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AVL India Seminar May 2018
Workshop:Emission on testbed: Bharat-VI Challenges
Dieter Florian
Kurt Engeljehringer
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 2Public
Emission Legislation
Introduction
Summary
ContentContent• Diesel, Gasoline
• PM + PN Measurement• Data Quality Aspects
BS 6 – Challenges for Emissions
Discussion
• LD, HD, NRMM
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 3Public
India: BS-VI challenges
Light Duty PC and CV• 2020 Bharat IV VI• 2020 RDE monitoring• 2023 RDE Limits (TA and COP)
Fuel consumption5.5 l/100km 4.7 l/100km
Gasoline:NOx: 80 60 mg/km moderatePM: 4.5 mg/km no problem, but large result scatteringPN: 6E11#/km moderate on testbed
Diesel:NOx: 180 80 mg/km De-NOx mandatoryPM: 25 4.5 mg/km requires DPFPN: 6E11#/km requires DPF
PN will be the leading limit, PM will automatically well below limit, but measurement will show high scattering
Fuel Quality!
RDE:clean under all “normal condition of use”Gasoline (GDI) challenge: GPF will be require, with complex implementationDiesel challenge: low NOx under all conditions
• EGR + LNT only very small engines (maybe)• EGR + SCR• EGR + LNT + SCR for larger and powerful vehicles
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 4Public
India: BS-VI challengesNew test procedures (GTR-4): much more to test
ESC WHSCETC WHTCNOX screening WNTE Random 15 mode test
In-Service compliance (PEMS) Off-Cycle emission compliance statement
Heavy Duty vehicles• 2020 Bharat-IV VI• UNR-49 GTR-4
Limits:HC: 0.55 0.16 g/kW-h -70%NOx: 3.5 0.46 g/kW-h -87%NH3: 25 10 ppm -60%PM: 0.03 0.01 g/kW-h -63%PN: new 6E11#/kW-h totally new
Full set of exhaust aftertreatment required, EGR, Oxi-Cat, DPF and SCR PN is becoming the leading particulate property. An engine fulfilling PN
will be well below the PM limit. SCR is a “chemical factory” in the vehicle, requires extensive nitrogen+
(NO, NO2, NOx, NH3) analysis via FTIR (AVL SESAM i60 FT).
Fuel quality: low sulfur fuel is mandatory!
Non-Road Mobile Machinery• Challenges will be quite the same
as for Heavy Duty• 2020 Bharat-III IV with GTR-11• 2023 Bharat-V with PEMS
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 5Public
Round Robin Results
Averag results of each labNr. Lab # of tests CO2 [g/km] CO [g/km] THC [g/km] NOx [g/km]
EU-6 Limits (130 target) 1,000 0,100 0,060
1 JARI-1 3 160,4 0,334 0,026 0,0082 NTSEL 3 164,4 0,328 0,036 0,0193 TOYOTA 3 156,8 0,313 0,019 0,0104 JARI-2 1 159,6 0,303 0,024 0,0085 ARAI 3 162,4 0,361 0,032 0,0126 NIER 4 163,9 0,263 0,025 0,0107 Kpetro (KEMCO) 3 158,3 0,382 0,028 0,0118 KATRI 3 163,5 0,373 0,030 0,012
AVG 23 161,2 0,332 0,028 0,011Delta min-max 5% 36% 62% 98%Standard deviation 2% 11% 18% 29%
WLTP Round Robin test in Europe and Asia 2015/2016:• Per region 2 “Golden” vehicles (Gasoline and Diesel)• All labs accepted for certification accordingly to UN-ECE Reg 83 and
prepared for WLTP• “Golden test engineer” • Outlier removed and statistical evaluation
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 6Public
Asian Round Robin: Diesel EU-4
AVE SD RSDg/km g/km %0.787 0.131 16.60.936 0.016 1.70.914 0.038 4.11.093 0.009 0.80.898 0.134 14.90.933 0.109 11.7
LMHxH
Lab. D 5Lab. E 3Lab. H 3Lab. A 2All data -Inter lab -
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PMLab. D 5Lab. E 3Lab. H 3Lab. A 2All data -Inter lab -
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AVE SD RSDmg/km mg/km %
24.2 1.4 5.922.9 0.4 1.820.9 2.9 13.721.8 1.6 7.422.8 2.2 9.722.4 1.2 5.5
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PNLab. D 5Lab. E 3Lab. H 3Lab. A 2All data -Inter lab -
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AVE SD RSD#/km #/km %
