ENGINE HD AND NRMM

HORIBA solutions for heavy duty applications

Dr. Javier Gómez – Global Application Manager Engine Test

© 2021 HORIBA, Ltd. All rights reserved

Agenda

1 Motivation

2 Engine Dynamometers – Tandem configuration

3 FQ – Fuel Flow Meter

4 MEDAS – Altitude Emulator

5 RDE+ – Road to rig correlation

6 Conclusions

© 2021 HORIBA, Ltd. All rights reserved 2

MOTIVATION

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Overview
Product Overview

Engine Test Wind Tunnel

Systems & Balances
Dynamometers

Chassis Altitude Simulation

Dynamometers Mechatronics & Thermal
Mechanical System Testing

Brake
Dynamometers Fuel Flow
Measurement

Container Test
Cell Solutions

© 2021 HORIBA, Ltd. All rights reserved 4

Motivation
Heavy Duty legislation trend

Heavy duty on-road Other off-road

4% of the on-road fleet in the EU Multiple possible configurations depending on
the demands and technologies
25-30% of on-road CO2 emissions
Operational costs are utmost important to be
75% of the freight tone-kilometers competitive in the future

EU-28 CO2 EMISSIONS

3.64GTCO2

Marine
GHG emissions from international shipping Transport
represent 2,2% of the total
Annual growth of world’s trade carried by sea: Others
3,8%
Target reduction of ships’ GHG by 2050: >50%
Source: “Overview of the heavy-duty vehicle market and CO2 emissions in the European
Union”, Muncrief, R. and Sharpe, B., ICCT Working Paper 2015-16

© 2021 HORIBA, Ltd. All rights reserved 5

Motivation
RDE topics
Effort and Cost

Yesterday RDE: increased effort, time & risk

Concept Development Certification SOP Load
▪ No empty vehicle
▪ Heating / AC on
Time
Trip
Effort and Cost

Today (RDE) ▪ City – Rural – Highway

▪ Up to 160 km/h
▪ 90 – 120 min
Increased Effort Increased Time
Driver
Time ▪ Gentle and aggressive
Effort and Cost

Trend & HORIBA solutions

Ambient conditions
Reduced Effort ▪ -7 °C to 35 °C
▪ Up to 1300 m in Europe, 2400 m
Increased Effort Reduced Time in China
Time

© 2021 HORIBA, Ltd. All rights reserved 6

Motivation
RDE topics
Effort and Cost

Yesterday HORIBA Solutions: bring the road

Concept Development Certification SOP to the test cell

Time
Effort and Cost

Today (RDE)

Increased Effort Increased Time

Time
Effort and Cost

Trend & HORIBA solutions

Reduced Effort

Increased Effort Reduced Time

Time

© 2021 HORIBA, Ltd. All rights reserved 7

Motivation
HORIBA key components for sustainable engine testing

Fuel Automation Power

Battery Simulation

Altitude

Emission

© 2021 HORIBA, Ltd. All rights reserved 8

ENGINE DYNAMOMETERS

© 2021 HORIBA, Ltd. All rights reserved

Engine dynamometers
Types

Series DYNAS3 DT WT
Type AC machine Hydraulic dynamometer Eddy-current dynamometer
Operation modes Absorbing / driving Absorbing Absorbing
Power range [kW] 145 – 1,000 400 – 12,600 190 – 600
Torque range [Nm] 308 – 5,150 1,000 – 160,000 600 – 3,000
Max. Speeds [rpm] 4,500 – 18,000 1,500 – 10,000 4,000 – 10,000

Example

Prefered solutions for large engine application

© 2021 HORIBA, Ltd. All rights reserved 10

Engine dynamometers
Technologies available

AC Dynamometer Hydraulic Dynamometer

State-of-the-art technology High power density
Absorbing and driving operation Only absorbing mode and stationary operation
Dynamic operation for cycle simulation Robust design with low maintenance cost
Good price / performance ratio Excellent price / performance ratio
up to 1MW
− especially for high power/torque
1,400 HORIBA DYNAS3 HORIBA with long time experience
systems in the market

© 2021 HORIBA, Ltd. All rights reserved 11

Engine dynamometers
Technologies available

AC dynamometer Intermediate
bearing Tandem Dynamometer
Hydraulic A tandem dynamometer is a combination of 2 loading
dynamometer
units
Adapter
flange to
specimen
In most of the cases an “active” loading unit (AC
dynamometer) is combined with a “passive” loading
unit (hydraulic dynamometer)
Combining the advantages of both dynos
− Demand for low motoring power at high speeds
− Higher dynamic is needed compared with stationary
behavior of pure hydraulic dynos
− Test stands with high power, torque and speed in
combination with low moment of inertia
− Limitations on the power supply avoid the use of a large
AC dynamometer

