Heavy Duty Engine Certification Requirements

Heavy Duty Engine Certification Workshop
Dr. Christoph R. Weidinger

20.05.2014
Contents 1/4
 Heavy duty engine emission certification in general

 Applicable regulations (ECE and EU)
 Engine net power measurement
 Engine exhaust smoke measurement
 Engine exhaust emission measurement
 Testing required for Euro 2 / Euro 3 / Euro 4 heavy duty engine emission
certification
 ECE R 85 net power measurement
 ECE R 24 exhaust smoke measurement
 ECE R 49 Revision 3 for emission level B (equal to Euro 2)
 ECE R 49 Revision 4 for row A emission level (equal to Euro 3)
 ECE R 49 Revision 4 for row B1 emission level (equal to Euro 4)
Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 2

ECE Regulations Required for Emission Certification

 ECE Regulation No. 85 Revision 1 (09.09.1990)
last amended by Amendment 5 (10.05.2010)
 “UNIFORM PROVISIONS CONCERNING THE APPROVAL OF INTERNAL
COMBUSTION ENGINES OR ELECTRIC DRIVE TRAINS INTENDED FOR THE
PROPULSION OF MOTOR VEHICLES OF CATEGORIES M AND N WITH
REGARD TO THE MEASUREMENT OF THE NET POWER AND THE
MAXIMUM 30 MINUTES POWER OF ELECTRIC DRIVE TRAINS”
 Results required
 Maximum net power and corresponding speed
 Maximum net torque and corresponding speed
 Shape of the maximum power curve
 basis for determination of test speeds and torques for the emission test
 Download of texts: http://www.unece.org/trans/main/welcwp29.htm


 “UNIFORM PROVISIONS CONCERNING:
I. THE APPROVAL OF COMPRESSION IGNITION (C.I.) ENGINES
WITH REGARD TO THE EMISSION OF VISIBLE POLLUTANTS
II. THE APPROVAL OF MOTOR VEHICLES WITH REGARD TO THE
INSTALLATION OF C.I. ENGINES OF AN APPROVED TYPE
III. THE APPROVAL OF MOTOR VEHICLES EQUIPPED WITH C.I.
ENGINES WITH REGARD TO THE EMISSION OF VISIBLE
POLLUTANTS BY THE ENGINE
IV. THE MEASUREMENT OF POWER OF C.I. ENGINE”
 Exhaust smoke during maximum power curve
 Exhaust smoke during free acceleration

 Engine exhaust emissions (emission level B - “Euro 2”)

obsolete since Revision4 was published
 “UNIFORM PROVISIONS CONCERNING THE APPROVAL OF
COMPRESSION-IGNITION (C.I.) AND NATURAL GAS (NG) ENGINES
AS WELL AS POSITIVE-IGNITION (P.I.) ENGINES FUELLED WITH
LIQUEFIED PETROLEUM GAS (LPG) AND VEHICLES EQUIPPED
WITH C.I. AND NG ENGINES AND P.I. ENGINES FUELLED WITH
LPG, WITH REGARD TO THE EMISSIONS OF POLLUTANTS BY THE
ENGINE”
 Bake specific CO, THC, NOx and PM during 13 Mode Test

 Engine exhaust emissions (row A & B1 - “Euro 3” & “Euro 4”)

 “UNIFORM PROVISIONS CONCERNING THE MEASURES TO BE TAKEN
AGAINST THE EMISSION OF GASEOUS AND PARTICULATE POLLUTANTS
FROM COMPRESSIONIGNITION ENGINES FOR USE IN VEHICLES, AND THE
EMISSION OF GASEOUS POLLUTANTS FROM POSITIVE-IGNITION
ENGINES FUELLED WITH NATURAL GAS OR LIQUEFIED PETROLEUM GAS
FOR USE IN VEHICLES”
 Bake specific CO, THC, NOx and PM during ESC Test
(add. NOx-Check at 3 random points within control area)
 Exhaust Smoke during ELR-Test
(add. 1 random point within control area)
 Bake specific CO, THC, NOx and PM during ETC Test
(eventually only brake specific NOx)

