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Exhaust emissions, fuel consumption and vehicle dynamics tests on chassis dynamometers

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On this site:

See more:

  • Testing CO₂ emissions, fuel consumption, and electricity consumption
  • Testing exhaust emissions, fuel consumption, and electricity consumption of hybrid cars
  • Testing the efficiency of TWC, DOC, NSC, and SCR catalytic converters, as well as DPF and GPF particulate filters
  • PEMS – testing emissions from light and heavy vehicles and off-road machinery
  • Type approval testing

Chassis dynamometers – presentation of infrastructure and equipment

We specialise in performing testing in the field of exhaust emission and fuel consumption, such as:

  • work on reducing emissions of harmful exhaust compounds,
  • emission tests according to EU (EURO 4/5/6), EPA/CARB US norms and Japanese norms,
  • emission tests at positive and sub-zero ambient temperatures,
  • conducting modal analysis of harmful concentrated and diluted exhaust compounds,
  • emission tests on vehicles powered by liquid fuels, gaseous fuels (LPG, CNG) and biofuels,
  • solid particle emission tests using the gravimetric method and measurements of particle number (PN), including quantification according to particle diameter,
  • efficiency testing and selection of exhaust gas aftertreatment systems: TWC, DOC, DPF, GPF, POC, LNT, SCR (and combinations thereof),
  • measurements of vehicles’ dynamic parameters on the chassis dyno,
  • fuel consumption and CO2 emission tests
  • motorcycle exhaust emission and performance tests,
  • tests of exhaust emissions from light- and heavy-duty vehicles (cars, vans and trucks) under real world conditions using portable emissions analysers (PEMS).

We have two laboratories equipped with modern, single-roller AVL chassis dynos. The first laboratory has a 2WD chassis dyno, located in a test cell with ambient temperature regulation ranging from +14°C to +30°C; the second laboratory features a 4WD chassis dyno, located in a WEISS climatic chamber, which allows test to be conducted at ambient temperatures from -35°C to +60°C.

Laboratory No. 1

Laboratorium emisji nr 1

Schematic diagram of laboratory No. 1, showing the 4WD AVL chassis dynamometer, the AVL sampling and dilution system, AVL analysers and particle number counter.

Equipment of Laboratory No. 1:

  • Exhaust emissions analysis system – AVL AMA i60 D1 LE
  • Exhaust emissions analysis system – AVL AMA i60 R2
  • Emissions sampling system – AVL CVS i60 LD LE
  • Particle matter sampling system – AVL PSS i60 SD
  • Solid particle counter – AVL 489 APC plus
  • Climatic chamber from +14°C to +30°C
  • Chassis dyno – AVL 2WD

Laboratory No. 2

Laboratorium emisji nr 2

Schematic diagram of laboratory No. 2, showing the WEISS climatic chamber, the 4WD AVL chassis dynamometer, the HORIBA sampling and dilution system, HORIBA analysers and HORIBA particle number counter.

Equipment of Laboratory 2 with climate chamber:

  • Exhaust emissions analysis system – HORIBA MEXA 7400 HTRLE
  • Exhaust emissions analysis system – HORIBA MEXA 7500 DEGR
  • Emissions sampling system – HORIBA CVS 7400 S
  • Particle matter sampling system – HORIBA DLS 7100 E
  • Solid particle counter – HORIBA MEXA-2000 SPCS
  • Climatic chamber – WEISS WK 643’/35-60/Ro, with temperature range from -35°C to +60°C
  • Chassis dyno – AVL 4WD

Exhaust emission measurements via the CVS method with sample bags

Measurement of gaseous and solid exhaust gas components at ambient temperatures from 20°C to 30°C over the NEDC, WLTC, FTP-75, US06, SC03, JC08, WMTC driving cycles, according to requirements within European, American and Japanese regulations.

