AT1577_E12.pdf

User’s Guide

PUMA Open V1.2Legal Cycle Services

January 2005

ID Number: AT1577E

Rev. 12

The contents of this document may not be reproduced in any form

or communicated to any third party without the prior written

consent of AVL. While every effort is made to ensure its correctness,

AVL assumes no responsibility for errors or omissions which may

occur in this document or for damage caused by them.

All mentioned trademarks or registered trademarks are owned by

their respective owners.

Printed in Austria at AVL

Copyright 2005 by AVL List GmbH, Graz - AustriaCopyright 2005 by AVL List GmbH, Graz - AustriaCopyright 2005 by AVL List GmbH, Graz - AustriaCopyright 2005 by AVL List GmbH, Graz - Austria

Table of Contents 1

Table of Contents

1 What you should know................................................................................................ 31.1 Safety Instructions .........................................................31.2 Intended Use...................................................................31.3 Statutory Test Cycles in Puma Open............................4

1.3.1 Light Duty Test Cycles ................................................. 41.3.2 Heavy Duty Test Cycles............................................... 51.3.3 Legal Specifications..................................................... 51.3.4 Available Heavy Duty Test Cycles ............................... 51.3.5 Available Light Duty Test Cycles ................................. 6

1.4 About This Manual .........................................................61.4.1 Abbreviations and Glossary Terms.............................. 71.4.2 Typographic Conventions ............................................ 81.4.3 Online Help .................................................................. 91.4.4 We want to Hear From You ......................................... 9

2 Light Duty Cycles....................................................................................................... 112.1 Overview........................................................................112.2 Requirements................................................................11

2.2.1 Additional Normnames............................................... 122.2.2 Import Driving Profiles................................................ 132.2.3 Import Monitoring Function ........................................ 142.2.4 Create Own Tests ...................................................... 18

2.3 Generate Tolerance Band and Look-Ahead Driver ...212.3.1 Parameters for VTOL and LAD.................................. 222.3.2 Generate Tolerance Band.......................................... 25

Generate ECE ...................................................... 27Generate FTP ....................................................... 29Create New Definitions ......................................... 30Activate Tolerance Band....................................... 31

2.3.3 Activate Look-Ahead Driver (LAD)............................. 32Additional Points Function .................................... 33Speed Curve Filtering Function ............................ 35Raise Shift Plateau Function ................................ 38Useful Information................................................. 41Look-Ahead Driver Activation Object.................... 42

2.4 Tolerance Band Monitoring .........................................432.4.1 Principle of Tolerance Band Monitoring ..................... 43

Monitoring ’V_Tolerance_Monitoring’ ................... 44Helper scripts and activation objects .................... 45Formula ’V_Tolerance_Check’ ............................. 46

2.4.2 ECE Monitoring.......................................................... 47

PUMA OpenPUMA OpenPUMA OpenPUMA OpenS t a t u o r y T e s t C y c l e s - L i g h t D u t y

Table of Contents2

2.4.3 EPA Monitoring .......................................................... 472.4.4 Online Window........................................................... 48

3 Heavy Duty Cycles ETC and HDTC .......................................................................... 513.1 Overview........................................................................513.2 Requirements................................................................53

3.2.1 Additional Normnames............................................... 533.2.2 Modification of Test Facility Parameters (TFP).......... 573.2.3 Modification of Unit Under Test Parameters (UUT) ... 583.2.4 Test Import (BSQ, SSQ) ............................................ 59

3.3 Parameterization of Full Load Curve Recording .......603.3.1 Parameterization of Full Load Curve in EMP............. 603.3.2 Parameterization ETC (ECE)..................................... 63

Parameterization in ECT....................................... 63Parameterization in EMP ...................................... 63

3.3.3 Parameterization HDTC (EPA) .................................. 64Parameterization in ECT....................................... 64

3.4 Test Description ...........................................................653.4.1 Overview.................................................................... 653.4.2 Recorder Parameterization (REC)............................. 673.4.3 Measurement Request (MRQ)................................... 693.4.4 Profile Parameterization (SSQ).................................. 713.4.5 Parameterization for Regression Analysis Activation 72

3.5 Test Execution ..............................................................733.5.1 Full Load Curve Recording ........................................ 733.5.2 Test Run .................................................................... 75

3.6 Regression Analysis ....................................................763.6.1 Function ..................................................................... 763.6.2 Results ....................................................................... 78

3.7 ESC Test Cycle .............................................................793.7.1 Generation of ESC Test Cycle................................... 813.7.2 Parameters of ESC Test Cycle .................................. 84

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Safety Instructions 3

1 What you should know

This documentation describes the functions of "statutory test cycles" for passenger cars (light duty) and for trucks (heavy duty) in the PUMA Open test bed system.

This section contains information on the following topics:

Safety Instructions

Intended Use

Statutory Test Cycles in Puma Open

About This Manual

Searching for topics:

Detailled information to the functionalities of light duty and heavy duty you will find at:

“What you should know” on page 3

“Heavy Duty Cycles ETC and HDTC” on page 51

1.1 Safety Instructions

This documentation contains important Warnings and Safety Instructions that users must observe. Only by careful observance of these requirements and safety instructions can a smooth operation be guaranteed.

1.2 Intended Use

Statutory test cycles (light duty) serve for testing passenger car engines on PUMA Open test beds, especially with regard to measuring exhaust emissions. The permissible emission values are specified by (the respective country's) legislative bodies. Light duty test cycles must not be used for testing truck engines.

Statutory test cycles (heavy duty) serve for testing truck engines on PUMA Open test beds, especially with regard to measuring exhaust emissions. The permissible emission values are specified by (the respective country's) legislative bodies. Heavy duty test cycles must not be used for testing passenger car engines.

For any use outside the application purpose mentioned or in the case of non-observance of the necessary requirements and safety instruc-tions no guarantee and/or liability shall be assumed.

PUMA Open PUMA Open PUMA Open PUMA Open S t a t u t o r y T e s t C y c l e s - L i g h t D u t y

Statutory Test Cycles in Puma Open4

1.3 Statutory Test Cycles in Puma Open

Statutory test cycles are "standardized" test runs that are used for the certification of combustion engines on engine test beds or chassis dynos by means of defined driving profiles.

Typical examples Typical examples for light duty statutory test cycles are FTP75, J1015, etc.. Typical examples for heavy duty statutory test cycles are FTP75, ECE R83, etc..

Kinds of statutorytest cycles

The PUMA Open system is comprised of two distinct kinds of statutory test cycles:

Statutory test cycles for passenger cars (light duty)

Statutory test cycles for trucks (heavy duty)T

1.3.1 Light Duty Test Cycles

Light Duty Tests are statutory test cyles which mainly serve to test passenger car engines.

The requirement is a time-based vehicle speed profile that is run on a chassis dyno or on an engine test bed.

In PUMA Open, these tests are carried out by dynamic steps (SSQ).

a

Important: The component "statutory test cycles for passenger cars" and "statutory test cycles for trucks" contains the software functions to define the respective parameters and run statutory test cycles for passenger cars.

The test cycles are available in the form of the legally required demand values as BSQ tests.

Complete statutory test cycles including emission measurements and evaluations are available as application packages (AVL GEM301H).

Important: Configuration ISAC is needed to perform light duty tests!

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Statutory Test Cycles in Puma Open 5

1.3.2 Heavy Duty Test Cycles

The functions included enable the recording of full load curves and the automatic running of transient profiles which are available in a normalized (percentage or calculated) form.

Demand value output

The demand value output (PUMA steady-state steps or SSQ sequences) is effected by means of steady-state engine control modes (speed/torque/alpha), which are adjusted to the respective engine by using the characteristic quantities of the specific engine (denormalized values).

Full load characteristic

The recording of the specific full load characteristic for the respective heavy duty transient test is performed automatically and in compliance with the relevant regulations. The standard test cycles are available as driving profiles (SSQ), but can be adapted slightly to meet the user's needs.

Regression analysis

The concluding regression analysis according to ECE and EPA provides information about the quality of the control.

1.3.3 Legal Specifications

The contents of the statutory test cycles are specified by the legislative bodies of the relevant regions (EPA, ECE, etc.), taking into account the following criteria:

Test run execution (vehicle speed, gear shift points, etc.) in compliance with the allowed deviations of the actual speed

Definition of measurements to be taken during the test run (emission measurements, etc.)

Monitoring of exhaust emission limits during a whole test cycle

1.3.4 Available Heavy Duty Test Cycles

The scope of delivery includes wo ready test cycles:

TST_ETC TST_ETC contains the ECE specifications for the European Transient Cycle.

TST_HDT TST_HDT contains the EPA specifications for the Heavy Duty Transient Cycle.