2.8E+13 1.2E+12 4.33.5E+13 4.1E+12 11.73.9E+13 4.1E+12 10.35.4E+13 1.1E+12 2.03.7E+13 9.1E+12 24.63.9E+13 9.3E+12 23.8
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NOx:• Reproducibility (Lab to Lab): 15 %• Repeatability (in Lab): 1 – 16%
PM: Note vehicle has no DPF• Reproducibility (Lab to Lab): 10 %• Repeatability (in Lab): 2 – 14 %• with lower emission (DPF) this numbers will go up
PN: Note vehicle has no DPF• Reproducibility (Lab to Lab): 25 %• Repeatability (in Lab): 2 – 12 %• with lower emission (DPF) this numbers will go up
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 7Public
WLTP Round Robin Tests (2015/2016)Gasoline vehicle• European Round Robin Test• BMW 116i
Mean SD RSD (%)
CO2 [g/km] 163 2.3 1.4
NOx [mg/km] 11 3.7 32.8
CO [mg/km] 335 61.2 18.2
HC [mg/km] 27 6.4 23.5
Asian RRT (Gasoline) - all data
• Asian Round Robin Test• Toyota WISH, 1.8l, 105kW, CVT
Mean SD RSD (%)
CO2 [g/km] 161 2.6 1.6
NOx [mg/km] 95 27.2 28.6
CO [mg/km] 456 67.9 14.9
HC [mg/km] 41 9.1 22.5
EU RRT (Gasoline) - all data
Diesel vehicle• European Round Robin Test• Alfa Romeo Giulietta with DPF
• Asian Round Robin Test• Mahindra XUV500, 2.2l, 103kW, 6MT, no DPF
Mean SD RSD (%)
NOx [mg/km] 291 35.7 12.3
CO [mg/km] 39 15.4 39.2
HC [mg/km] 8 3.7 46.2
PM [mg/km] 0.23 0.2 69.2
PN [#/km] 5.0E+11 1.3E+11 25.4
EU RRT (Diesel) - all data
CO2 [g/km] 3.2135 4.3
Mean SD RSD (%)
169 10.2 6.0
177 * 1.4 * 0.8 *
NOx [mg/km] 898 134.2 14.9
CO [mg/km] 235 66 28.1
HC [mg/km] 33 14.2 42.5
PM [mg/km] 23 2.2 9.7
PN [#/km] 3.7E+13 9.1E+12 24.6*) exclude Lab. D's data
CO2 [g/km]
Asian RRT (Diesel) - all data
Take away:
Inter Lab. Reproducibility
CO2: 2 – 4 %
CO: 15 – 40 %
HC: 20 – 45 %
NOx: 15 – 30 %
PM: 10 – 70 %
PN: 20 – 30 %
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 8Public
Challenges for PM/PN Emission Measurement
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 9Public
Particulate Matter (PM) MeasurementUncertainty Trend as factor of strengthened Limits
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Euro-1/I Euro-2/II Euro-3/III Euro-4/IV Euro-5/V Euro-6/VI
PM Limits over time
LD PM Limit [mg/km] HD PM Limit [mg/kW-h]
Passenger cars and LD CV:• 140,0 mg/km Euro-1• 4,5 mg/km Euro-6
Heavy Duty Trucks and Busses:• 3,6000 g/kW-h Euro-I• 0,0010 g/kW-h Euro-VI
Measurement Uncertainty:• Signal to noise is decreasing significantly
Uncertainty
3600
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 10Public
Particulate Matter (PM) MeasurementComparison PFDS (SPC 478) vs. CVS (PSSi60)
Measurement Uncertainty for BS-6 increasing for low PM levels PN more robust compared to PM
PM equivalent when fulfilling the PN limit
Data Source: AVL
PN limit for EU 6 LD = 6*1011 #/km
PN mass equivalent ~ 0.4–0.5 mg/km PN mass ~ Faktor 10 < limit 4.5mg/km
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 11Public
Particulate Matter (PM) MeasurementReduction of Filter Mass & Change in PM Composition
EmissionLevel
Elementary Carbon
Condensed + absorbed
HC
Sulfates +
Nitrates
Other Artefacts
Comments
Euro 1, 2 +++ +++ - - Reduced emission by engine
optimization No exhaust aftertreatment
Euro 3, 4 +++ + + - HC and CO reduction by DOC DOC increases sulfate formation
Euro 5 - +++ +++ -
99% soot reduction by DPF HC and sulfates are still the same,
but are contributing relatively more to the total mass as before
Euro 6 - - - ++ Low sulfur fuel removes sulfates Complex SCR chemistry increases
other PM artefacts
EU 5/6 (BS-6) Improvements for existing Particulate Mass (PM) Procedure: HEPA & HC filtered air for exhaust dilution Cyclone pre-classifier Improved sample temperature control 47 +/-5°C Deletion of back-up filter (Artefact Trap!)
