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3AVL FuelSystem PLU
Target Application: Fuel Consumption Measurement
High performing device for light-duty engines in R&D test beds
Small Off-Road Engine
Light-duty Engine
Heavy-duty Engine
Large Engine
Pe
rfo
rma
nc
e
Engine size
AVL FuelSystem PLU
AVL FuelExact PLU
4AVL FuelSystem PLU
Driving factors
Backward compatibility with KMA4000 and PLU401/1xx
Performance Improvement
Embedded Functional Check, Usability and
Safety
Electronic I/F
Hydraulic I/F
Software
5AVL FuelSystem PLU
Backward Compatibility
Low switching costs
Low TCO
Fast installation and
commissioning
KMA4000
FuelSystem PLU
6AVL FuelSystem PLU
Improved Performance and additional Features
Feature AVL KMA 4000 AVL FuelSystem PLU Customer Benefit
Measurement
data-rate [Hz]
5 10 (@ Ethernet w/ boost data) Higher precision in dynamic conditions
Sampling rate [Hz] 5 100 @EtherCAT Easy synchronisation with the test bed automation
system
Enginee feed and
return pressure
sensors
no yes Diagnostics, automatic pressure measurement
Ethernet /
EtherCAT
no yes Easy to integrate into test bed automation systems.
Remote device control and service.
Multiple user simultaneous operation (maintanance,
service etc..)
7AVL FuelSystem PLU
Embedded Functional Check, Usability and Safety
• Functional check of sensors, temperature conditioning and pressure control
• Online plausibility of the measurement data
• AVL User Device Interface (DUI)
• Standardized error handling
• External AVL In-Screen “Instrument Controller”
• Emergency stopping
8AVL FuelSystem PLU
PLU 121 Sensor
• no pressure drop over the sensor
• Long time stability of the calibration
• high accuracy and reproducibility
• short measurement time at low flow rates
• large measurement range• proven technology
PLU121 sensor Flow range [l/h] Resolution [p/cm³]
Type 20 0.05…20 11600
Type 75 0.15…75 3400
Type 150 0.35…150 1700
Type 300 0.8…300 840
10AVL FuelSystem PLU
AVL FuelSystem PLU general overview
Feature AVL FuelSystem PLU Customer Benefit
Measurement Range 0.05 … 300 l/h Suitable from smaller up to larger engines
Sensor resolution 11600 @ 0,05 – 20 [l/h]
3400 @ 0,13 – 75 [l/h]
1700 @ 0,35 – 150 [l/h]
840 @ 0,8 – 300 [l/h]
Smaller measurement error in the lower measurement
range.
Bubble sensor Yes
Response time < 125 ms Capable to measure in fast dynamic conditions
Fuel Temperature
Conditioning Range
10 … 70 °C Allows operation of engine operation at different
temperature
Temperature Stability < 0.1 °C Higher repeatability
Functional check Temperature and pressure control,
plausibility check
Reduce wrong measurement
12AVL FuelSystem PLU
AVL FuelSystem PLU: hydraulic diagram
PLU121
Preconditioning circuitMeasurement circuit
Bubble sensor and automatic venting
Fuel PumpFuel Pump
14AVL FuelSystem PLU
Functional check: a quick overview
• Functional check of PLU sensor
• Functional check of pressure regulator and pump
• Proves the functional stability of the conditioning loop
15AVL FuelSystem PLU
Functional check: plausibility of PLU sensor
PLU121PUMP ON
VENTING ON
Check done on 2 different flow settings
16AVL FuelSystem PLU
Functional check: pump, pressure regulator and conditioning circuit
Pressure and Temperature
SensorsPUMP ON
VENTING OFF
Check done on 3 different flow settings
17AVL FuelSystem PLU
Operating panel
S1: Power On/Off
S2: Switch between manual and remote operation
S3-S6 only work if S2 is on manual, if S2 is on
remote, then operation only via DUI/Ethernet or CAN
S3: Switch on inlet pump
S4: Switch on outlet pump
S5: Venting
S6: Automatic fuel change (option)
18AVL FuelSystem PLU
Electronic Interfaces
Power 230V/AC
Emergency stop (-X9)
Additional grounding
Ethernet
EtherCAT
CAN
19AVL FuelSystem PLU
Interfaces to the automation system
I/F (protocol) Device control Data acquisition
(update rate)
Ethernet (AK) • Online , integral or preselected time
measurement
• Statistical data: average, std. deviation
• Online plausibility
• Temperature control target value
• Error messages
• Service software, fuel exchange, venting
functional check
Volume flow [10 Hz]
Mass flow [10 Hz]
Density [1 Hz]
T of Density [1 Hz]
T of PLU Sensor [1 Hz]
Engine feed temperature [1 Hz]
Engine feed pressure [1 Hz]
Engine return pressure [1 Hz]
Etc..
EtherCAT up to 100Hz Volume flow [10 Hz]
Mass flow [10 Hz]
Density [1 Hz]
T of Density [1 Hz]
T of PLU Sensor [1 Hz]
Engine feed temperature [1 Hz]
Engine feed pressure [1 Hz]
Engine return pressure [1 Hz]
CAN
Profinet
D I/O
Device states (CAN/Profinet)
Emergency-Stop (D I)
Sum error (D O)
Error messages (CAN/Profinet)
20AVL FuelSystem PLU
Online measurements
Measurement time
Measurement numbers
Dem Outlet Temp.
Mass Flow Standard deviation
Moving average Relative st. dev.
Measurement uncert.
Outlet temperatureTemp. @ density sensorDensityDemanding venting time
Select mass vs. flow
21AVL FuelSystem PLU
Measurement with preselected time
Measurement time
Average
Standard deviationMinimum
PlausibilityMaximum
Select mass vs. flow
Integral values
Real-time values
23AVL FuelSystem PLU
Options
Filling pump Fuel filter unit
Shut-off valve
Electrical Control Unit“OSEBox”
Overflow detectorInlet press reducer.
Valve for automatic fuel exch.
Ext. pressure regulator
AVL in-screen
Flame filterHeating bath
Trolley