The two transient test cycles HDTC and ETC are available in a normalized form, i.e., relative demand value tracks. The necessary adaptations can be made by means of the graphical editor SSQ.

In addition, there are two templates for the ESC test cycle (with or without additional points (modes)).

Important: Configuration EMCON400 or ISAC400 is needed to carry out heavy duty tests!


About This Manual6

1.3.5 Available Light Duty Test Cycles

The PUMA Open test bed system supports the parameterization and performance of the following statutory test cycles, which are available as dynamic step sequences (SSQ):

ECE1504_05M EU/ECE test cycles (ECE regulations 15/04 and 15/05).

FTP75 EPA test cycle

J1015 Japan 10.15 mode cycle

JAPAN11 Japan 11 mode cycle

SC03 EPA additional cycle aggressive behavior

US06 EPA additional cycle with air-conditioning unit

1.4 About This Manual

Target group The documentation is intended for test bed engineers who set the filter functions for PUMA Open channels (normnames) and use them in PUMA Open.

This documentation cannot and is not meant to replace adequate training!

Requirements In order to be able to work with statutory test cycles, you must meet the following requirements:

Basic knowledge of PUMA Open

Basic knowledge of setting test run parameters (BSQ, SSQ)

Basic knowledge of emission measuring technologies

Secondary literature

For further information on this topic, please refer to the following AVL documentation:

AT1806E10 "ISAC400"

AT1748E10 "Parameterization Tools"

Important: The Puma Open system contains the complete driving profiles with the possibilities of tolerance band monitoring and optimization by means of the look-ahead driver. Complete statutory test cycles including emission measurements and evaluations are available as application packages (AVL GEM 301L).

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About This Manual 7

1.4.1 Abbreviations and Glossary Terms

BSQ Block Sequence Editor

CITT Curb Idle Transmission Torque

DYS Dynamic Step

ECE Economic Commission for Europe (UN Organization)

ECE R 15 Emission regulation (contains test cycle "part 1" from ECE R 83)

ECE R 83 ECC (European Urban Cycle) and EUDC Cycle (MVEG and NEFZ)

EPA Environment Protection Agency (US)

ESC European Stationary Cycle

ETC European Transient Cycle

New test run for truck and bus engines. This test cycle will be used for emission certification together with ESC test run.

EUC Elementary Urban Cycle (part of ECE R 83)

EUDC Extra Urban Driving Cycle (part of ECE R 83)

FTP Federal Test Procedure (transient test cycle for passenger cars))

FTP75 Transient test cycle for passenger cars and light trucks, derived from the statutory test cycle FTP-72. Is used for emission certification testing of passenger car and light truck engines in the U.S.

HDTC Heavy-Duty FTP Transient Cycle

J1015 Japan 10-15 mode test cycle - is used in Japan for the emission certifi-cation testing of passenger cars.

LAD Look-Ahead Driver

LAFY Los Angeles Freeway (part of FTP cycle)

LANF Los Angeles Non Freeway (part of FTP cycle)

MVEG ECE+EUDC test cycle

NYNF New York Non Freeway (part of FTP cycle)

OICA/ACEA Also called ESC test run

SC03 Addition to FTP test cycle. Is used for emission simulation in connection with air-conditioning systems.

SFTP US06 & SC03 - addition to FTP test cycle

SSQ Step Sequence Editor

UDC Urban Driving Cycle (part of ECE R 83)

US06 Addition to FTP test cycle - simulation of aggressive highway driving.

VTOL Velocity tolerance


About This Manual8

1.4.2 Typographic Conventions

This documentation uses the following icons and standard text styles:

ATTENTION:

Icon and text indicate a warning of situations or actions that could potentially lead to personal injury, hardware damage and/or significant data loss.

Important: Icon and text indicate very important information or instructions. If these instructions are ignored, you will not be able to finish, or will have (significant) difficulties finishing the actions described in this documentation.

Note: Icon and text refer to further information (tip, literature, etc.).

Example: The gray example box describes an example.

Standard text styles and their use:

Bold Parameters; control elements in windows and dialog boxes; important text

Italics Foreign or new terms; book titles; wherever you are required to type user-dependent information such as characters or text. If you read, for example, macro name, then you are required to type the name of a macro.

UPPERCASE LETTERS

Keys; shortcut keys; operating states; file name extensions

Courier Programming examples; source code

Times New Roman Formulas

Menu | Option Describes how to select a menu item (here called Option) found in the menu (here called Menu).

Bullets, lists and their use:

1.

2.

Step-by-step procedures; sequential lists

Unordered series of concepts, items or options

–

–

Unordered series of concepts, items or options in the form of subordinate clauses

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About This Manual 9

1.4.3 Online Help

This printed manual is also available as online Help.

Open the online Help:

via the PUMA Open menu Helpor by pressing the control key F1 for context-sensitive Help.

1.4.4 We want to Hear From You

AVL continually strives to improve its documentation and, with this thought in mind, we would like to hear what you have to say about it.

Whether you want to suggest an improvement to a particular manual, complain that a concept is not explained well enough or point out an error, we want to know.

To this end, we have created the following e-mail address for all documentation-related correspondence:

[email protected]

We look forward to hearing from you!


About This Manual10

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Overview 11

2 Light Duty Cycles

This section contains detailed information on the following topics:

Overview

Requirements

2.1 Overview

The functions of the system enable the automatic running of dynamic light duty test cycles on an engine test bed by use of ISAC 400 driver and vehicle simulation.

The test cycles are available to users as driving profiles, which can be adapted slightly and run on the engine test bed.

Velocity tolerance band

A velocity tolerance band can be generated automatically for the respective cycle. The current vehicle velocity is monitored during the run time.

Look-ahead driver

The function look-ahead driver is used to simulate the behavior of an experienced driver who achieves minimum throttle movement by making the best possible use of speed profile tolerances. Reasonable gear shift handling can especially help to reduce the drop in actual speed during the gear shifting procedure.

2.2 Requirements

Certain requirements must be met in order to be able to work with light duty test cycles. This section contains detailed information on the following requirements:

Additional Normnames

Import Driving Profiles

Import Monitoring Function

Create Own Tests


Requirements12

2.2.1 Additional Normnames

In order to be able to use the functions tolerance band monitoring and look-ahead driver, you will need additional normnames.

Important: These normnames are taken into account automatically with standard installations.

For a customer specific normname directory, the following norm-names must be added by means of the NED (in the group Calculated Quantities).

Channel Name

System Name Description

LAH_TB_H lkahead_tolb_hi Velocity tolerance band, upper limit LAH_TB_L lkahead_tolb_low Velocity tolerance band, lower limitLAD_V lkahead_calc_vel Look-ahead driver: speed

Note: For online monitoring by means of scripts and formulas the following normnames (in the group Calculated Quantities) are required:

Channel Name

System Name Description

QcNOK QcNOK Quality Check failed for whole cycleQcCnt QcCnt Quality Check counter / timer for actual violationQcCnt15 QcCnt15 Quality Check counter for violations less 15 secQcCntAct QcCntAct Quality Check flag for checking only onceQcEnable QcEnable Quality Check flag for enabled formulaQcVioHi QcVioHi Quality Check indicator for upper violationQcVioHLo QcVioHLo Quality Check indicator for lower violationQcVioCnt QcVioCnt Quality Check counter for overall violationsQcVioTim QcVioTim Quality Check violation timeQcVioTyp QcVioTyp Quality Check type (0..ECE 1..FTP)

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Requirements 13

2.2.2 Import Driving Profiles

Carry out the following steps in order to import a driving profile:

1. Start the Application Manager.

2. Start the PUMA Open Explorer.

3. Select target directory (e.g. \ComputerName, \Projects, \AVL, \Project Data).

4. Activate the function Import in the right-hand area of the Explorer (click with right mouse button in the right-hand window).

5. Select the desired XML file from the directory dat\xml (cycletem-plates.xml)

Fig. 1 Import driving profile

Important: In the test shown in the figure above, no test cycle (BSQ) has been defined; the profile templates are contained as dynamic step sequences (SSQ) in the Library subdirectory.


Requirements14

2.2.3 Import Monitoring Function



3. Select target directory (e.g. \ComputerName, \Projects, \AVL, \Project Data).

4. Activate the function Import in the right-hand area of the Explorer (click with right mouse button in the right-hand window).

5. Select the desired XML file from the directory dat\xml (cycletem-plates.xml)

VTOLTest In the test shown in the figure below, the Library subdirectory contains the components for the tolerance band monitoring:

Note: The limit definitions and formulas are contained as examples in the test supplied (VTOLTest).

Fig. 2 Import monitoring function

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Requirements 15

Fig. 3 Components for tolerance band monitoring


Requirements16

Profile ’ECE1505EU3’

Example of an ECE driving profile.

