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Test description
Procedure
Steady
performance test
Transient test
Reproduction
approval tests
Closure chart p - V
p- (bold)
As a test independently or
simultaneously with other tests as a tool
for system testing.
Test with
monocylinder
engine AVL 5403
GDI (gasoline direct
injection) and 5402
CR DI diesel (direct
injection common
rail)
Activity Type
Combustion
process
analysis:
Technical Terms
Exemplification
Range in ppm
0 200 000
8 000 100 000
0 8 000
0 10 000
0 1 000
0 10 000
0 250 000
0 1 000
N2O
CH4
C2H2
C2H4
C2H6
C4H6
C2H5OH
IC5
NC8
AHC
NC5
HCHO
CH3CHO
COS
SO2
HNCO
HCN
HCOOH
Nitrous oxide
Methane
Acetylene
Ethylene
Ethane
1,3 Butadiene
Ethanol
Iso-Pentane
n-Octane
Aromatic hydrocarbons
n-Pentane
Formaldehyde
Acetaldehyde
Carbonyl sulfide
Sulfur dioxide
Isocyanic Acid
Hydrogen Cyanide
Formic Acid
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 200
0 1 000
0 1 000
0 1 000
0 1 000
The AVL 439 Opacimeter (G004) is the 4 generation of measurement instrument for recording exhaust gas
opacity in internal combustion engines using opacimetry, i.e. the measurement of the reduction of visible light
in a measuring chamber through which the sample gas is passed. The measurement value output will be
-1
indicated as well as in opacity N [%] or the absorption value k [m ].
Exhaust gas is passed through the measurement chamber where opacity is measured.
The AVL 439 Opacimeter is frequently used in development and certification areas. Because of its technical
design authorised testing laboratories like the RWTV in Germany or the UTAC in France have officially
accepted the 439 for statutory tryouts.
The operator interface of the 439 incorporates different algorithms for the electronics filtering of the
measured signal, which are defined and required in statutory test cycles.
By using the 439 tests i.e. the ELR test cycle (EURO 3, EURO 4) or the ECE R24 test cycle then results can
be easily achieved.
Note 3: For a more accurate analysis and a deeper understanding of all abilities laboratory can analyze this
data sheet in full.
Contact person:
Name: Dean Prof. Dr. Eng. Nicolae Burnete
Function: Project Manager
Email: Nicolae.Burnete@arma.utcluj.ro
Name: Lecturer Dr. Eng. Bogdan Ovidiu Varga
Function: Responsible for procurement and PR
Email: vbogdan@arma.utcluj.ro
Institution: Technical University of Cluj-Napoca
Phone: 0040-264415490,Fax: 0040-264415490
Web page:
www.testecocel.utcluj.ro
Technical Description
1.00.00
INFRASTRUCTURE, FACILITIES
AND SUPPLY SYSTEMS
1.01.00
CIVIL WORKS
TESIN2000.00
1.01.01
Double wall for separation of the control room from the test room (15+5+10 cm)
Acoustic door from control room to test room 35dBA
Acoustic window (35dBA)
Mezzanine construction 3 m height (300 kg/m2) (side load, concrete floor).
Openings on existing roof for ducts (ventilation, gas extraction, water, electric)
Excavation of test room floor for pit construction (acc. drawing A02)
Baseplate foundation and pits (acc. drawing A02)
Covering metal plates for pit and trenches and floor painting.
External wall with acoustic door (1,2 x 2,1 m), replacing glasses with panels on ground floor
only.
Excavating 20 cm base for cold chamber 2,5x2,5 m
Finishing works (painting, etc.)
Suitable furniture for the entire test area / cell test.
The contracting authority will purchase in parallel with this tender services for preliminary
planning of the cell so that AVL will coordinate with the builder for the foundation, thickness of
walls and pits / recesses for technological equipment. The builder's obligation is to attain the
foundation pit, walls and floor of the test cell, the rest of facilities will be done by AVL according
to these specifications.