Emission measurement and calculation for: CO, CO2, NO, NOx, THC, CH4, NMHC, PM, PN

WLTC, NEDC

Regulations:

  • UNECE Global Technical Regulation (GTR) No. 15
  • UNECE Regulation No 83 and EC 715/2007 – EC 692/2008 Regulations
  • USA EPA Regulation CFR Title 40 part 86
  • Japanese Regulation TRIAS (31-J042(2)-02, 31-J042(3)-02, Attachment 42 – Technical Standard)
  • Regulation (EU) No. 168/2013
  • UNECE Global Technical Regulation (GTR) No. 2
  • Regulation (EU) 2017/1151 as amended up to Reg. (EU) 2018/1832

Vehicle exhaust emission tests at temperatures from -35˚C to 60˚C

Measurements of exhaust emission via various methods (from sample bags, continuous measurments) over various drive cycles (NEDC, WLTC, FTP-75, HFET, US06, SC03, JC08, RDE or custom) in a climatic chamber with the following parameters:

  • temperature control ranging from -35°C to +60°C, with an accuracy of ±1,2°C during emission testing,
  • absolute humidity control during emission test ranging from 5,5 to 15,0 grams of water per 1 kg of dry air in the temperature range from +20°C to +35°C,
  • humidity variation ≤ 5%..

The purpose of such tests is evaluation of the influence of different environmental conditions on the level of exhaust emissions.

Modal analysis of diluted and undiluted exhaust

Continuous harmful gas exhaust component emission measurements at a frequency of 10 Hz over various drive cycles (NEDC, WLTC, FTP-75, HFET, US06, SC03, JC08, RDE simulation, or custom cycles).

Diluted exhaust measurement – 1 sampling point downstream of the vehicle.
Diluted exhaust concentration measurement: CO, CO2, NO, NOx, THC
Diluted exhaust emission calculations: CO, CO2, NO, NOx, THC

Undiluted exhaust measurement – any 2 sampling points, beginning with the engine exhaust manifold to a sampling point downstream of the vehicle.
Undiluted exhaust concentration measurement: CO, CO2, O2, NO, NOx, NO2, THC, CH4
Undiluted exhaust emission calculations: CO, CO2, O2, NO, NOx, NO2, THC, CH4

In the graph: Efficiency of the catalytic system (on the example of CO emissions) – based on the modal analysis of undiluted exhaust gas

Analiza modalna spalin rozcieńczonych i nierozcieńczonych

Continuous measurements of NH₃ concentrations and additionally N₂0, NO and NO₂

Dynamic measurement of NH₃ concentration (additionally N₂0, NO and NO₂) before and after SCR exhaust aftertreatment system
Measurement used in development tests, mainly in WLTC and RDE, for AdBlue injection management optimisation and efficiency improvement of SCR exhaust aftertreatment system.

Measurement ranges of HORIBA MEXA-ONE-QL-NX:

  • NH₃: low 0 – 50 ppm, high 0 – 2000 ppm
  • N₂0: low 0 – 100 ppm, high 0 – 2000 ppm
  • NO: low 0 – 100 ppm, high 0 – 5000 ppm
  • NO₂: low 0 – 50 ppm, high 0 – 2000 ppm

Measurement ranges of AVL AMA i60 LDD:

  • NH₃: 0 – 5000 ppm

Equipment

  • NH₃, N₂0, NO and NO₂ concentration measuring device HORIBA MEXA-ONE-QL-NX
  • NH₃ concentration measuring device AVL AMA i60 LDD
Pomiar ciągły stężenia NH₃ oraz dodatkowo N₂0, NO i NO₂

Solid particle number (PN) measurement

Measurements of the number of solid particles in exhaust are conducted on diluted or undilted exhaust. Solid particles of nominal diameter from 23 nm to 2,5 µm are measured.