EU Regulations Required for Emission Certification

 80/1269/EEC (16.12.1980)
last amended by 1999/99/EC (15.12.1999)
obsolete by 31.12.2013 (see Regulation (EC) No. 595/2009)
 “Council Directive 80/1269/EEC of 16 December 1980 on the
approximation of the laws of the Member States relating to the engine
power of motor vehicles”
 Maximum net power and corresponding speed
 Maximum net torque and corresponding speed
 Shape of the maximum power curve
 basis for determination of test speeds and torques for the emission
test
 Download of texts: http://eur-lex.europa.eu/en/index.htm


 72/306/EEC (16.12.1980)
 “Council Directive of 2 August 1972 on the approximation of the laws of
the Member States relating to the measures to be taken against the
emission of pollutants from diesel engines for use in vehicles”
 Exhaust smoke during maximum power curve
 Exhaust smoke during free acceleration

 Engine exhaust emissions (emission level B - “Euro 2”)

 88/77/EEC (03.12.1987)
obsolete since 1999/96/EC has been published
 “Council Directive 88/77/EEC of 3 December 1987 on the approximation
of the laws of the Member States relating to the measures to be taken
against the emission of gaseous pollutants from diesel engines for use in
vehicles”
 Bake specific CO, THC, NOx and PM during 13 Mode Test

 Engine exhaust emissions ( “Euro 3” & “Euro 4”)

 88/77/EEC (03.12.1987) as amended by 1999/96/EC (16.02.2000)
repealed by 2005/55/EC (28.09.2005)
repealed by Regulation (EC) No. 595/2009 (18.06.2009) (“Euro VI”)
last amended by 2nd Correction (31.07.2009)
 “DIRECTIVE 2005/55/EC OF THE EUROPEAN PARLIAMENT AND OF THE
COUNCIL of 28 September 2005 on the approximation of the laws of the Member
States relating to the measures to be taken against the emission of gaseous and
particulate pollutants from compression-ignition engines for use in vehicles, and
the emission of gaseous pollutants from positive-ignition engines fuelled with
natural gas or liquefied petroleum gas for use in vehicles”
 Bake specific CO, THC, NOx and PM during ESC Test
(add. NOx-Check at 3 random points within control area)
 Exhaust Smoke during ELR-Test
(add. 1 random point within control area)
 Bake specific CO, THC, NOx and PM during ETC Test
(eventually only brake specific NOx)

Net Power Measurement acc. to ECE R 85
Basic Requirements
 Steady state engine testcell with

 appropriate sensors
 proper conditioning
 Production engine with vehicle specific intake and exhaust system
 Auxiliary devices fitted according to net power definitions
 Intake air conditions within limits
 Calculation of net power
 Proper reference fuel

Sensors and Their Required Accuracy
Quantity Accuracy Remark
Engine speed ± 0.5% pt
± 1% pt Larger tolerance applies in lower half of

Engine torque
(± 2% pt) measuring range
max. 15 cm upstream engine inlet (air

Intake air temperature ±2K
cleaner)
Fuel consumption ± 1% pt
Coolant temperature Not specified Temperature specified by the manufacturer
Oil temperature Not specified Temperature specified by the manufacturer
Fuel temperature Not specified Temperature specified by the manufacturer
Barometric Pressure ± 100 Pa
Pressure in intake duct ± 50 Pa
Pressure in exhaust duct ± 200 Pa

Ambient Conditions
 Reference conditions
 Reference Temperature T0: 298 K
 Reference dry pressure pS0: 99 kPa
 Limitations
 Intake air temperature (PI Engines): 288 K ≤ T ≤ 308 K
 Intake air temperature (CI Engines): 283 K ≤ T ≤ 313 K
 Dry intake air pressure: 80 kPa ≤ pS ≤ 110 kPa