© 2021 HORIBA, Ltd. All rights reserved 12

Engine dynamometers
Technologies available

DYNAS3 HT 350
336 kW rated power (driving)
350 kW rated power (absorbing)
985 Nm rated torque (driving)
1005 Nm rated torque (absorbing)

DT-1200-1
1200 kW rated power (absorbing)
7500 Nm rated torque (absorbing)

© 2021 HORIBA, Ltd. All rights reserved 13

Engine dynamometers
Tandem configuration

▪ Flexible concept allows to combine different types of AC machines and hydraulic dynamometers
▪ Reference list with realized tandem systems in different ranges

Tandem Configurations DYNAS3 (AC Dynamometer) DT (Hydraulic Dynamometer)

Tandem HT250+DT700-1 250 kW 718 Nm 700 kW 3,000 Nm

Tandem HT350+DT700 350 kW 1,005 Nm 700 kW 3,000 Nm

Tandem HT350+DT900-1 350 kW 1,005 Nm 900 kW 4,000 Nm

Tandem HD460+DT1200 462 kW 2,680 Nm 1,200 kW 7,500 Nm

Tandem HD890+DT6300-2 895 kW 5,150 Nm 6,300 kW 70,000 Nm

Tandem HD3000+DT12600-2 3300 kW 18,620 Nm 12,600 kW 150,000 Nm

© 2021 HORIBA, Ltd. All rights reserved 14

Engine dynamometers
Application examples

Hydraulic Dynamometer DT2-12600-2 Tandem Dynamometer HD890+DT6300-2

▪ 12,600 kW / 150,000 Nm / maximum speed 2,500 rpm ▪ During installation and commissioning at HORIBA

© 2021 HORIBA, Ltd. All rights reserved 15

Engine dynamometers
HORIBA TITAN Engine

Modules Test Field Automation Automation System Operator Area

Internet (TCP/IP) Customer
▪ Test field Interface
STARS Desktop USV for STARS Ethernet/serial STARS SPARC Control
automation STARS Cluster Server
test data (Office) Automation Workstation HMI Operator Panel Cabinet Main Power

▪ Automation Loading Unit Measuring Equipment

system CAN/Ethernet
EtherCAT/CAN
Fuel Consumption Meter
CAN
▪ Operator SPARC Controller
Safety Module Basis & Extended I/O LAM Measuring Module
Indication System
Customer
area Interface Oil Consumption Meter

▪ Loading unit Exhaust Gas Analyzer

Vehicle-CAN
Main Power

Particle Sampling System

19” Measuring Modules
▪ Measuring Air Flow
Temperature, Pressure, Calibration System
equipment Throttle Position
Control Unit
Engine Electric
Switch Box
Blow By Meter
Current, Voltage
Opacimeter
Weather Station
▪ Conditioning (Temp/Hum/Bar)
Smoke Meter

units Conditioning Units

CAN Conditioning

Fuel Controlling
Engine Combustion Charged
Engine Water (integrated in
Oil Air Air
FQ)
Customer
Variable-frequency drive DYNAS3 load unit Interface
Facility Water-Feed & Return

© 2021 HORIBA, Ltd. All rights reserved 16

FQ – FUEL FLOW METER

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Application and Engine size overview
HORIBA Fuel Measurement Solutions

Engine size (kW)

5000

FQ-4000
1500

FQ-3210CR FQ-3110DP / FQ-3210CR

400
FQ-3200CR
FQ-3100DP/ FQ-3200CR
FQ-1200CR

Durability R&D Dynamic calibration

Production Steady State Emission Develop.
Quality Analysis Calibration (DoE) Certification
FQ-1200CR/ FQ-3xxx FQ-4000 Applications

© 2021 HORIBA, Ltd. All rights reserved 18

Measurement principle
Coriolis and Differential Pressure

Differential Pressure Coriolis

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FQ-4000HD Architecture – Flow sensors
Coriolis Sensor

Measuring converter

Main electronic module for

Modbus RS485
Measuring converter housing

Transmitter

DN Max. limit Zero point drift

[mm] [inch] [kg/h] [kg/h]
8 1/8“ 0…1000 0,02

© 2021 HORIBA, Ltd. All rights reserved 20

FQ-4000HD Architecture – Flow sensors
DP sensor (optional)

Servo driven displacement pump

Power supply 24 VDC ▪ Speed controlled to Δp = 0
Signal output pulses 5V ▪ Speed signal directly proportional to
volume flow
▪ High measuring span up to 1:1000

Inside gear head for

fast response

No differential pressure
No wearing effects loss across the meter
▪ Excellent long-time ▪ Speed controlled to Δp = 0
stability of calibration