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 12Public
Particulate Matter (PM) MeasurementBest Praxis for robust BS-6 PM Measurement
BS-6 will force introduction of DPF / GPF:
PM values become ~10 times below the limit of 4.5mg/km
Measurement uncertainty will increase, however PM measurement still we stay manageable, since well below limit!
Improvement of existing BS-4 procedures required!1.0
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Limit 4.5 mg/km
Key Success Factors for robust BS-6 PM Measurement:
Clean dilution system (CVS or PFDS) background!
Highest dilution air quality (HEPA, HC, humidity) background!
Always use small filter size (47mm) less artefacts!
Proper filter handling is crucial transfer/conditioning/weighing!
Use of automated systems for filter handling + weighing!
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 13Public
Particle Number – What is it about?PN procedure acc. UN-ECE R83 implemented with Euro5/2007
Measurement ProcedureMeasurement ProcedureCVSCVS
1. Cyclon removes particles > 2.5µm2. Dilution + Conditioning removes
particles < 23nm3. Sensor counts particles in the range
of 23nm – 2.5µm Complex calibration procedure
1. Cyclon removes particles > 2.5µm2. Dilution + Conditioning removes
particles < 23nm3. Sensor counts particles in the range
of 23nm – 2.5µm Complex calibration procedure
Chassis DynoChassis Dyno
11
11
Dilution and Conditioning
22
22
Sensor
33
33
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 14Public
Particle Number – What is it about?PN procedure acc. UN-ECE R83 implemented with Euro5/2007
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 15Public
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 16Public
Challenges for PN – CALIBRATIONUN-ECE-R83 (Rev. 5) + UN-ECE-R49 (Rev. 6)
Dilution & Condtioning
Filt
er
Soot SourceSoot Source Size ClassifierSize Classifier ReferenceReference
Core SensorCore Sensor
AVL Calibrationacc. ISO 17025
Soot SourceSoot Source Size ClassifierSize Classifier ReferenceReference
Calibration Boundary Conditions
No standard materials for re-calibration at testbed Complex procedure for aerosol measurement specified Facility for radioactive equipment + skilled operators
Consequences: Yearly Re-Calibration by qualified Lab required! Expected PN Uncertainty > Gas Measurement!
Calibration Boundary Conditions
No standard materials for re-calibration at testbed Complex procedure for aerosol measurement specified Facility for radioactive equipment + skilled operators
Consequences: Yearly Re-Calibration by qualified Lab required! Expected PN Uncertainty > Gas Measurement!
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 17Public
Expected PN - Measurement UncertaintiesBased on international Round Robin experience
References: • Giechaskiel et al; SAE 2010-01-1299• Vogt et al, 14th ETH Conference, Zürich,
August 1-4th 2010• Giechaskiel et al; Aerosol Science and
Technology, 46:719–749, 2012• Inter Laboratory Correlation Exercise, JRC 2015• Giechaskiel et al. 2010, MST, 21, 045102• AVL interne Messdaten
Uncertainty for thePMP - Reference Methode
for PN – Type Approval
Uncertainty for thePMP - Reference Methode
for PN – Type Approval
11 ±8%±8%
Instrument Repeatabilityat the same CVS AnlageInstrument Repeatabilityat the same CVS Anlage
22 ±15%±15%
Instrument Reproducibilityat the same CVSInstrument Reproducibilityat the same CVS
33±20-25%±20-25%
PNCPNC Testbed ReproducibilityDifferent Particle Counter and CVS Round Robin for TA @ testbed
Testbed ReproducibilityDifferent Particle Counter and CVS Round Robin for TA @ testbed
±20-30%±20-30%44
Additional Uncertainty for PNby different sampling positions CVS vs. Tailpipe
Additional Uncertainty for PNby different sampling positions CVS vs. Tailpipe
Uncertainty contributionto PN-PEMS correlation
RDE CF = 1.5
Uncertainty contributionto PN-PEMS correlation
RDE CF = 1.5
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 18Public
Correlation APC to PN-PEMSImpacting Factors for CF = 1.5
CF = 1,5:
±50% or±1E+11 [#/km]
CF = 1,5:
±50% or±1E+11 [#/km]
PN- PEMSDC oder CPC
PN- PEMSDC oder CPC
JRC conclusion: uncertaintyPN-PEMS/Tailpipe vs. PMP/CVSis maximum ±50%
CF = 1 + 50% Margin
Influencing factors: Sampling Position / losses uncertainty for PN Uncertainty exhaust mass flow Uncertainty vehicle speed
Re-evaluation of CF on a yearly basis
JRC conclusion: uncertaintyPN-PEMS/Tailpipe vs. PMP/CVSis maximum ±50%
CF = 1 + 50% Margin
Influencing factors: Sampling Position / losses uncertainty for PN Uncertainty exhaust mass flow Uncertainty vehicle speed
Re-evaluation of CF on a yearly basis
Reference @ CVS
PEMS sampling
50% Margin is already consumed by the Measurement Uncertainty of the PEMS method!!