Profile ’P1_und_P2’

Example of an EPA driving profile.

Recorder This recorder definition contains all relevant quantities of the tolerance band monitoring. However, this recorder is not necessary for the func-tion.

Formula ’V_Tolerance_Check’

These cyclic formulas are calculated depending on the respective limits and contain the legal exceptions for upper/lower deviations from statutory limits.

Fig. 4 Formula Editor

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Requirements 17

Monitoring ’V_Tolerance_Monitoring’

These limits contain the parameters of the individual upper or lower deviations of the current speed and the overall result of the monitoring.

Fig. 5 Step specific limits


Requirements18

2.2.4 Create Own Tests

You may combine the following components with the respective driving profile (with generated tolerance band) to create your own tests:



In order to create the test, you have to copy these components from the example's library (by means of the PUMA Open Explorer) into the library of the new test. In addition, the desired profile with generated tolerance bands is required.

Important:

You must insert the respective activation object at the beginning of the profile by Legal Cycles:

Start ECE

Start FTP

The following Cycle must be inserted at the end of the profile:

Stop

Fig. 6 Driving profile in the PUMA Open Explorer (SSQ)

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Requirements 19

Activation object Legal Cycle Services

Start (ECE)

Start (FTP)

Stop

Fig. 7 Activation object Legal Cycle Services


Requirements20

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Generate Tolerance Band and Look-Ahead Driver 21

2.3 Generate Tolerance Band and Look-Ahead Driver

Using the function Tools | Velocity Tolerance and Look-Ahead Driver, you can create additional demand value tracks for a specific profile for

– upper tolerance band

– lower tolerance band and/or

– optimized demand speed (look-ahead driver)

in the form of a newly generated profile:


2. Select the desired profile (in the library of the test or a common directory).

3. Invoke by use of the function Tools | Velocity Tolerance and Look-Ahead Driver (to load the profile that has been selected).

Below you will find detailed information on the following topics:

Parameters for VTOL and LAD

Generate Tolerance Band

Activate Look-Ahead Driver (LAD)

Fig. 8 Velocity Tolerance and Look-Ahead Driver

Note: For velocity tolerance we use the abbreviation VTOL, and look-ahead driver is abbreviated as LAD.


Generate Tolerance Band and Look-Ahead Driver22

2.3.1 Parameters for VTOL and LAD

Define the parameters in the window Velocity Tolerance and Look-Ahead Driver:

Sequence Prop-erties

The following parameters are set in the Sequence Properties area:

New sequence name

Under New sequence name, the name of the new sequence to be generated can be defined. The name of the original profile plus exten-sion _gen is used as a default (if nothing is entered).

Activation area If you want to use the functions Velocity Tolerance Band and Look-Ahead Driver only over a certain area, you can select an area at Activation Area (by default, this is the whole SSQ area).

Fig. 9 Velocity Tolerance and Look-Ahead Driver

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Create speed tolerance tracks (VTOL)

If you select this parameter (tick), velocity tolerance tracks for the upper and lower tolerance bands will be generated.

Tolerance time This parameter is used to define the tolerance time for the calculation.

Value range: 0.5 to 5 seconds

Upper speed limit This parameter is used to define the upper speed limit.

Value range: 0.1 to 10 km/h

Lower speed limit This parameter is used to define the lower speed limit.

Value range: 0.1 to 10 km/h

Create look-ahead driver (LAD)

If you select this parameter (tick), a track for the look-ahead driver will be generated.

LAD time This parameter defines the time distance of the new points generated by LAD.

Value range: 0,5 to 5,0 seconds

Additional points This parameter is used to define the number of additional points for an existing point.

Available values: 0, 2, 4, 6

Filter speed curve This parameter is used to disable/enable (tick) the function Filter speed curve.

Filter time This parameter is used to define the time frame for the calculation of the filtered velocity track.

Value range: 1 to 20 seconds

Utilization This parameter is used to define the degree of utilization of the filtered value in relation to the tolerance band:

0%, no deviation from original curve

100%, full utilization of tolerance range

Note: If a profile with the same name already exists in the library, you can overwrite it. You are asked whether you want to overwrite a profile in the dialog box: Overwrite sequence with the given name if it exists.

Note: For further information, please refer to 2.3.2 "Generate Toler-ance Band" on page 25!

Note: For further information, please refer to 2.3.3 "Activate Look-Ahead Driver (LAD)" on page 32!



Raise shift plateau

This parameter is used to disable/enable (tick) the function Raise shift plateau.

Time before gearshift

With this parameter you set the time from which the demand vehicle speed is to be increased.

Time after gearshift With this parameter you set the time until which the demand vehicle speed is to be increased.

Raise at100 km/h

With this parameter you determine for how many km/h the demand vehicle speed is to be increased at 100 km/h. The current value is interpolated linearily.

Set FTP Defaults You use this button to set the default setting for the FTP cycle.

Set ECE Defaults You use this button to set the default setting for the ECE cycle.

Input/Se-lection field for names

You can define an existing or a new cycle name for the default settings in this field.

OK You start the generation by choosing the OK button. Afterwards the application will be closed.

Cancel By use of Cancel, you close the application without generating a driving profile.

Note: For detailed information, please refer to "Raise Shift Plateau Function" on page 38.

Note: For detailed information, please refer to "Generate FTP" on page 29.

Note: For detailed information, please refer to "Generate ECE" on page 27.

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2.3.2 Generate Tolerance Band

In addition to the mandatory speed profile, driving cycles for statutory emission tests must also have a tolerance band, within which the actual vehicle speed must remain so that the test passes as valid.

You can generate the upper and lower velocity tolerances depending on the original track and the necessary related parameters.



3. Select the profile template (from a library).

4. Activate Tools | Velocity Tolerance and Look-Ahead Driver.

5. Set the parameters.

6. Click OK.

The following figure shows a detail of a driving profile before and after the generation of the tolerance bands:

Note: The profile that has been generated only becomes visible after the F5 key has been pressed.

Fig. 10 Driving profile before and after VTOL



The two tolerance tracks are defined by means of system channels which are standard normnames:


Generate ECE

Generate FTP

Create New Definitions

Activate Tolerance Band

LAH_TB_H for upper tolerance band LAH_TB_L for lower tolerance band

Note: The parameters contained in the starting profile, such as e.g. engine commands, measurements, activation objects, etc., are kept during the generation.

ATTENTION!

Changes in the profile are overwritten if the generation is repeated!

Important: Any changes that you want to remain during the genera-tion may only be made in the original profile!

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Generate ECE

The default settings for the ECE test cycles (ECE1504, ECE1505, etc.) can be set by means of the Set ECE Defaults button.

This setting also includes the defaults for the values for the look-ahead driver (LAD).

Statutory values for ECE

The statutory values for the tolerance time and the velocity tolerances comply with the requirements of directive 70/220/EEC or regulation ECE R-83.

The following figures show a profile detail before and after the genera-tion of tolerance bands (and look-ahead driver).

Parameters ECE Parameters

Create speed tolerance tracks ONTolerance time 1 secUpper speed limit 2 km/hLower speed limit 2 km/hCreate look-ahead driver ONLAD time 1 secAdditional points 2Filter speed curve ONFilter time 2 secUtilization 50%Raise shift plateau ONTime before gearshift 10 secTime after gearshift 2 secRaise at 100 km/h 2 km/h

Fig. 11 Profile detail before the generation



Fig. 12 Profile detail after the generation

Important: To ensure the “Bend” of the tolerance bands, at least two points are always inserted!

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Generate FTP

The default settings for the FTP test cycles (FTP75, SC03, US06, etc.) can be set by means of the Set FTP Defaults button.

This setting also includes the default setting for the values for the look-ahead driver (LAD).

The statutory values for the tolerance time and the velocity tolerances comply with the requirements of EPA 40CFR86 §86.115-78.

The following figures show a profile detail before and after the genera-tion of tolerance bands (and look-ahead driver).

Parameters FTP

Create speed tolerance tracks ONTolerance time 1 secUpper speed limit 3.2 km/hLower speed limit 3.2 km/hLAD time 1 secCreate look-ahead driver ONAdditional points 0Filter speed curve ONFilter time 6 secUtilization 80%Raise shift plateau OFFTime before gearshiftTime after gearshiftRaise at 100 km/h

Fig. 13 Profile detail before the generation

Fig. 14 Profile detail after the generation



Create New Definitions

The default settings for ECE and FTP can be varied and stored under a new name as a reusable setting.

1. Activate Tools | Velocity Tolerance and Look-Ahead Driver.

2. Change the desired parameters.

3. Activate drop-down menu at the bottom of the window.

4. Select Add new and enter the name.

5. Choose the OK button.

6. If you want to activate this default setting, you must select it from the drop-down menu (as shown in the figure below).

