID & EV

AVL List GmbH

Engeljehringer Kurt | Emission Test Systems | 07 April 2015 |

CO2 / GHG regulations

Engeljehringer Kurt | Emission Test Systems | 07 April 2015 |

WE DONT HAVE A PLANET B

Limited Resources of:

Engeljehringer Kurt | Emission Test Systems | 07 April 2015 |

CO2 AND CLIMATE CHANGE

Al Gore showing the

Engeljehringer Kurt | Emission Test Systems | 07 April 2015 |

ENVIRONMENT and RESOURCES

CO2 is a global problem

CO2 emitted per country:

Climatic change is real.

CO2 emitted per person:

97% of all scientific studies say, there

Engeljehringer Kurt | Emission Test Systems | 07 April 2015 |

ENVIRONMENT and RESOURCES

CO2 scenarios for worldwide transport

The forecast scenarios for the increase

Engeljehringer Kurt | Emission Test Systems | 07 April 2015 |

CO2 / GHG regulations

Engeljehringer Kurt | Emission Test Systems | 07 April 2015 |

CO2 AND GREEN HOUSE GAS EMISSIONS

China: gasoline vehicles only. More

Kurt Engeljehringer | Emission Test Systems | 31 August 2016 |

GHG (2012-2016) 263 -> 225 gCO2/mi

Corporate Average Fuel Economy

Fuel Consumption Stage-II

Fuel Economy Targets

17 km/l or 140 g GHG/km

130 g/km CO2

GHG (2017-2025) 212 -> 143 gCO2/mi

6.9 l/100km (161 gCO2/km)

Fuel Economy Targets 2015

Fuel Consumption 5l/100km (117 gCO2/km)

Fuel Economy Targets 2020

24.3 km/l or 97 g GHG/km

Average fuel consumption

km/l related to vehicle weight

LCGC (Low Cost Green Car) scheme

Government program to push

Kurt Engeljehringer | Emission Test Systems | 31 August 2016 |

Incentives for vehicles with less than 50g/km, by counting it

A manufacturer selling 1 Mil. cars per year

95 Mil. per year

Kurt Engeljehringer | Emission Test Systems | 31 August 2016 |

USA: GREEN HOUSE GAS (GHG) EMISSIONS

which continues to be valid, even after introduction of the GHG standards.

USA implemented a Green House Gas (GHG) standard

US labeling information for car buyers

Kurt Engeljehringer | Emission Test Systems | 31 August 2016 |

Tailpipe GHG emissions:

Total GHG emissions:

includes tailpipe- and emissions for

Kurt Engeljehringer | Emission Test Systems | 31 August 2016 |

CO2 / GHG regulations

Kurt Engeljehringer | Emission Test Systems | 31 August 2016 |

GAP BETWEEN LAB AND REAL LIFE

The impact of the drive cycle is typically over estimated

ICCT International Council on Clean Transportation 2014

CO2 (Fuel consumption) Correlation NEDC versus WLTC