Calibration of Fuel Consumption Devices

@ ASAM Open Technology Forum

Dr. M. Wiesinger, R. Schantl
18.5.2011

AVL OPEN DEVELOPMENT PLATFORM

Common Requirement Management

Office
Simulation

MIL/SIL
Testing

HIL
Testing

Battery
TestBed
Testing

E-Motor
TestBed
Testing

Engine
TestBed
Testing

AWD
TestBed
Testing

Chassis
Dyno
TestBed
Testing

Road
Testing

Models

Real World

Virtual World

Common Dataware, Modelware, Testware

Evaluations
Calibration Data
Test methods

Test Processes
Why should it fly?
We have a heterogenous Tool Chain
Consistent,
comparable
results
We
need homogenous
Data

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

AVL OPEN DEVELOPMENT PLATFORM

Common Requirement Management

Office
Simulation

MIL/SIL
Testing

HIL
Testing

Battery
TestBed
Testing

E-Motor
TestBed
Testing

Engine
TestBed
Testing

AWD
TestBed
Testing

Chassis
Dyno
TestBed
Testing

Road
Testing

Models

Real World

Virtual World

Common Dataware, Modelware, Testware

Evaluations
Calibration Data
Test methods

Test Processes
Why should it fly?
We have a heterogenous Tool Chain
Consistent,
comparable
results
We
need homogenous
Data

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

OVERVIEW

Why to calibrate fuel consumption instruments?

Calibration in accordance to EPA CFR Part 1065 / ECE R49

Calibration Methods Analysis - Discussion

Summary

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

Why to Calibrate (Fuel) Instruments?

Regulations:

ISO
In accordance to supplier information

US EPA CFR Part 1065 / UN ECE R49

For performing emission certification test runs

Quality Insurance:

Projects
To reduce repetitive measurements caused by erroneous results
To identify reasons for implausible results (e.g.: leakages, engine)

Facilities
To enable flexible use of test cells by facility-wide comparable
measurements

Company-Locations
To ensure comparable results at different development locations

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

What does that mean for the equipment and the

procedures?

Easy and fast installation

Low calibration effort with minimum use of resources

(fuel, manpower, test-bed downtime)

Secure procedure (reproducible and precise results)

Fulfillment of ISO and Emission Regulations

Automatically generated standardized calibration

reports

Compatibility of different fuel measurement devices

Calibration of the whole measurement chain

Clear traceability of calibration equipment (PTB, NIST)

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

EPA CFR Part 1065 / UN ECE R49

Calibration tasks defined by regulations:

Linearity verification

EPA: on annual basis or more frequently if required by supplier

ECE: upon suppliers information

Verification of accuracy, repeatability and noise

EPA: recommended upon initial installation and after major maintenance

ECE: not required

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

Linearity verification
max. engine fuel consumption

Calibration procedure:

m& UUT = a0 + a1m& REF

measurement device (UUT)

Estimate of Error

a0

Standard Estimate of Error

10 calibration points

Zero the instrument

Determine max. flow rate

Calibrate at 10 flow rates

for 30s @ 1Hz

Calculate least square

linear regression

tan = a1

zero point

reference value (REF - Calibration device)

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

m& UUT = a0 + a1m& REF

Calculate Standard
Estimate of Error

Calculate Coefficient of
2
Determination r

Linearity verification limits

Parameter

Formal description

Limit

Absolut value of offset

a0

1% m& max

Slope

a1

0.98 K 1.02

Standard Estimation of Error

SEE

2% m& max

Coefficient of Determination

r2

0.990

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

flow rate

Verification of accuracy, repeatability and noise

Standard Deviation

Accuracy

Error

Zero device

Adjust mean flow rate of
test

calibration points
REF

error

Calibration procedure:

Repeatability = 2

UUT

Calibrate 10 x 30s @ 1Hz

@ mean flow rate of test

Calculate:

std

calibration points

Noise=2 rms

Mean value

Standard deviation

errors

calibration points

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

Calculate Accuracy,
Repeateability and Noise
10

Verification limits

Parameter

Formal description

Limit

Accuracy

m& UUT m& REF

2% of point or
1.5 % of max.

Repeateability

1% of point or
0.75 % of max.

Noise

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

2 rms

0.5 % of max.

11

Calibration methods
Master Calibration
Fuel
Reference

Fuel
Measurement

Limited environmental influences

Sensor calibration

No information on the whole fuel

circuit

Fuel
Conditioning

Master
Sensor

AVL Mass Flow Meter

A
m= p
g

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

12

Calibration Methods
Direct Sensor Calibration

Fuel
Measurement

Limited environmental influences

Calibration of sensor function

instead of calibration of the flow
rate

No information on the whole fuel

circuit

Not allowed for EPA / ECE

calibration

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

13

Calibration Methods
System Calibration

AVL Fuel Reference

Fuel
Measurement

Fuel
Conditioning

Same environmental influences

as during measurement

System calibration

All measurement influences are

validated (measurement device,
setup on the test cell,
environmental conditions)

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

Fuel
Reference

14

Influences on Fuel Calibration

Fuel
Measurement

Fuel
Reference

Fuel
Conditioning
Ambient temperature

Fuel Consumption

Sensor

Fuel Consumption

UUT
Fuel Return

Leveling by Fuel Conditioning

Virtual flow rate by heat influence

M& =

cp

( ... Volume expansion; cp spec. heat cap. @ const. press.

with

cp

g
hW

Storage effects of pressure regulators and elasticities (hoses)

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

15

AVL Fuel Reference

System Calibration

AVL Fuel Reference

Fuel
Measurement

Fuel
Conditioning

Performs a complete System calibration

Circulates fuel back to the UUT to minimize temperature

effects and spare fuel

Monitors automatically environmental conditions

Manual or automated flow rate adjustment

Automated report generation in accordance to US EPA

and UN ECE

Minimized calibration effort

Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

Fuel
Reference

16

SUMMARY

New emission legislation require extended calibration and verification methods
for fuel consumption devices

Sensor calibration cannot fulfill a complete validation of the fuel system

By a system calibration all influences on the test bed can be validated and
checked

To prevent environmental influences to the calibration results automated
monitoring and procedures are advantageously

The AVL Solution AVL Fuel Reference serves as a solution for fulfilling today's
calibration demands on the test bed:

Calibrations in conformance to ISO, US EPA and UN ECE

Comparable measurement results in the whole test field (one calibration
solution for all fuel consumption measurement devices)

Easy and fast identification of reasons in case of implausible measurement
results
Dr. M. Wiesinger ASAM Open Technology Forum, May 2011

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