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 19Public
Ensure Data Quality for PM/PNApplication Know-How + Enhanced Conditions Measurement
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 20Public
Impacting Factors for Accuracy on System LevelCertification Aspects - Calculation
Example based on: ECE/TRANS/180 - Annex 7 Calculations (WLTP, GTR-15, Euro-6d temp), some calculations might be slightly different depending on actual test bed configuration:
VmixCVS Volumedil. exhaust
PowerAnalyzer
RaRel. humidity
Pdsat. vap. pressure
PBatm. pressure
CeConcentrationDil. Exh. Cont
CeConcentrationDil. Exh. Bag
CddConcentrationDil. Air Bag
Concentrations, corrected [ppm]:
Dilution Factor
Fuel propertiesx, y, z
Fuel properties
Gaseous Mass Emissions [g/km]:Gaseous Mass Emissions [g/km]:
NOx humidity correction factor:
Specific humidity:
Particulate Mass Emission [mg/km]:Particulate Mass Emission [mg/km]:
Densities: Ρi@ 273.15 K (0 °C) and 101.325 kPa:
Carbon monoxide (CO) ρ=1.25 g/lCarbon dioxide (CO2) ρ=1.964 g/lNitrogen oxides (NOx) ρ=2.050 g/lHydrocarbons:
for petrol (E0) ρ=0.619 g/1for petrol (E5) ρ=0.632 g/1for petrol (E10) ρ=0.646 g/lfor diesel (B0) ρ=0.620 g/lfor diesel (B5) ρ=0.623 g/l……
Particle Number Emission [#/km]:Particle Number Emission [#/km]:
Flow-weighted average:
VepVolume@ filter
PNCC = PN conc.k, fr = factors
dDistancedriven
PePM mass
collected on filter
TimeValidation
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 21Public
Impacting Factors for Accuracy on System LevelCertification Aspects - Calibration and Maintenance
VmixCVS Volumedil. exhaust
PowerAnalyzer
RaRel. humidity
Pdsat. vap. pressure
PBatm. pressure
CeConcentrationDil. Exh. Cont
CeConcentrationDil. Exh. Bag
CddConcentrationDil. Air Bag
Fuel propertiesx, y, z
VepVolume@ filter
PNCC = PN conc.k, fr = factors
dDistancedriven
PePM mass
collected on filter
TimeValidation
• Distance• Torque• Velocity
Chassis Dyno
• Temperature• Barometric pressure• Humidity (Intake air)
Ambient climatic condition
• Wind speed / motor speed
Blower
• Current• Voltage
Power Analyzer
• CFV’s calibration• Pressure upstream CFV• Temperatur upstream CFV
CVS Full flow dilution
• Mass Flow Meter• PM Temperature
PM Particulate Sampler
• Linearity• Calibration gases
Gaseous Emission Bench
• CPC calibration• PN factor evaluations
PN Particle Counter
• Concentration certificates• Purity certificates• Traceability
Calibration and operation gases
• Weight• Filter conditioning• Filter handling
PM Particle Scale
Manual inputs are a common issue for problems, like wrong fuel parameters
Leaks are common issue for problems
Plausibility checks, result validation and result release procedures are important
Calibration and maintenance is crucial for low emission testing
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 22Public
Complexity for Aerosol Measurement
Multiple Compounds, Soot dominating PM
Different Technologies measure different Aerosol Fractions!
Temp., Press, humidity, loss Mechanisms for PN etc. need to be considered
Correlation of Particle Measurement DevicesAspects for Emission Aerosol Measurements in R&D
Application Know-How
Core-Sensor &Dilution / Conditioning / Samplingin-house Technology
Best Praxis Calibration Methodology
Empirical Correlation Experience see Product Application Guides
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 23Public
Tailpipe
Correlation of Particle Measurement DevicesAspects for Sampling Position
Engine out
8 Dilution Tunnel(CVS or PFDS)*
ExhaustAftertreatment
Engine
Certification
Light duty vehicles, R83Heavy duty engines, R49 Low Temperatures < 52°C Low Pressure Diluted, low concentrations Defined regulative procedure
Research and Development High temperatures up to 1000°C High pressures up to 1bar High PN/PM Concentrations Select appropriate Instruments Apply specific EO sampling kits Consider Correlation Aspects
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 24Public
Correlation between Soot Mass and PM/CVS
SAE 2012-01-1254
• Correlation between soot mass (BC, MSS) and PM (CVS) has already been demonstrated during the EPA Measurement Allowance Program for HD In-Use Compliance Testing
• On the Road validation with exhaust “doped” with bypass (PM ~30 mg/hphr)
• Robust Correlation• PM is app. 85% Soot• Depending on engine, vehicle, load etc.