Fig. 15 Assign name for default setting

Fig. 16 Select name

Note: The default settings for ECE and FTP can also be changed by modifying the values for ECE or FTP.

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Activate Tolerance Band

In order to activate the formulas defined under 2.2.3 "Import Monitoring Function" on page 14, you must insert the start of the respective moni-toring at the beginning of the profile by means of the activation objects Start (ECE) or Start (FTP).

Fig. 17 Activate tolerance band



2.3.3 Activate Look-Ahead Driver (LAD)

Tolerance band In addition to the specified speed profile, driving cycles for statutory emission tests must also have a tolerance band, within which the actual vehicle speed must remain so that the test passes as valid. A test bed driver on a chassis dyno can use this tolerance band in the sense of a minimum throttle movement. Before gear shift procedures, the test bed driver can accelerate the vehicle beyond the demand vehicle speed to compensate for the drop in speed during the gear shifting.

Look-Ahead Driver function

On the dynamic engine test bed, the test bed driver is simulated by a speed regulator. The demand speed at the regulator input and the momentary vehicle speed determine the throttle movement. The look-ahead driver now enables the output of a separate demand speed profile, and this profile simulates the behavior of a test bed driver. Compliance with the tolerance band is checked on the basis of the legally stipulated speed profile.

Driving profile With this tool the modified driving profile can be created. The user may still edit the newly created profile afterwards. The aim of this procedure is to make changes “smoother” at those points of the speed profile where the demand acceleration changes, in order to obtain a lesser throttle movement (alpha) and facilitate the compliance of the actual driving speed with the tolerance band.

The tool forms the linear mean value of the demand speed over a parameterized time and enables the automatic insertion of “gear shift plateaus”. A gear shift plateau is an increase in the demand speed before gear shifting, in order to compensate for the drop in speed of the vehicle during the gear shift procedure.

For driving profiles with a relatively big step duration (e.g.: ECE cycle) additional steps can be inserted at the relevant spots for a finer gradu-ation.

Activation from test cycle

From the test cycle, the look-ahead driver can be activated or deacti-vated by means of activation objects from the BSQ/SSQ.


Additional Points Function

Speed Curve Filtering Function

Raise Shift Plateau Function

Useful Information

Look-Ahead Driver Activation Object

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Additional Points Function

This function is used to generate further demand value points around existing demand value points in a dynamic profile. The demand values that have been defined are interpolated linearily at the newly inserted points.

This function is needed in order to:

generate the key points for the tolerance band to be generated for synthetic driving profiles (e.g. ECE cycles),

guarantee a better possibility of filtering for synthetic and real driving profiles.

LAD time The parameter LAD time defines the time distance of the points to be inserted (by means same number as Tolerance time.

Additional points The parameter Additional points indicates how many points should be generated symmetrically around an existing demand value point.

The number of additionally generated points is predefined at 2,4 or 6.

The time distance in which the additional points are inserted is defined indirectely by the parameterized tolerance time.

2 additional points

If 2 points are inserted, the time distance before and after the existing demand value point exactly matches the parameterized tolerance time.

4 additional points

If 4 points are inserted, these are inserted in addition to the points described above also at half the tolerance time before and after the demand value.

6 additional

Fig. 18 Additional points with LAD

Fig. 19 2 additional points



points If 6 points are inserted, new points are inserted also at one and a half of the tolerance time in addition to the points described above.

Fig. 20 Insertion of additional points with LAD

Note: If with the tolerance band generation function no points before and after the original point at the time distance of the tolerance time are defined, these are generated automatically even if the option Additional points is turned off or if the value is 0.

Note: If any points to be inserted lie before or after an existing point in terms of time, they will not be inserted!

Important: The use of this option leads to a multiplication of data quantities and should preferably be used only for synthetic profile defi-nitions (e.g. ECE cycles)!

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Speed Curve Filtering Function

The Filter speed curve function helps to “smooth” the driving profile within the legally specified tolerance band. In this context, the newly inserted demand value track of the look-ahead driver is modified while the original track of the speed specification remains unchanged.

The algorithm forms the linear mean value over the specified time while compliance with the tolerance band is ensured at the same time.

Requirements The driving profile is filtered under the following criteria:

Control mode RG/v (must also be met in the previous and subse-quent steps)

Gear greater than 0

Filter time Time observed in seconds for the mean value formation.

Utilization Maximum degree of utilitzation of the filtered point relative to the toler-ance band.

Fig. 21 Parameter for speed curve filtering

Fig. 22 Filter speed curve (1)



If the possible time for filtering is smaller than the time that has been specified (at the margins of the area), then the mean is taken over the maximum time still possible.

Fig. 23 Filter speed curve (2)

Note: This also holds true for the beginning of RG/v sequences or for starts from standstill.

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Example: Below an example for the filter:

Fig. 24 Original profile

Fig. 25 Filter time 6 seconds, utilization 80%

Fig. 26 Filter time 10 seconds, utilization 100%



Raise Shift Plateau Function

The Raise shift plateau function serves to raise the demand speed during gear shifting in order to compensate for the drop in vehicle speed that occurs during the gear shift procedure due to air resistance and friction.

With this function the demand speed before and after the gear shift procedure can be “increased” relative to the absolute speed.

Parameters for ’Raise shift plateau’

The following parameters are available for the Raise shift plateau function:

Time before gearshift

This parameter indicates the time of the linear increase before the moment of gear shifting [s].

Time after gearshift This parameter indicates the time of the linear increase after the moment of gear shifting [s].

Raise at100 km/h

Raising of speed at 100 km/h. The respective current value is interpo-lated linearily [km/h]

Note: This function is activated only in the case of shifting to a higher gear.

Important: This function only makes sense for a theoretical shift plateau (synthetic driving profile, e.g.: ECE cycle). In the case of real recorded driving profiles, this behavior already exists in the profile recorded.

Fig. 27 Parameter for "Raise shift plateau"

Note: The respective increase in speed depends on the current demand speed, the parameter Raise at 100 km/h and the time distance to the moment of gear shifting.

At the moment of gear shifting, the increase only depends on the parameter Raise at 100 km/h and the demand speed:

Example: Parameter Raise at 100 km/h = 4 km/h

Demand speed at shift point = 50 km/h

New increased demand speed at moment of gear shifting = 2 km/h

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For all other demand value points within the time range time before gear shifting to time after gear shifting, the increase is interpolated linearily depending on the moment of gear shifting.

Example:

Current demand value point is at a distance of 60% of the time before gear shifting and the relative increase in speed is 2 km/h.

Increase of this demand value is 60% of 2 km/h = 1.2 km/h

Fig. 28 "Raise shift plateau" function

1 Moment of gear shifting2 Points in this area are modified3 Time before gear shifting4 Time after gear shifting5 Increase in speed by 2 km/h6 This point is increased by 60% of 2 km/h (= 100%)

Tabelle 1:

Important: The time definitions for time before gear shifting and time after gear shifting must not overlap with the previous and subsequent increases!



Requirements The criteria for a raise in the gear shift plateau are as follows:

Control mode RG/v must be defined in the previous and subse-quent steps

Gear shift criterion must have been set to ’Gear’

Current gear must be greater than 0 (not when starting)

Subsequent gear must be greater (upshift)

Important: If a further gear shift procedure is defined within the time range to be modified, then changes are executed only up to this procedure.

Fig. 29 Raise shift plateau - time overlap

Fig. 30 Modified demand value curve with gear shift procedure

ATTENTION!

When gear shift plateaus are inserted, it is not monitored whether tolerance bands are observed!

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Useful Information

Synthetically Defined Driving Profiles (examples ECE and Japan cycles)

The demand speed value of the driving profile is based on a theoretical ramp with gear shift plateaus in between. The gear shift plateau is defined with a constant speed during the gear shift procedure.

However, this is not the case in real conditions. The vehicle speed will drop slightly during this phase depending on the existing air resistance and friction. In order to avoid this deviation between demand value and actual value after the gear shift procedure (when the regulator tries to compensate and thus causes higher exhaust emissions), one can use the function “Raise shift plateau”. This function helps to keep the devia-tion as small as possible after the gear shift procedure.

This function can be used together with the “Filter” function and the insertion of additional points.

Real Recorded Driving Profiles (example FTP75)

The speed profile was recorded with a vehicle under real conditions (and with the gear shift procedures carried out). The driving profile therefore also represents the related drop in speed during the gear shift procedure.

Therefore it does not make sense to use the “Raise shift plateau” func-tion for these cycles!

You can use the “Filtering” function in order to optimize the path of the throttle actuator (and the related exhaust emissions) making the best possible use of the statutory tolerances.



Look-Ahead Driver Activation Object

The look-ahead driver function can be turned on and off by means of the step sequence activation object in the BSQ.

