22.05.2015

AVL KMA Mobile – Tech Day Italy – 21 May 2015

Romain Lardet - CONFIDENTIAL

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Application Areas for On Board Testing

Standard fuel consumption measurement @ constant speeds for 60/90/120 km/h

Measurement of customer relevant fuel consumption

Comparison of fuel consumption measurement

chassis dyno versus street

engine test bed versus street

Evaluation of competitive vehicles

Climatic tests with fuel consumption measurement

heat test e.g. in Death Valley

cold test e.g. in Kiruna

Fuel consumption measurements with complaint cars

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Customer Requirements

High accuracy and reproducibility

under real road condition

Easy handling and installation

No influence of vehicle parameters

For gasoline and diesel engines

Applicable with returnless engine as

well as engine with return

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Overview of the KMA Mobile

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AVL KMA Mobile

Modular Design

Measuring module

includes sensors and electronic

can be used standalone for engines

without return flow

Conditioning module

includes all hydraulic components

Used additional with measuring module

for engines with return flow

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Types of vehicle fuel supply systemsSimplified schematic

… without return flow

or with return flow …

Filter Fuel

pump

Tank

pump

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Flow measurement solutions for different vehicle fuel supply systems

Flow meter integration into fuel supply line

Differential measurement of fuel supply flow and back flow with 2 flow meters?

Filter Fuel

pump

Tank

pump

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tank

fuel pump

10 l/hUncertainty of flow measurement = 0.5%

%

150 l/h x 0.5 % = +- 0.75 l/h

140 l/h x 0.5 % = +- 0.7 l/h

maximum deviation: 1.45 l/h

measurement uncertainty at 10 l/h: u = 15% !

fuel rail

pressure

regulator

150 l/h

140 l/h

Limited Accuracy Solution

Fuel Supply System with Return Flow Differential Flow Measurement

filter

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Tank

Tankpumpe

10 l/h

Rail

150 l/h

140 l/h

150 l/h

140 l/h

10 l/h

Total measurement uncertainty = 0.5 %

= 0.05 l/h

Fuel Supply System with Return Flow Recirculation of Return Flow - Direct Flow Measurement

pressure

regulator

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Fuel Supply System with Return Flow Fuel Consumption Measurement with Single Flow Meter

tank

fuel pump

fuel rail

pressure

regulator

inlet pumpoutlet

pumpflow meter

heat

exchanger

KMA Mobile scope of supply

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Filter Fuel pump

Tank pump

KMA Mobile Measurement Module

KMA Mobile Measurement Module + Conditioning Module

Fuel Supply System with Return Flow Direct Fuel Consumption Measurement

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Measuring Module

Measuring Ranges:

Type 075 : 0.16 ... 75 l/h 0.12 ... 56 kg/h*

Type 150 : 0.35 ... 150 l/h 0.26 ... 110 kg/h*

Type 300 : 0.8 ... 300 l/h 0.6 ... 225 kg/h*

(*at a density of 0.75 g/cm3)

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Conditioning Module

2 up to 4 fuel pumps enable the universal

use at different engines

Pumps can be used as inlet- or outlet-

pumps

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Measurement principle

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Servo-controlled displacement meter

no pressure difference between inlet and

outlet (Δp = 0)

no internal leakage flow

o Indepentent of Viscosity or

Temperature

nearly without wearing

o long life time of measuring system

o long term stability of calibration

null shift stability of sensor

high accuracy and reproducibility

large measurement ranges

field proven technology

PLU measuring principle (Δp = 0)

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PC Service Software

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Display of Measurement Values

(Online Values)

Alphanumerical Display

Graphical Display

Display of Device Status

Control of the Measurement Device

Data Logging

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Device Status

PC Software

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Graphical Display

of online Values

PC Software

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Alphanumerical Display

of online Values

PC Software

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Action Buttons

PC Software

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Messages

PC Software

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Main Settings

PC Software

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PC Software

Integral view

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Alphanumerical Display

of integrated Values

PC Software

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Action Buttons

to start & stop

Integration

PC Software

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Intermediate

Values

PC Software

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Start Stop

PC Software – Data Logging

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Diesel settings

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Diesel passenger car with tank pump

both Modules

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Tank

Fuel filter with:

- Water separator

- Heater (optional)

High

pressure

pump

CP3

Gear

pump

Suction

throttle

(M-PROP)

Temp. dep.

Recirculator valve

(optional)

Rail pressure sensor

max. 1600 bar

Common

Rail

Pressure limiter

valve (DBV)

Flow

limiter

Injector (1...n)

Prefilter

both

Modules

Diesel passenger car without tank pump

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Diesel Unit Injector

both

Modules

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Tests at LMM for the Tech Day

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RENAULT Megane

Megane3 4 portes

1.9L Dci, 4 cylinders

Diesel engine with return flow

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Impact of auxiliary consumers on the car used for the Tech Day

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Fuel consumptionThrottle position

EngineTorqueCar speed

Rail pressure

NMVEG cycle transient measurement

70 Km/h

50 Km/h

As the rail pressure goes suddenly up during the gear change, the consumption signal is also seeing a peak because fuel gets stored in the rail

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NMVEG cycle – Comparison Carbon balance/KMA Mobile

Cold start

Hot start

Ecart balance carbone/KMA Mobile:Cold start: - 1,5%Hot start: -2,5%

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NMVEG cycle – Comparison Carbon balance/KMA Mobile

Cold start

Hot start

Testing conditions:• Simple integration for this test with

KMA Mobile outside the vehicle in order to facilitate access during the 2 hours demo

• Installation is not optimized.• The spread KMA Mobile vs C-

Balance can be reduced by optimizing the setup

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KMA Mobile Installation

Example

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Mini Cooper

MINI Cooper S

1.6 Liter, 4 Zylinder/16 V

Gasoline engine without return flow

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Fuel Consumption Impact of Light, Rear Window Heating, Fan

Rear Window Heating off

Fan off aus

Light off

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Volvo Truck

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Main Features of KMA Mobile

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Summary – main features

Large Measurement Range

between 0.16 l/h and 300 l/h

Short Measurement Time

high data quality due to low measurement uncertainty

± 0.1% (reproducibility of sensor calibration factors)

High Dynamics

rise time (t10 – t90) down to 125 ms and data acquisition rate of up to 3 Hz

Comparability of Data

same measurement principle as for test bed solutions

No influence on the Engine Fuel System

feed pressure adjustable between -0.3 bar and 5 bar for diesel engines

Feed pressure up to 10 bar for gasoline returnless engines

Easy and fast installation

22.05.2015

Thank you for your Interest

www.avl.com