Engine Description

Auxiliary Equipment

Power Correction Methodology
 Measured power

Pmeasured   nmeasured  Md measured
30000
 Auxiliary correction
PAuxiliaries  Pmissing  Pfitted
 Measured net power
Pmeasured ,net  Pmeasured  PAuxiliaries
 Corrected net power

Pcorrected ,net  f PowerCorrection  Pmeasured ,net

Power Correction Factor
 PI engines 1.2
 99   T 
0.6
f PowerCorrection      
 s
p  298 
 CI engines
f PowerCorrection  f a
fm
q
f m  0.036   1.14
r
 CI engines (NA & SC)
 99   T 
0.7
f a      
 s
p  298 
 CI engines (TC & TCI)

0.7
 99   T 
1.5
f a      
 s
p  298 

1,2

Power Correction Factor Limitations
 PI engines
 Power correction factor: 0.93 ≤ fPowerCorrection ≤ 1.07
 CI engines

Net Power Measurement
 Measurement of stabilized condition

 Sufficient number of speed points incl. lowest speed, highest speed,
speed at maximum power and speed at maximum torque
 Speed, torque, temperature substantially constant 1 minute before start
of measurement
 Speed tolerance during measurement: ± 1 % or ± 10 1/min whichever is
greater
 2 averaged measurements, max. ± 2 % difference in torque
 Acceptance criteria
 Power deviation to declared maximum net power: max. ± 2 %
 Power deviation at all other loads: max. ± 4 %
 Speed deviation: max. ± 1.5 %

Exhaust Smoke Measurement acc. to ECE R 24
Basic Requirements

 Calculation of corrected value of absorption coefficient


Engine torque
Intake air temperature ±2K max. 15 cm upstream engine inlet
Fuel temperature ±2K Temperature specified by the manufacturer
Opacimeter ± 0.05 1/m 0.9 to 1.1 s total response time

Ambient Conditions
 Reference conditions
 Limitations
 Intake air temperature (PI Engines): 288 K ≤ T ≤ 308 K
 Intake air temperature (CI Engines): 283 K ≤ T ≤ 313 K
 Dry intake air pressure: 80 kPa ≤ pS ≤ 110 kPa

Engine Description

Auxiliary Equipment

Power Correction Methodology
 Measured power

Pmeasured   nmeasured  Md measured
30000
 Auxiliary correction
PAuxiliaries  Pmissing  Pfitted
 Measured net power
Pmeasured ,net  Pmeasured  PAuxiliaries
 Corrected net power

Pcorrected ,net  f PowerCorrection  Pmeasured ,net

 PI engines 1.2
 99   T 
0.6
 s
p  298 
 CI engines
f PowerCorrection  f a
fm
q
f m  0.036   1.14
r
 99   T 
0 .7
 s
p  298 

0.7
 99   T 
1.5
 s
p  298 


Power Correction Factor Limitations
 PI engines
 CI engines

Net Power Measurement

of measurement
greater
 Power deviation to declared maximum net power: max. ± 2 %
 Power deviation at all other loads: max. + 6 % / - 2 %
 Speed deviation: max. ± 1.5 %

Athmospheric Factor for Smoke Measurement

 99   T 
0.7
f a      
 s 
p 298 

0.7
 99   T 
1.5
f a      
 s 
p 298 
 CI engines
 Atmospheric factor: 0.98 ≤ fa ≤ 1.02

Steady State Smoke Measurement

of measurement
greater
 Light absorption coefficient below limit at all speeds
 Limit depends on nominal exhaust flow (tabulated)

Light Absorption Coefficient Limit

Free Acceleration Smoke Measurement
 Measurement during transient full load condition

 Engine must be in good mechanical condition
 On engine testcell: engine needs to be disconnected from engine dyno
 On engine testcell: add. inertia to be mounted on flywheel corresponding
to inertia of gearbox inlet shaft
 On vehicle: Gearbox in neutral, clutch closed
 Accelerator pedal operated quickly in order to get maximum fuel
injection
 Min. 6 accelerations, last 4 peak measurements within 0.25 1/m, no
decreasing sequence, average of last 4 peaks to be used during
calculation