© 2021 HORIBA, Ltd. All rights reserved 21

FQ-4000HD Technical Data
Performance data

Description Value
Measuring range DP Sensor: 0.5…400l/h (0.378…300kg/h)
Coriolis Sensor: 1… 1000kg/h (1.2…1200 l/h)

Temperature control range 15 …80°C

with 10 kW heater (CAST X2500) max. 60°C
with 30 kW heater (CAST X4000) max. 80°C

Temperature stability 0.5°C

Pressure control range fuel outlet 0.3** .. 6 bar
Vacuum pressure regulator -0.3 .. 6 bar

Pressure control range fuel return -0.3*... 2 bar

Fuel circulation range adjustable 1000 .. 4000 l/h

© 2021 HORIBA, Ltd. All rights reserved 22

FQ-4000HD Technical Data
Supply data and dimensions

Description Value
Fuel supply pressure 0,5 .. 1 bar
with Option inlet pressure regulator max. 5 bar
Fuel supply pressure 15 .. 30°C
2 … 6 bar

1935 mm
Cooling water supply pressure
Cooling water supply/ return temperature 6..15 / 12..21 °C
Coolig water supply feed <3000l/h
Electrical supply voltage 400V
Electrical supply frequency 50 Hz
Electrical supply current (without heating) 32 A
Overall dimensions WxHxD 2000 x 1935 x 850 mm
Weight Ca. 850kg
Ambient temperature +5 ... +40°C
Type of protection (electr. Part) IP 44

© 2021 HORIBA, Ltd. All rights reserved 23

FQ-4000HD Technical Data
Hydraulic Interfaces

1. Fuel supply G3/4“ inside thread on roller ball vane

2. Fuel drain G3/4“ inside thread on roller ball vane
3. Fuel outlet to engine G1“ inside thread on roller ball
vane
4. Fuel return from engine G 1“ inside thread on roller
ball vane
5. Ventilation 16mm fitting for tube
6. Cooling water supply G1“ inside thread
7. Cooling water return G1“ inside thread
8. Compressed air supply 10mm hose connection

© 2021 HORIBA, Ltd. All rights reserved 24

MEDAS – ALTITUDE
EMULATOR

© 2021 HORIBA, Ltd. All rights reserved

MEDAS operation principle
Differences with an altitude chamber

▪ The engine / car inside low pressure atmosphere

▪ High energy consumption
▪ High total cost of ownership
Altitude chamber.
Conditioned atmosphere
(pressure, temperature and humidity)

Room Vacuum Engine /

atmosphere
system Vehicle

© 2021 HORIBA, Ltd. All rights reserved 26

MEDAS operation principle
MEDAS

▪ The engine / car inside low pressure atmosphere

▪ High energy consumption
▪ High total cost of ownership

MEDAS
Conditioned
atmosphere
Room
(pressure, Engine /
atmosphere
temperature Vehicle
and
humidity)

© 2021 HORIBA, Ltd. All rights reserved 27

MEDAS performance
Summary at a glance: Any ambient condition in the world, inside your test cell

Altitude
From sea level to more than 5000 m
5000 m
▪ Highest road in Europe: 3300 m (Veleta, Spain)
▪ Test bench altitude can be located up to 2000 m above Simulated
sea level altitude
Mass flow
Up to 5000 kg/h with a single MEDAS 2000 m
▪ Several MEDAS can be coupled in parallel for higher
mass flow Test
▪ No limitation on the minimum engine flow bench
altitude
Temperature and humidity
0m
From -45 °C to +50 °C and from 10% to 95%
▪ With extra MEDAS Temperature and Humidity Modules
▪ Humidity up to 65 gH2O/kgDryAir

© 2021 HORIBA, Ltd. All rights reserved 28

MEDAS performance
Summary at a glance: modular approach with flexible configurations

MEDAS
Full altitude and mass flow simulation
▪ Limited temperature control
▪ Transparent to humidity

MEDAS + MTM
Full altitude and temp. simulation
▪ Only drying capability, without humidifying
▪ Dynamic profiles (RDE capable)

MEDAS + MTM + MHM MEDAS AHU

Full altitude, temperature and humidity Flexible T&h simulation
▪ Without dynamic capability
▪ Dynamic profiles (RDE capable)
▪ Can operate with or without MEDAS
▪ Complete range up to 65 g/kg

© 2021 HORIBA, Ltd. All rights reserved 29

Correlation results
MEDAS can replicate any RDE test with same engine performance and emissions than altitude
chamber or road tests

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MEDAS technical specifications
Summary tables