This activation object contains the following functions:

Enable look-ahead driver

Disable look-ahead driver

Activation object in test cycle

In the test cycle, you use this activation object as follows:

Fig. 31 "Step Sequence" activation object

Fig. 32 Activation object in test cycle

Important: The look-ahead driver must be activated before the start of the test cycle (which has been generated with look-ahead driver).

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Tolerance Band Monitoring 43

2.4 Tolerance Band Monitoring

The tolerance band monitoring is performed online during the test cycle. This section contains detailed information on the following topics:

Principle of Tolerance Band Monitoring

ECE Monitoring

EPA Monitoring

Online Window

2.4.1 Principle of Tolerance Band Monitoring

The statutory cycles are performed using the driver and vehicle simula-tion (ISAC). Whether the actual speed value is within the tolerance band is monitored during the run time by limit monitoring, scripts and formulas.

Requirements A driving profile with a generated tolerance band must be avail-able (look-ahead driver is optional).

Limit monitoring is active during the whole test cycle.

In the event of a limit violation a script is executed, which issues a message and turns on the cyclic calculation over the duration of the violation. At the same time, a monitoring function to check whether the tolerance limit is reached again is turned on.

The statutory conditions are monitored over the duration of the violation.

When the tolerance limit is reached again, a script is executed, which issues information on the violation.

Further detailed information in this section:



Fig. 33 Tolerance band monitoring


Tolerance Band Monitoring44


These limits apply to the parameters of the individual upper or lower deviations of the current speed and the overall result of the monitoring.

V_ACT > LAH_TB_H

Violation of upper tolerance band occurred

V_ACT < LAH_TB_H

Violation of upper tolerance band within range again

V_ACT > LAH_TB_L

Violation of lower tolerance band occurred

V_ACT < LAH_TB_L

Violation of lower tolerance band within range again

Furthermore, this group contains the monitoring of the overall result which is represented as value of the normname QcNOK (validity of the tolerance band monitoring).

The script LcsVTOLUpper is executed.

Note: For detailed information, please refer to our manual "AT1761 Limit Monitoring"!

Note: The reactions to violations are assigned to the below scripts!

Example: Parameterization of limit monitoring (monitoring of the upper limit):

Fig. 34 Limit monitoring - "Reaction" tab

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Helper scripts and activation objects

In PUMA Open there are following helper scripts available for reaction on limit violations:

Helper scripts

The individual scripts contain the control of the below calculation and the message output with the relevant system information, such as point in time, SSQ step number and duration of the violation.

Behavior in the case of limit violations

If the statutory limits are violated or exceptions occur, the helper script LcsVTOLNotOK which provides information on the cause of the nega-tive evaluation is executed:

VTOLUpper Violation of upper tolerance band occurred

VTOLUpperOK Violation of upper tolerance band within range again

VTOLLower Violation of lower tolerance band occurred

VTOLLowerOK Violation of lower tolerance band within range again

Important: You must insert the respective activation object Legal Cycle Services (according to ECE or FTP) by action track Commands.

Start (FTP) Start of monitoring according to EPA / FTP regulations

Start (ECE) Start of monitoring according to ECE regulations

Important: You must insert the activation object Stop at the end of the driving profile.

Stop Stop of monitoring

LcsVTOLNotOK Tolerance check failed




The cyclic formula is calculated depending on the respective limits and contains the legal exceptions for upper or lower deviations from the statutory limits.

This formula is processed cyclically at a frequency of 10 Hz:

Note: For detailed information on the subject "Formulas in PUMA Open", please refer to our manual "AT1756 Formula Handling"!

public QcCnt, QcCntAct, QcCnt15, QcNOK

if QcEnable then // is tolerance check enabled

QcCnt = QcCnt + 1 // count time

if QcVioTyp = 1 then // check according to EPA regulation

if QcCnt > 20 then // check for violation > 2 sec

if QcCntAct = 0 then // check only once

QcCnt15 = QcCnt15 + 1 // increment counter for violations > 2 sec

if QcCnt15 > 3 then // 2 sec violation more than 3 times

QcNOK = 1 // cycle failed

endif

QcCntAct = 1 // mark as checked

endif

endif

if QcCnt > 150 then // violation longer than 15 sec


endif

endif

if QcVioTyp = 0 then // check according to ECE regulation

if QcCnt > 5 then // check for violation > 0,5 sec


endif

endif

else

QcCnt = 0

QcCntAct = 0

endif

Important: If the normnames are changed, these must be considered in the calculation!

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2.4.2 ECE Monitoring

Deviations by +/- 2 km/h between the speed indicated and the theoret-ical speed during acceleration, constant speed and deceleration when the vehicle is braked are permissible. In a transition from one test section to the next section, higher-than-specified velocity tolerances are permissible as long as such deviation does not last longer than 0.5 seconds.

2.4.3 EPA Monitoring

The following velocity tolerances apply:

Upper limit 3.2 km/h over the highest point of the curve during one second of the specified time span.

Lower limit 3.2 km/h under the lowest point of the curve during one second of the specified time span.

Permissible upper deviations

Fluctuations in speed which exceed these limits (as might be the case during gear shifting) are permissible if they do not last for more than 2 seconds at a time.

Up to three additional violations of the velocity tolerance are per-missible, as long as they are less than 15 seconds and clearly documented.



2.4.4 Online Window

At the beginning of the test cycle, the online window of the monitoring is displayed:

QualCheck indicator upper viol.

These fields show colors (red/green) for the status of the current toler-ance violation.

QualCheck indicator lower viol.

These fields show colors (red/green) for the status of the current toler-ance violation.

QualCheck counter actual violat.

This field indicates the current duration of a violation in seconds.

Quality Check failed whole cycle

This field gives a visual indication (red/green) of the current total status of violations according to the applicable legislation.

Normnames The normnames that are available can be used for further decisions during the test cycle (e.g. cancel current test cycle if it is no longer valid).

Fig. 35

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Messages window

The messages window indicates the violations that occurred and their elimination, togther with the respective number, time, step number and duration:

Fig. 36 Messages window



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Overview 51

3 Heavy Duty Cycles ETC and HDTC


Overview

Requirements

Parameterization of Full Load Curve Recording

Test Description

Test Execution

Regression Analysis

3.1 Overview

Requirement for tests

Before the execution of a test, it is necessary to record the full load characteristic for denormalization.

These data can be stored in the Unit Under Test Parameters (UUT) for later tests.

Content of test cycle

The automatic test cycle contains the following steps:

Start recorder All data that are relevant for evaluation (regression analysis) are stored as recorder data in the test result.

Run test cycle When the profile is loaded (normalized values), the data that have been determined by means of recording the full load characteristic (reference speed for 0% and 100% or torque values of the full load characteristic) are denormalized.

During the run, these data (demand and actual values) are stored in the ASAM-ODS database.

Store relevant characteristic quantities

For the evaluation it is also necessary to store the relevant character-istic quantities. Those are for example:

Max. torque of full load characteristic

Speed with maximum torque

Maximum power

Speed with maximum power

Start evaluation The evaluation (PUC/CONCERTO) is automatically started by means of the activation object Regression Analysis, function Start Applica-tion.

Trigger evaluation The evaluation is triggered by means of the activation object Regres-sion Analysis, function Analyze.

Calculate regres-sion results

The regression analysis is made on the basis of the results stored in the database (recorder data and the characteristic quantities stored) using scripts and macros in PUC/CONCERTO.

PUMA Open PUMA Open PUMA Open PUMA Open S t a t u t o r y T e s t s - H e a v y D u t y

Overview52

Transfer of results The results obtained must be transferred from PUC/CONCERTO to PUMA. This means, the statutory limits and the characteristic quanti-ties of the regression analysis that were determined online are sent from PUC/CONCERTO to PUMA.

Storing results PUMA stores the results in the form of a measurement.

Displaying the values of a regres-sion analysis

The current values (and limits) are displayed in a separate PUMA window.

The color markings (red/green) provide information on compliance with the respective statutory limits.

All results and limits are available as normnames in the PUMA Open system.

Fig. 37 Function of heavy duty test cycles in PUMA Open

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Requirements 53

3.2 Requirements

Certain requirements must be met in order to be able to work with heavy duty test cycles. This section contains detailed information on the following requirements:

Additional Normnames

Modification of Test Facility Parameters (TFP)

Modification of Unit Under Test Parameters (UUT)

Test Import (BSQ, SSQ)

Parameterization of Full Load Curve in EMP

Parameterization ETC (ECE)

Parameterization HDTC (EPA)

Overview

Recorder Parameterization (REC)

Profile Parameterization (SSQ)

Parameterization for Regression Analysis Activation

Full Load Curve Recording

Test Run

Function

Results

3.2.1 Additional Normnames

Additional normnames are needed in order to be able to carry out the regression analysis.