Light Absorption Coefficient Limit

Exhaust Emission Measurement acc. to ECE R 49 Rev 3
Basic Requirements

 Calculation of brake specific gaseous exhaust and particulate emissions
 Particulate weighing equipment

Steady State Emission Measurement

 13 different load steps at idle, intermediate and rated speed
 Total mode time: 6 min
Maximum transition time: 1 min
Sampling time gaseous emissions: at least 3 min of the mode
Averaging time gaseous emissions: last 1 minute
Sampling time particulates: at least last 20 s
No timing tolerance defined.
 Weighted brake specific gaseous exhaust emission below limit (CO,
THC, NOx)
 Weighted brake specific particulate exhaust emission below limit


 Rated speed
 means the maximum full load speed allowed by the governor as
specified by the manufacturer in his sales and service literature, or,
 if such a governor is not present, the speed at which the maximum
power is obtained from the engine, as specified by the manufacturer in
his sales and service literature
 Intermediate speed
 means the speed corresponding to the maximum torque value if such
speed is within the range of 60 to 75 % of rated speed
 in other cases it means a speed equal to 60 % of rated speed
 Data source
 Full load curve according to ECE R 85.

Sensors and Their Required Accuracy (ECE R 85)

Engine torque
Intake air temperature (± 2 K) max. 15 cm upstream engine inlet
Fuel temperature ±2K Temperature specified by the manufacturer

Absolute Humidity ± 5% pt
Exhaust Gas
±5K
Temperature
Other Temperatures ± 1.5 K
Concentrations ± 2.5% pt for ranges <100pm: ± 3ppm
Microgram Balance ± 2% pt precision
Microgram Balance ± 2% readability based on recommended weight

Ambient Conditions
 Reference conditions for test conditions

 Reference conditions for NOx correction
 Reference temperature T0: 302 K
 Reference absolute humidity: 10.71 g/kg
 Reference conditions for volumes
 Reference dry pressure pS0: 101,315 kPa

Engine Description

Auxiliary Equipment

Exhaust Smoke Measurement acc. ECE R 49 Rev 3
Auxiliary Equipment and Dyno Setting

Engine Test Conditions
 PI engines (NA & SC) 1 .2

 99   T 
0.6
F      
 s
p  298 
 PI engines (TC & TCI) 0.65

 99 
0 .5
 T 
F     
 ps   298 
 99   T 
0.7
F      
 s
p  298 
0.7
 99   T 
1 .5
F      
 s
p  298 

Ambient Factor Limitations
 Ambient factor: 0.96 ≤ F ≤ 1.06

Result Calculation Methodology
 Exhaust massflow
Gexh  G Air  GFuel
 Pollutant mass flow
X Mass  K x  X conc  GExh
 Weighted Result
X
X MassFlow,i WFi
 (P  P
i Aux ,i ) WFi

Basic Requirements
 Transient engine testcell with

 Tests to be performed
 European Stationary Cycle – ESC
 European Load Response Test – ELR
 European Transient Test – ETC
 Calculation of brake specific gaseous exhaust, exhaust smoke value and particulate
emissions
 Particulate weighing equipment

ESC Test
 Measurement of semi-stabilized condition

 13 different load steps at idle, speed A, B, C
 Additional load steps within control area possible
 Multiple testruns for particulate sampling possible
 Total mode time: 2 min (idle 4 min)
Maximum transition time: 20 s
Averaging time gaseous emissions: last 30 s
Sampling time particulates: at least last 20 s, end must be within 5 s of
mode end
No timing tolerance defined.
THC, NOx)

ESC Test

ESC Test
 Test Speeds A, B, C
 Calculated based on low engine speed nLo (50% max. power speed) and
high engine speed nHi (70 % max. power speed)
 Data source
 Full load curve according to ECE R 85
 Declared values to be used if values based on measurements are within 3
%.