Regulations

  • UNECE Global Technical Regulation (GTR) No. 15
  • UNECE Regulation No. 83
  • Regulation EC 715/2007 – EC 692/2008

Equipment

  • Solid particle counter – HORIBA MEXA-2000 SPCS
  • Solid particle counter – AVL 489 APC plus

Continuous measurements of solid particle distribution (number and size)

Solid particle distribution measurements – both in terms of the number and the size of solid particles emitted. Such measurements are conducted using a TSI EEPS 3090 spectrometer. The measurment allows a classification of the diameters of solid particles emitted from the engine under test. The device has the following measuring range: from 5,6 to 560 nm.
Such measurements permit observation of the dynamic evolution of solid particle emissions – during the first few seconds following cold engine start, during regeneration of a particle filter and over any driving cycle. The results of the measurement are used for optimisation of:

  • the combustion process in various types of combustion engine
  • exhaust aftertreatment systems
  • effectiveness of solid particle filters (DPF or GPF)
Spektrometr – TSI EEPS 3090

Equipment

  • TSI EEPS 3090 spectrometer

Continuous measurements of soot concentration

Measurement used in development tests for optimisation purposes:

  • Combustion process in various types of combustion engines – ECU calibration
  • exhaust aftertreatment systems
  • DPF filtration effectiveness
  • Accumulation, regeneration and regernation (burn out) of solid particle filters
  • Engine start-up phases

Equipment

  • Soot concentration measuring device – AVL Micro Soot Sensor 483

Exhaust gas opacity measurements

Exhaust gas opacity is a result of the presence of solid particles (mostly soot – black smoke), hydrocarbons (blue smoke) and water vapour (white smoke). At a soot content of 100-300 mg/m3 the exhaust gas opacity is noticeable. Black smoke appears at concentrations of approx. 500 mg/m3. An increase in exhaust gas opacity is usually accompanied by an increase in the emission of other harmful exhaust gas components (CO2, CO, HC, NOx).

Exhaust smoke opacity measurement is conducted by using an adsorption opacimeter, which makes use of phenomena relating to the absorption of visible radiation (light) passing through the gas.

Equipment

  • Absorption opacimeter – AVL Opacimeter 439
Pomiar zadymienia spalin - Dymomierz Absorpcyjny – AVL Opacimeter 439

Regulations

  • UNECE Regulation No. 24

Dynamic vehicle tests on 2WD and 4WD chassis dynos

Measurements of powertrain power and torque

Measurements of powertrain power and torque performed on a chassis dyno, on 1 or 2 axles. Measurements performed directly on the wheels, together with measurements of drive system losses, gives the final level of power and torque on the engine output shaft. Measurement range: 0 – 258 kW per axle.

The following measurements can be performed:

  • static – at a constant, set speed at one or multiple points, depending on requirements
  • dynamic – over the entire vehicle speed range/engine rotational speed range

The results of the measurements are characteristics:

  • intermediate – at a constant, set pressure on the accelerator pedal
  • external – at maximum pressure on the acceleration pedal, indicating the maximum performance of the powertrain over a given vehicle speed range/engine rotational speed range.

Road inclination simulation

AVL Zoellner 4WD/2WD chassis dynos allow simulation of road inclination during drive cycles and all other chassis dyno tests.

Measurements of vehicle dynamics

Measurement of vehicle dynamics, namely is acceleration time from 0 to 100 km/h (62 mph), acceleration time in a given gears, acceleration to the maximum speed of 250 km/h (150 mph).

Engine operation control optimisation

Engine operation control optimisation at constant speed or with the power supplied by the dyno.

Devices

  • Chassis dyno – AVL Zoellner 4WD
  • Chassis dyno – AVL Zoellner 2WD

Measurements of vehicle dynamics at temperatures from -35˚C to 60˚C

Equipment in the chassis dyno laboratory permits tests of vehicle dynamics at ambient temperatures from -35˚C to 60˚C to be carried out.
The aim of those tests is to evaluate the impact of these external factors on the power and torque of the powertrain and other parameters characterising the work dynamics of the engine.

Equipment

  • Climatic chamber – WEISS WK 643’/ -35°C to +60°C
  • Chassis dyno – AVL Zoellner 48” 4WD

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