Important: These normnames are taken into account automatically with standard installations.

If you use a customer specific normname directory, you will have to add the following normnames with NED:

Norm-name (English)

Norm-name (German)

Description Unit D DT M# BK B# S# VG#

OFF

System Name

DNORMTYP

DNORMTYP

Transient denorm. 0=US,1=EU,2=no

- 0 Real 8 30 1 2 7 0 DNORMTYP

N_REF0 N_REF0 Speed 0% for Transient denorm.

rpm 1 Real 8 30 1 2 5 0 N_REF0


Requirements54

N_REF100 N_REF100 Speed 100% for Transient denorm.

rpm 1 Real 8 30 1 2 6 0 N_REF100

T_MAX_FL M_MAX_VL

max.torque from full load curve

Nm 0 Real 1 21 1 1 1 0 T_MAX_FL

N_TMAXFL

N_TMAXVL

Speed at max.torq.full-load curve

rpm 0 Real 1 21 1 1 2 0 N_TMAXFL

P_MAX_FL

P_MAX_FL

Max.Power from full load curve

kW 0 Real 1 21 1 1 3 0 P_MAX_FL

N_PMAXFL

N_PMAXFL

Speed max.Power full load curve

rpm 0 Real 1 21 1 1 4 0 N_PMAXFL

CITT CITT Curb idle transmittion torque

Nm 0 Real 8 24 1 3 1 72 ECT_CITT

N_MRS N_MRS Measured rated speed acc. to EPA

rpm 0 Real 8 30 1 7 1 0 EPA_N_MeasRated

NREF_ECE

NREF_ECE

Param. rated speed acc. to ECE

rpm 0 Real 8 30 1 7 1 4 EMP_N_Ref

N_FL_MAX

N_VL_MAX

Max. speed for full load curve

rpm 0 Integer

8 30 1 4 1 2 EMP_FL_Nmax

N_FL_MIN N_VL_MIN Min. speed for full load curve

rpm 0 Integer

8 30 1 4 1 0 EMP_FL_Nmin

REG_PHAS

REG_PHAS

Regression phase

- 0 Real 8 24 0 0 0 0 REG_PHAS

TRAN-STYP

TRAN-STYP

Type of transmission 0=Man 1=Aut

- 2 Integer

8 26 1 3 1 8 TRANSTYP

actgd_n actgd_n Regression: slope speed

- 2 Real 1 23 1 1 1 14 actgd_n

actgd_md actgd_md Regression: slope torque

- 2 Real 1 23 1 1 1 18 actgd_md

actgd_p actgd_p Regression: slope power

- 2 Real 1 23 1 1 1 22 actgd_p

acto_n acto_n Regression: offset speed

rpm 2 Real 1 23 1 1 1 26 acto_n

acto_md acto_md Regression: offset torque

Nm 2 Real 1 23 1 1 1 30 acto_md

Norm-name (English)

Norm-name (German)


OFF

System Name

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Requirements 55

acto_p acto_p Regression: offset power

kW 2 Real 1 23 1 1 1 34 acto_p

actc_n actc_n Regression: coefficient speed

- 2 Real 1 23 1 1 1 38 actc_n

actc_md actc_md Regression: coefficient torque

- 2 Real 1 23 1 1 1 42 actc_md

actc_p actc_p Regression: coefficient power

- 2 Real 1 23 1 1 1 46 actc_p

actse_n actse_n Regr.: stan-dard devia-tion speed

rpm 2 Real 1 23 1 1 1 50 actse_n

actse_md actse_md Regr.: stan-dard devia-tion torque

% 2 Real 1 23 1 1 1 54 actse_md

actse_p actse_p Regr.: stan-dard devia-tion power

% 2 Real 1 23 1 1 1 58 actse_p

act_sht act_sht Regression: shift of values

s 2 Real 1 23 1 1 1 62 act_sht

actd_p actd_p Regr.: number of deleted points

- 2 Real 1 23 1 1 1 66 actd_p

act_pi act_pi Regression: integrated power

- 2 Real 1 23 1 1 1 70 act_pi

act_pd act_pd Regression: integr. dem. power

- 2 Real 1 23 1 1 1 74 act_pd

RA_Start RA_Start Start of eval-uation

s 1 Real 10 50 1 2 1 0 RA_Start

RA_Nmaxd

RA_Nmaxd

Maximum std. devia-tion speed

rpm 0 Real 10 50 1 2 2 0 RA_Nmaxd

RA_Nming RA_Nming Minimum gradient of speed

- 3 Real 10 50 1 2 3 0 RA_Nming

RA_Nmaxg

RA_Nmaxg

Maximum gradient of speed

- 3 Real 10 50 1 2 4 0 RA_Nmaxg

RA_Nmaxo

RA_Nmaxo

Maximum offset of speed

Rpm

0 Real 10 50 1 2 5 0 RA_Nmaxo

Norm-name (English)

Norm-name (German)


OFF

System Name


Requirements56

RA_Nminc RA_Nminc Minimum correlation of speed

- 3 Real 10 50 1 2 6 0 RA_Nminc

RA_Tmaxd RA_Tmaxd Maximum std. devia-tion torque

Nm 1 Real 10 50 1 2 7 0 RA_Tmaxd

RA_Tming RA_Tming Minimum gradient of torque

- 3 Real 10 50 1 2 8 0 RA_Tming

RA_Tmaxg RA_Tmaxg Maximum gradient of torque

- 3 Real 10 50 1 2 9 0 RA_Tmaxg

RA_Tmaxo RA_Tmaxo Maximum offset of torque

Nm 1 Real 10 50 1 2 10 0 RA_Tmaxo

RA_Tminc RA_Tminc Minimum correlation of torque

- 3 Real 10 50 1 2 11 0 RA_Tminc

RA_Pmaxd RA_Pmaxd Maximum std. devia-tion power

KW 1 Real 10 50 1 2 12 0 RA_Pmaxd

RA_Pming RA_Pming Minimum gradient of power

- 3 Real 10 50 1 2 13 0 RA_Pming

RA_Pmaxg RA_Pmaxg Maximum gradient of power

- 3 Real 10 50 1 2 14 0 RA_Pmaxg

RA_Pmaxo RA_Pmaxo Maximum offset of power

KW 2 Real 10 50 1 2 15 0 RA_Pmaxo

RA_Pminc RA_Pminc Minimum correlation of power

- 3 Real 10 50 1 2 16 0 RA_Pminc

RA_Pmini RA_Pmini Minimum integrated power

- 2 Real 10 50 1 2 17 0 RA_Pmini

RA_Pmaxi RA_Pmaxi Maximum integrated power

- 2 Real 10 50 1 2 18 0 RA_Pmaxi

DYS_CONT

DYS_CONT

Control mode of DYS

- 0 Integer

2 4 1 1 1 36 DYS_CONT

PUCSYNC PUCSYNC Syncronisa-tion with PUC

- 0 Integer

8 24 0 0 0 0 PUCSYNC

Norm-name (English)

Norm-name (German)


OFF

System Name

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Requirements 57

3.2.2 Modification of Test Facility Parameters (TFP)

The standard installation already includes the below modifications. If you use customized parameters, the following additions are required.

Further data storage tables

Create the following new data storage tables (DST) in the parameter block TFP using PAM:

1. DSTHDTD

Contains the characteristic quantities for the regression analysis.

2. Name DSTHDTR

Contains the results of the regression analysis.

Fig. 38 Storage table DSTHDTD

Fig. 39 Storage table DSTHDTR


Requirements58

Additions in KEY 3. Add the following entries (storage keys) to the parameter block KEY:

RA and

RR

3.2.3 Modification of Unit Under Test Parameters (UUT)

The standard installation already includes the below modifications. If you use customized parameters, the following additions are required.

Modifications in ECT

1. You must expand subgroup REAL by adding normname REG_PHAS in the parameter block ECT.

2. In the parameter block ECT you must expand subgroup INTEGER by adding the normnames SELECT and PUCSYNC:

Fig. 40 Parameter block KEY

Fig. 41 Parameter block ECT (subgroup REAL)

Fig. 42 Parameter block ECT (subgroup INTEGER)

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Requirements 59

3.2.4 Test Import (BSQ, SSQ)

Carry out the following steps in order to import a test:

1. Start the Application Manager

2. Start the AVL Explorer

3. Select target directory (e.g. NameOfComputer/Projects/AVL/ Project Data)

4. Choose the function Import in the right-hand area of the BSQ (click with left mouse button in the right-hand window).

5. Import the desired XML files from the dat\xml directory (TST_ETC.XML or TST_HDT.XML).

6. Generate test cycle.

Fig. 43 Import test cylce in BSQ


Parameterization of Full Load Curve Recording60

3.3 Parameterization of Full Load Curve Recording

The full load characteristic is recorded automatically (with a constant gradient of 8 rpm) to form the basis for the denormalization of the demand value tracks, which is absolutely necessary for running tran-sient test cycles. According to the test cycle (HDTC or ETC) the respective full load curve is selected and parameters for the engine specific speeds are defined when the unit under test is parameterized (block EMP and block ECT).