System Weight (kg) Size (mm) Power (kW) Water Compressed air
LxWxH (bar)
MEDAS 5012V 1500
2040 x 1150 x 1645
MEDAS 5012VO 1650 Max: 45 Max. 15 m³/h
MEDAS 5015V 1650 Usually: 15 – 30 5 – 30 °C
2500 x 1150 x 1645
MEDAS 5015VO 1800 5–6
MEDAS 5050V Max. 51 m³/h
2200 3254 x 1265 x 1955 Max: 135
5 – 30 °C
MTM ST Max: 85 Max. 15 m³/h
1100 1715 x 1150 x 1955
Usually: 45 – 60 5 – 15 °C
MHM 0.3 m³/h
950 1715 x 1150 x 1955 Max: < 2 No need
Tap water
MEDAS AHU Varies No need

Several MEDAS / MTM / MHM can be coupled in parallel to multiply the mass flow

© 2021 HORIBA, Ltd. All rights reserved 31

MEDAS Installation
Interfaces to engine and test cell supplies

Roof intake
Removable panels

Engine Engine intake

crankcase

Engine exhaust
Touchscreen

Drains
(automatic drain External Wheels
as option) connections (fix feet as
CAN Emergency MEDAS option)
Compressed Ethernet stop outlet
air Water Emergency stop

© 2021 HORIBA, Ltd. All rights reserved

MEDAS Installation
RDE Application with MEDAS and HORIBA systems

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MEDAS Installation
Engine Test cell example

Location: CMT-Motores Térmicos, Universitat Politècnica de València (Spain)

Engine intake

Engine
crankcase

Engine exhaust

© 2021 HORIBA, Ltd. All rights reserved 34

MEDAS Installation
Chassis Dyno test cell example

Location: HORIBA Biwako (Japan) Insulation to reduce Reduction close

temperature losses to engine intake
Engine intake

Engine exhaust

Reinforced
soft pipes

Reinforced
soft pipes

© 2021 HORIBA, Ltd. All rights reserved 35

MEDAS Installation
Chassis Dyno test cell example

Location: HORIBA Biwako (Japan)

Engine
exhaust Engine
intake
Leak proof
connections

Water
Engine exhaust
Drains Compressed
air

© 2021 HORIBA, Ltd. All rights reserved 36

RDE+

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Available Applications
RDE+

▪ RDE+ is a development and validation

methodology that reduces cost, time & risk
▪ It is a development toolset and new
development process for emissions
compliance development STARS ENTERPRISE
▪ Combines virtual tools with HORIBA’s
advanced real-world testing methodologies, RDE+ VIRTUAL RDE+ POWER RDE+ CHASSIS RDE+ ROAD
hardware & software
▪ RDE+ reduces the number of prototype
vehicles required -, saving up to $17M in a
vehicle programme

▪ RDE+ is a MODULAR solution comprising

HORIBA hardware and software with
process applications in STARS Enterprise
▪ Enhanced productive road testing
▪ “Road-to-Rig” and “RDE in the Lab” DESIGN & VERIFICATION &
SPECIFICATION DEVELOPMENT VALIDATION CERTIFICATION
▪ Simulation and hardware-in-the-loop (HiL)

© 2021 HORIBA, Ltd. All rights reserved 38

Available Applications
RDE+

REPLICATION EMULATION
Reproduction of the on-road drives on chassis, Ability to repeatedly reproduce realistic scenarios for
powertrain and engine dynos calibration, development and validation

SIMULATION AUTOMATION
Simulation of real-world driving connected to chassis, Automated laboratory and dyno control systems
powertrain and engine dynos (HiL) integrated with remote connectivity

© 2021 HORIBA, Ltd. All rights reserved 39

CONCLUSIONS

© 2021 HORIBA, Ltd. All rights reserved

HORIBA is your right partner: wide portfolio and experience

Engine dyno FQ MEDAS State of the art

More than More than More than
technology
1500 Dynas3 500 50
inside
installed installed installed

Multiple
Covering from
configurations
Light-Duty to
to adapt
Heavy-Duty
changing
applications
needs

© 2021 HORIBA, Ltd. All rights reserved

HORIBA is your right partner: wide portfolio and experience

Engine dyno FQ MEDAS RDE+

More than More than More than State-of-the-art
1500 Dynas3 500 50 tools and
installed installed installed methodologies

Multiple
Covering from
configurations
Light-Duty to
to adapt
Heavy-Duty
changing
applications
needs

© 2021 HORIBA, Ltd. All rights reserved

HORIBA is your right
partner also for Heavy-
Duty applications
HORIBA has all the required know-
how and applications to cover
current and future needs in the
Heavy-Duty range

World-wide Extense product The best

company portfolio and team behind
experience
Contact
Dr. Javier Gómez
HORIBA Europe GmbH
Landwehrstraße 55
64293 Darmstadt (Germany)

Phone: +49 6151-5000-3525

Fax: +49 6151-5000-1515
E-mail: javier.gomez@horiba.com
www: http://www.horiba.com
© 2021 HORIBA, Ltd. All rights reserved 45