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 25Public
Correlation between Soot Mass and PNImpact of Agglomeration Effects on PN
Correlation PN and Soot Mass (Black Carbon)Soot Measurement also correlates to PN (PMP) soot is the main contributor to “solid PN” pre-calibration by MSS final calibration by APC
0.001
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So
ot
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Detection Limit MSS
Soot Mass vs. PN for NEDC
• PN concentration remains constant atlevels <107 p/cm3
• A concentration of 108 p/cm3 for 50 nm particles decreases by ~23% in 3sec.
• Agglomeration is not important for post-DPF or GDI applications
• At same time soot mass stays constant!
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 26Public
Task Application Conditions Test cell type MeasurementBase Calibration EAS Calibration -7°C – +30°C Engine Test bed
Chassis Dyno or PowertrainCVS, PTS, APC, AMAPre- and Post Cat AMAMSS
Cold start Cold StartHeat-up and Warm up strategy
Start test without driveoff,focus on +23°C
Engine Test BedVehicle (Cold start place)
Pre- & Post-Cat AMAAPCMSS
SCR SCR Layout and control strategyAdBlue injectionValidation of homogenous mixing
Full temperature range Engine test bed or powertrain Pre- & Post-Cat FTIR
GPF / DPF DPF / GPF Characterization stationary operationFilter loadingFilter regeneration
Engine Test Bed Pre- & Post-PF APCPre- & Post-PF MSSSmokeMeter or Opacimeter
Start & EOGPF and DPF calibration
EO emission ModelSmoke map (Diesel)PF filter loading modelNTE testsActive / Passive Regeneration
Dynamic Tests run temperatures down to -30°C (depending on OEM -25 to -40°C)
Chassis Dyno or Powertrain
In-vehicle
Pre- & Post-PF APCPre- & Post-PF MSS
PN-PEMSMSS
RDE Calibration Calibration in the wide engine map range RDERobustness evaluation
-7°C – +30°C (RDE Boundary)-30°C for AES ContinuityAltitude (0 – 1300 – 2400m)
Chassis Dyno or PowertrainSpecific RDE cyclesRoad-2-Lab approach
CVS, PTS, APC, AMAPre- and Post Cat AMAFTIRMSS
RDE Validation Robustness evaluation -7°C – +30°C (RDE Boundary)Altitude (0 – 1300 – 2400m)
Road PEMS
Passenger Car Calibration EU-6 + RDEOverview for Typical Testing Set-Up
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 27Public
Testing Tasks
GPF Characterization
1) Determination of pressure drop ΔP GPF
2) Determination of filtration efficiency η GPF
Regeneration Measurements
1) Continuous Regeneration
2) Regeneration in Fuel cut-off
GPF Verification Dyn/Cycle
3) Active increase of Passive Regeneration by GPF heating
CAT GPF Muffler
2×APC 2×MSS
CAT GPF Muffler
2×APC 2×MSS
Up to 3×AMA
1×AMA
Best praxis Application ExampleGasoline: GPF characterization on Testbed RDE
EU RDE PN-PEMS Gasoline
Targeting GPF introductionon GDI vehicles
GPF filtration efficiency < DPF
GDI Raw emissions + Filter Loading < Diesel
GDI Back-pressure sensitivity!
GDI Cold Start challenge!
Complex characterizationcompared to DPF
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 28Public
New Challenges for robust BS-6 Emission Measurement (Gaseous, PM, PN)
Control of impacting factors on Test System Level required
Ramp-up Operator Skills & Application Know-How
Data Quality
Frequent Instrumentation Maintenance + QA-checks
Yearly re-calibration for PN Instrumentation (APC + PN-PEMS) mandatory!
Standardization of Testbed set-ups for background reduction signal/noise
Benefit from AVL EU-6 implementation experience @ global customers
Proven test bed emission systems & -instrumentation solutions
Best praxis methodology support for specific application challenges
SUMMARY
Dieter Florian, Kurt Engeljehringer | Emissions | May 2018 | 29Public
Our Customer Emissionis our Mission
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