Engine speed ± 2% pt
± 3% pt
Engine torque FS tolerance applies for values ≤ 20% FS
(± 0.6% FS)
Temperatures ≤ 600 K ±2K
Temperatures ≥ 600 K ± 1 % pt
Fuel consumption ± 2% Of engine’s maximum fuel consumption
± 2% pt 1% of engine’s maximum air consumption,

Air consumption
(± 1% max.) whichever is greater
± 2.5% pt 1.5% of engine’s maximum air

Exhaust gas flow
(± 1.5% max.) consumption, whichever is greater
Relative humidity ±3% absolute
Absolute Humidity ± 5% pt

± 2% pt or
Concentrations Whichever is greater
± 0.3% FS
Opacimeter ± 0.01 1/m Readability
Flow
(diluted exhaust and ± 2 % pt 0.2% in case of partial flow systems
dilution air)
Microgram Balance 2 µg Precision, standard deviation
Microgram Balance 1 µg resolution

Ambient Conditions
 Reference conditions for test conditions

 Reference conditions for NOx correction (CI engines)
 Reference temperature T0: 298 K
 Reference absolute humidity: 10.71 g/kg
 Reference conditions for volumes
 Reference pressure pS0: 101,3 kPa

Engine Description

Auxiliary Equipment

Auxiliary Equipment and Dyno Setting

Engine Test Conditions
 PI engines 1 .2
 99   T 
0.6
F      
 s
p  298 

 99   T 
0.7
F      
 s
p  298 

0.7
 99   T 
1 .5
F      
 s
p  298 

Ambient Factor Limitations
 Ambient factor: 0.96 ≤ F ≤ 1.06

ESC Result Calculation Methodology
 Exhaust massflow
Gexh  G Air  GFuel
 Pollutant mass flow
X Mass  K x  X conc  GExh
 Weighted Result
X
X MassFlow,i WFi
 (P  P
i Aux ,i ) WFi

ELR Test
 Measurement of Exhaust Smoke during Load Steps

 3 different test speeds: speed A, B, C
 Load step from 10% load to 100% load
 1 additional speed steps and initial load within control area possible
 Total mode time: 30 s
Transition time: 20 s
Timing tolerances defined
 Weighted exhaust smoke value below limit

ELR Test

ELR Test
 Test Speeds A, B, C
 Low load torque:

 10% of maximum net torque
 Data source
 Full load curve according to ECE R 85
 Declared values to be used if values based on measurements are within 3
%.

ETC Test
 Measurement of exhaust emissions during transient engine operation

 Defined as normalized profile
 Denormalized based on full load curve
 Test length: 1800 s
 Speed / torque / power regression within tolerances
THC, NOx)

ETC Test

ETC Test
 Reference speed (100% speed)

 Data source: full load curve according to ECE R 85

 100% torque from dynamic full load curve
 Speed increase: 8 (1/min)/s

Regression Analysis
 Acceptance criterion for proper engine loading

 Best fit straight line for speed, torque and power
 Analysis to be done with 1 Hz data

Regression Analysis
 Permissible point deletions

ETC Measurement
 ETC measurement
 Starts when engine has reached idle
 Stop bag filling / particulate sampling immediately after completition of
the test
 Stop integrating analyzers after system response time has been elapsed
 Measurement methodology
 Raw Exhaust & Partial flow particulates
 Full flow diluted / bag measurement with double diluted particulate
measurement
 Integrated result (not time resolved measurement required)

Test Field Quality Standards
Equipment Calibration / Calibration Check Standards
 All equipment used for measurement must be

 Maintained according to equipment manual / manufacturers
recommendation
 Calibrated according to equipment manual / manufacturers
recommendation
 Calibration interval
 As defined by equipment manual / manufacturers recommendation
 As defined by the applicable regulation
 Whichever is the shorter interval