3.3.1 Parameterization of Full Load Curve in EMP

You must define the following parameters in parameter block EMP:

Minimum [rpm] This parameter is used to define the lower limit of the engine map (should be less than or equal to the value of the curb idle speed parameter from ECT).

Fig. 44 Parameter block EMP

Important: If the speed limits (minimum, maximum) are changed, you must expand the data range using the menu item Expand from the PAM main menu bar. All torque values are set to 0 and a new recording of the full load characteristic is necessary.

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Parameterization of Full Load Curve Recording 61

Maximum [rpm] This parameter is used to define the upper limit of the engine map.

Ramp [rpm/s] This value (8 rpm/s) is specified by the relevant legislative body and cannot be altered.

Alternative normname of speed

Depending on the case, you may either parameterize a normname or leave this field blank:

Standard case If this field remains blank, the value of the normname from parameter block EMC that is allocated to system channel SV_dyno_speed is used (mostly N or SPEED)

Exceptional case If you wish to use a different speed signal (e.g. filtered more strongly), you must parameterize this normname.

Alternative normname of torque

Depending on the case, you may either parameterize a normname or leave this field blank:

Standard case If this field remains blank, the value of the normname from parameter block EMC that is allocated to system channel actual_ torque is used. It is subject to the respective configuration:

Dyno type APA100 ELB or HLB:

The normname of SV_dyno_Te_loadcell is used.

Dyno type AMK or AFA:

The normname of SV_torque_shaft is used (mostly TORQUE).

Exceptional case If you wish to use a different torque signal (e.g. filtered more strongly), you must parameterize this normname.

Full load curve according to

Here you select the relevant legislation:

ETC(EU) The parameterized reference speed according to ECE specified by the relevant legislative body is used for denormalization.

HDTC(US) The higher value of rated speed (from ECT) or measured rated speed according to EPA is used for denormalization.

Important: If the speed limits (minimum, maximum) are changed, you must expand the data range using the menu item Expand. All torque values are set to 0 and a new recording of the full load charac-teristic is necessary.

Important: The new normname must be defined also in the recorder and in the PUC INI-file (..\instpath\puc\data\req4puc.ini)!

Important: The new normname must be defined also in the recorder and in the PUC INI-file (..\instpath\puc\data\req4puc.ini)!



Measured rated speed according to EPA

This value is determined during the run time from the full load charac-teristic curve according to the regulations and can be displayed only after storing the Unit Under Test Parameters (once the full load curve has been parameterized according to HDTC). This value cannot be parameterized.

Parameterized reference speed according to ECE

When parameterizing the full load curve according to ETC, you must enter the reference speed (nref) for denormalization. The reference speed is determined from the steady-state measurement of the full load curve of the engine under net conditions.

Speed [rpm] This parameter indicates those speed values (x-axis for full load curve) at which the full load points are recorded.

Throttle [%] This value is constantly preset to 100% for the recording of a full load curve (and cannot be parameterized).

Torque [Nm] During the recording of a full load curve, these values are measured online; however, they can be edited later.

Important: When parameterizing a full load curve, you must take into consideration the following situations:

New parameters, or no full load curves have been recorded and stored:

In this case, the torque values are still 0. To run a statutory test cycle, you must record a full load curve!

Speed limits (minimum, maximum) have been changed and newly generated by means of “Expand”:

As all torque values are set to 0, a new recording of the full load characteristic is necessary.

Full load curve has been recorded and stored; however, a new curve should be recorded:

Use the menu item Expand from the PAM main menu bar to delete the data range. All torque values are set to 0 and a new recording of the full load characteristic is necessary.

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Parameterization of Full Load Curve Recording 63

3.3.2 Parameterization ETC (ECE)

For ETC you must perform the following parameterization:

Parameterization in ECT

Curb idle speed [rpm]

Set the parameters for the curb idle speed (rpm).

Parameterization in EMP

Minimum [rpm]

Maximum [rpm]

Full load curve according to ETC (EU):

Parameterized reference speed according to ECE

Fig. 45 Parameter block ECT for ETC (ECE)

Fig. 46 Parameter block EMP for ETC (ECE)



3.3.3 Parameterization HDTC (EPA)

For the HDTC (EPA) you must perform the following parameterization:

Parameterization in ECT

Rated speed [RPM] for determining the upper reference value (max from ..)

Curb idle speed [rpm]

Curb idle transmission torque CITT [Nm] (ECT block)

Fig. 47 Parameter block ECT for HDTC (EPA) (1/2)

Fig. 48 Parameter block ECT for HDTC (EPA) (2/2)

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Test Description 65

3.4 Test Description


Overview

Recorder Parameterization (REC)

Profile Parameterization (SSQ)

Parameterization for Regression Analysis Activation


Test Run

Function

Results

3.4.1 Overview

A BSQ test consists of various BSQ components (activation objects, BSQ objects, commands, etc.).

This imported test includes the BSQ objects Dynamic Steps and Recorder and Regression Analyses.

Fig. 49 Test run TST_ETC (BSQ)


Test Description66

Dynamic Steps and Recorder

BSQ object Dynamic Steps and Recorder defines the activation of recorder and profile.

Regression Analyses

BSQ object Regression Analyses defines the activation of evaluation.

Fig. 50 BSQ object Dynamic Steps and Recorder

Fig. 51 BSQ object Regression Analyses

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Test Description 67

3.4.2 Recorder Parameterization (REC)

The recorder (RECORDER_EURO3_ETC or RECORDER_HDT) contains all quantities necessary for the evaluation. They may not be altered or removed.

General tab The General tab of REC contains the following parameters:

Storage tab The storage tab of REC contains the following parameters:

Fig. 52 REC - General tab

Important: Pay attention to the result name (REG)!

Fig. 53 REC - Storage tab


Test Description68

Channels tab The Channels tab of REC contains the following parameters:

Fig. 54 REC - Channels tab

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Test Description 69

3.4.3 Measurement Request (MRQ)

Parameterzization of measurement requests (MRQ)Two measurement requests are required for the evaluation:

MRQD and

MRQR

MRQD This MRQ must be parameterized as follows:

Name: MRQD (in the General tab)

Result key: RA (in the General tab)

Storage table: DSTHDTD (in the Storage tab)

Fig. 55 MRQD - General tab


Test Description70

MRQR This MRQ must be parameterized as follows:

Name: MRQR (in the General tab)

Result key: RA (in the General tab)

Storage table: DSTHDTR (in the Storage tab)

Fig. 56 MRQR - General tab

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Test Description 71

3.4.4 Profile Parameterization (SSQ)

The test cycle includes the profiles ETCDYS or HDTDYS1 and HDTDYS2, respectively:

Fig. 57 Step sequences in BSQ/SSQ


Test Description72

3.4.5 Parameterization for Regression Analysis Activation

The regression analysis is activated in the test cycle by means of an activation object. This activation object Regression Analysis contains the following functions:

Start Application

Analyze

Before the activation object is used, the normname PUCSYNC is set to “0”, and after execution of the analysis (during which this normname is set to “1”), the system waits until the value is greater than “1”.

Fig. 58 Activation object for regression analysis

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Test Execution 73

3.5 Test Execution

Test execution includes the following work steps:


Test Run

Function

Results

3.5.1 Full Load Curve Recording

In the PUMA Open operating state MANUAL, you can open the Full Load Curve window by use of the menu item Functions | Engine | EMP Full Load Curve.

Start Starts recording of full load curve (only possible if the engine has been started).

Stop Stops recording of full load curve.

Fig. 59 Full load curve


Test Execution74

Save The Save function is used to store the Unit Under Test Parameters (UUT) including the full load curve.

In addition to the parameters of the full load curve, the following refer-ence speeds used for the denormalization are represented:

N_REF0 Reference speed for 0 %

N_REF100 Reference speed for 100 %

Note: If the measured rated speed nMRS cannot be calculated during the recording according to EPA, the following message will appear:

“Cannot calculate measured rated speed out of full load curve!”

This is the case, for instance, if the 98% value of the maximum power curve could not be determined.

Remedy: Increase speed of full load curve.

Important: When recording a full load curve, you must take into consideration the three following situations:

The speed limits (minimum, maximum) have been changed:

As all torque values are set to 0, a new recording of the full load characteristic will be necessary.

No full load curve has been recorded yet:

In this case, the torque values are still 0. To run a statutory test cycle, you must record a full load curve!

A full load curve has already been recorded and stored:

It is not necessary, but you may record the full load curve again.

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Test Execution 75

3.5.2 Test Run

After the test run has been started, the Recorder window is activated, which shows the test progression.

Fig. 60 Recorder during test run


Regression Analysis76

3.6 Regression Analysis

The regression analysis is performed by means of the data postpro-cessing tool (PUC or CONCERTO), which enables the calculation of quality criteria such as gradient, offset, correlation coefficient and standard deviation.

3.6.1 Function

The below calculations are carried out for speed, torque und power.

They are given in the formulas using speed as one example:

Regression

Fig. 61 Regression

Offset and gradient are calculated so that

attains a minimum value.By contrast,

and n ist the number of stored values.

n_regress n_offset n_gradient n_demand×+( )=

(n_errori)2

1

n∑

n_errori n= _regressi n_actuali–

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Regression Analysis 77

Standard deviation

Correlation coef-ficient

Integrated power

Tab. 2

rd 1n 2–------------ (n_offset n_gradient n_demandi n_–×+

1

n∑×=

The averaged actual speed is calculated as follows:

The averaged demand speed is:

n_corr

(n_actuali n_actual_aver) (n_demandi n_demand_aver)–×–1

n∑

(n_actuali n_actual_aver) (n_demandi n_demand_ave–1

n∑× r)–

1

n∑

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------=

n_actual_aver 1n--- n_actuali

1

n∑×=

n_demand_aver 1n--- n_demandi

1

n∑×=

The integrated power is calculated for both the demand values and actual values.

Integrated actual power (only positive power is taken into account):

Integrated demand power (only positive power is taken into account):

Difference between integrated actual power and demand power in percent:

p_actual_integr p_actuali1

n∑=

p_demand_integr p_demandi1

n∑=

p_actual_integrp_demand_integr------------------------------------------ 1– 100×


Regression Analysis78

3.6.2 Results

After the regression analysis has been calulated, the results are displayed automatically in the PUMA Open window shown below.

For speed, torque and power, the respective gradient, offset, correla-tion coefficient and standard deviation are calculated and displayed together with the statutory limits.

The integrated power, integrated demand power and power deviation are calculated.

In addition, the number of deleted points (normname acd_p) is avail-able and the time shift in [s] is displayed.

If all criteria are met, this can be seen easily from the color of the title bar (Quality Check Regression) (green = ok, red = error).

Fig. 62 POI window Regression Analysis

Important: The statutory limits are coded in the PUC formulas and cannot be changed.

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ESC Test Cycle 79

3.7 ESC Test Cycle

The ESC test cycle (European Stationary Cycle) is a 13-mode steady-state cycle, which is used to test the engine on the test bed in a number of steady-state modes. During the specified time the engine must be operated in every mode and carry out the engine speed changes and load changes in the first 20 seconds. Emissions are measured in every mode and calculated on the basis of the respective weighting factor.

The respective inspector in charge may require additional arbitrarily chosen modes during the certification.

The below table lists the respective modes (speed and torque) and the duration.

ESC Test Modes

Mode Engine Speed Load in %

Weighting % Duration

1 Idle 0 15 4 minutes2 A 100 8 2 minutes3 B 50 10 2 minutes4 B 75 10 2 minutes5 A 50 5 2 minutes6 A 75 5 2 minutes7 A 25 5 2 minutes8 B 100 9 2 minutes9 B 25 10 2 minutes10 C 100 8 2 minutes11 C 25 5 2 minutes12 C 75 5 2 minutes13 C 50 5 2 minutes


ESC Test Cycle80

Graphical repre-sentation of modes

The engine specific speeds A, B and C are determined as follows:

High speed The high speed n hi is the speed at which 70% of the maximum net power are attained.

Low speed The low speed n lo is the speed at which 50% of the maximum net power are attained.

Formulas for engine speeds

The engine speeds A, B and C must be calculated according to the following formulas:

A = nlo + 0.25(nhi - nlo)

B = nlo + 0.50(nhi - nlo)

C = nlo + 0.75(nhi - nlo)

Fig. 63 Modes

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ESC Test Cycle 81

The torque is determined from full load at a percentage rate relative to the respective speed point.

3.7.1 Generation of ESC Test Cycle

The step sequences “CycleTemplates” included in the delivery (see chapter “Test Import (BSQ, SSQ)” on page 59) contain two templates for the ESC test cycle:

ECSTemplate - template of ESC test cycle

ESCTemplateAdditional - template of ESC test cycle including additional points (modes)

These contain the statutory step sequences, which can be adjusted to the respective predefinitions of speeds A,B and C and the maximum torques thus rendered.

Fig. 64 Modes A, B, C

Important: The speeds A, B and C must be determined manually.


ESC Test Cycle82

A new step sequence is generated.

Invoke the ESC tool from the PUMA Open Explorer:

Procedure for generation:



3. Select the step sequence template (default: ESCTemplate).

4. Start generation by choosing Tools | European Stationary Cycle (ESC).

5. Set the parameters.

6. Press the OK button.

Fig. 65 Generate new step sequence

Note: For detailed information, please refer to “ESC Sequence” on page 83.

Note: The profile that has been generated only becomes visible after the F5 key has been pressed.

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ESC Test Cycle 83

When you start the generation of the new ESC sequence, the ESC window is displayed:

The parameters in this window have the following meaning:

ESC Sequence Input field for the name of the sequence to be generated (default setting is automatically proposed with extension _esc).

The following input fields refer to the 3 characteristic speed levels A,B and C:

Engine speed [rpm]

Input field for the speed.

Load [Nm] Input field for the maximum torque.

Correction Input field for the torque correction value (which is an absolute value added to the calculated load)

The parameters contained in the step sequence template such as, e.g.: engine commands, measurements, activation objects, etc. remain the same during the generation.

Fig. 66 ESC properties

ATTENTION:

Modifications in the profile are overwritten if the generation is repeated!

Important: Modifications that are intended to remain during the generation may only be made in the original profile!


ESC Test Cycle84

3.7.2 Parameters of ESC Test Cycle

The result of the generation is a step sequence with the values calcu-lated for the 13 modes:

Fig. 67 New step sequence for ESC

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Index 85

PUMA Open PUMA Open PUMA Open PUMA Open Gesetzliche Prüfläufe Light DutyGesetzliche Prüfläufe Light DutyGesetzliche Prüfläufe Light DutyGesetzliche Prüfläufe Light Duty

PUMA Open PUMA Open PUMA Open PUMA Open S t a t u t o r y T e s t C y c l e s - L i g h t D u t

Index

AAAAActivation area 22Activation objects 18, 31, 32, 42Additional points 23, 27Application packages 6

BBBBBSQ 59

CCCCCalculated quantities 12Control mode RG/v 35, 40

DDDDDemand speed 32Demand value points 33Demand value tracks 21, 35Deviations 47Driving profiles 13, 35

Import 13Real 33Real recorded 38, 41Synthetic 33, 38Synthetically defined 41

EEEEECE defaults 24ECT 58EMCON400 5EMP 60ETC 63

FFFFFilter time 23, 27, 29Filtering 33Formulas 46

cylic 46FTP defaults 24

GGGGGear 35, 40Gear shift 24

Time after 24, 27, 29, 38Time before 24, 27, 29, 38

Gear shift procedures 32, 38Gear shifting 32, 38

HHHHHDTC 64

IIIIISAC400 5

KKKKKEY 58

LLLLLimit 46, 47

Lower 47Upper 47

Limit violations 43Look-ahead driver 42

Disable 42Enable 42

MMMMMean value 35Mean value formation 35Messages window 49Monitoring 45

Start acc. to ECE 45Start acc. to EPA 45

MRQD 69MRQR 70

NNNNNormname directory 12

Customer specific 12Normnames 12, 46, 48

Additional 12

PPPPPAPACSI 59Permissible upper deviations 47Points 29

Additional 29, 33Filtered 35Inserted 33

RRRRRaise at 100 km/h 27, 29, 38Raise speed 38REC 67

SSSSSequence name 22Shift plateau 32, 41

Raise 27, 29Smoothing 35Speed limit 23

Lower 23, 27, 29Upper 23, 27, 29

System channels 26

TTTTTolerance band 32, 35, 44

Reactions to violations 44Violation lower 44Violation upper 44

Tolerance time 23, 27, 29, 33Tolerance tracks 26TST_ETC.XML 59TST_HDT.XML 59

UUUUUtilization 23, 27, 29

VVVVViolations

Total status 48

Index86

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AVL List GmbH

Hans-List-Platz 1, A-8020 Graz, Austria

Tel.: +43 316 787-0, Fax: +43 316 787-400

http://www.avl.com

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