 Calibration interval definitions in regulations

 Calibrate during installation / major mainenance
 Fixed interval
 When installing a new engine on a testcell
 Before each test
 Two basic types of equipment
 Equipment can be checked / recalibrated as part of regular maintenance
 Equipment must be turned in for check / recalibration

 Equipment can be checked / recalibrated as part of regular maintenance

 Can be done on site
 BUT: Needs proper certified / documented reference equipment on site /
on contract
 Equipment must be turned in for check / recalibration
 Equipment must be shipped to an accredited calibration lab for the
specific type of equipment
 Either an equivalent spare part is available or
 Testcell is down for a prolonged period

 To do for every measurement chain used during measurement

 Document the measurement method
 Document the way of installation
 Document the way of calibration
 Document the reference devices required for calibration / calibration
check
 Define the calibration interval for the lab
 Define acceptance criteria for usage
 Setup a procedure to prevent outdated equipment to be used in
measurements
 Documentation should be part of quality system
 Equipment calibration is a necessary but not sufficient prerequisite to assure
correct measurement results

Reference Equipment Standards
 All reference equipment required for calibration / calibration check must

have
 A valid certificate of a traceable calibration at time of calibration
 Better accuracy than equipment to check
 Maintained in good condition between the intervall
 As defined by reference equipment manual / manufacturers
recommendation
 As defined by accredited calibration lab (written on the certificate)
 (As defined by the applicable regulation)

Reference Equipment Standards
 Fixed interval in most cases
 Recalibration required when malfunction is suspected / after
maintenance
 Equipment must be normally turned in for check / recalibration to an
accredited lab
 Scheduling of recalibration required (especially if this cannot be done
locally!)
 Seldom possible on site

Heavy Duty Engine Certification Requirements

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Heavy Duty Engine Certification Workshop

Dr. Christoph R. Weidinger

 Heavy duty engine emission certification in general

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 2

 Engine net power measurement

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 3

 Engine exhaust smoke measurement

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 4

 Engine exhaust emissions (emission level B - “Euro 2”)

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 5

 Engine exhaust emissions (row A & B1 - “Euro 3” & “Euro 4”)

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 6

 Engine net power measurement

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 7

 Engine exhaust smoke measurement

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 8

 Engine exhaust emissions (emission level B - “Euro 2”)

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 9

 Engine exhaust emissions ( “Euro 3” & “Euro 4”)

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 10

 Steady state engine testcell with

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 11

Quantity Accuracy Remark

Engine speed ± 0.5% pt

± 1% pt Larger tolerance applies in lower half of

max. 15 cm upstream engine inlet (air

Coolant temperature Not specified Temperature specified by the manufacturer

Oil temperature Not specified Temperature specified by the manufacturer

Fuel temperature Not specified Temperature specified by the manufacturer

Barometric Pressure ± 100 Pa

Pressure in intake duct ± 50 Pa

Pressure in exhaust duct ± 200 Pa

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 13

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 14

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 15

PAuxiliaries  Pmissing  Pfitted

 Measured net power

Pmeasured ,net  Pmeasured  PAuxiliaries

 Corrected net power

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 16

 CI engines (TC & TCI)

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 17

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 18

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 19

 Measurement of stabilized condition

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 20

 Steady state engine testcell with

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 21

Quantity Accuracy Remark

Engine speed ± 0.5% pt

± 1% pt Larger tolerance applies in lower half of

Intake air temperature ±2K max. 15 cm upstream engine inlet

Coolant temperature Not specified Temperature specified by the manufacturer

Oil temperature Not specified Temperature specified by the manufacturer

Fuel temperature ±2K Temperature specified by the manufacturer

Barometric Pressure ± 100 Pa

Pressure in intake duct ± 50 Pa

Pressure in exhaust duct ± 200 Pa

Opacimeter ± 0.05 1/m 0.9 to 1.1 s total response time

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 23

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 24

Dr. Chr. R. Weidinger, Heavy Duty Certification Workshop 25

PAuxiliaries  Pmissing  Pfitted