1.02.00
UTILITIES
TESIN3000.00
Consists of:
Note:
Standard gas system for calibration is not necessary; we offer the gas analyzer SESAM
FTIR which does not require calibration gases
1.02.01
VENTILATION
TESIN3200.0101
System consisting of a inlet air unit, equipped with gravimetric filter, blower and impulsion grids,
and an extraction air unit consisting on a blower in box, grids and outlet ducts. System
3
capacity: 16.000m /h
Control
T
Air from ETC
1.02.02
EXHAUST EXTRACTION
TESIN3200.0102
System consisting of a blower for forced extraction, able to operate at high temperatures
(around 200C), ducting inside test cell, and chimney to the outside.
Fire flap
ENGINE
DP
Alarm
1.02.03
FUEL SUPPLY
TESIN3300.0104
The fuel circuit consists in a standard diesel tank, with capacity 1.500 liters, and canisters for
special fuels (customer scope).
The system comprises a pneumatic pump for the fixed tank, and a mobile pneumatic pump for
the canisters. These pumps will fill a daily tank of 20 liters capacity, located at a height of 5m, to
supply by gravity the fuel measurement and conditioning equipment. Also includes the piping
and connectors to/from the engine.
Daily tank
Venting
line
Main tank
Engine
Test
Cell
Fuel
Measurement
Barrels
Fuel
conditioning
FIRE ALARM
CENTRAL
Engine
1.02.04
The engine requires cooling water, to condition the internal engine coolant. The circuit must
provide water in adequate flow, pressure and temperatures, in order to supply the fluid to the
engine conditioner.
The proposed circuit consists of a air-cooled heat exchanger, located in the terrace, with cooling
capacity 150kW and operating temperatures 45-60C (outlet/inlet). The water will be supplied to
the test cell by means of a centrifugal pump, capacity 9m3/h and pressure 3bar, located in the
technical floor.
The circuit will include also all the piping to and inside the test cell, as well as the regulation and
monitoring devices.
Control
Engine test
cell
Air-cooled
Heat exchanger
1.02.05
This circuit is necessary to supply water in the range 7-12C to the fuel conditioning unit.
The system comprises an air cooled chiller, with capacity 1,5kW, temperature range 7-12C,
including pumping with flow 300l/h @ 3bar.
The circuit will include also all the piping to and inside the test cell, as well as the regulation and
monitoring devices.
Control
1.02.06
COMPRESSED AIR
TESIN3300.0103
A compressed air circuit with capacity 600l/min is necessary to supply the test cell devices
(baseplate, conditioners, etc.) as well as the preparation workshop for pneumatic tools.
The circuit consisting of a compressor 600l/min @ 9bar, the piping and filtering and regulation
elements.
1.02.07
The system comprises a fire and gas central for alarming, and the related fire sensors (1xflame
and 2xsmoke) and CO and HC sensors, as well as the alarming (horn and flash) devices.
The extinguishing will be manual, by means of a foam extinguisher in a trolley, and manual
powder extinghishers.
1.02.08
ELECTRICITY
TESIN3100.0101
Consisting of a central electric cabinet, connected to the building distribution panel, with all the
protections and outlets to supply the test cell equipment, lights, sockets, etc. Also includes the
operation devices (relays, contactors, etc.) to switch on/off the test cell and utilities devices.
Also includes all the cable trays, cabling, lights and sockets for the test cell, control room and
climatic chamber.
1.03.00
SERVICES RELATED TO
INFRASTRUCTURE AND FACILITIES
TESIN3000.00
1.03.01
Consisting of the calculations and design of the auxiliary circuits, the general layout, utilities
layout and diagrams, list of materials and documentation.
Project management consisting on overall PM and local support in installation and start up.
2.00.00
2.01.00
DYNAMOMETER
DYNAMOMETER
TP00ASTA.00
2.01.01
Foot mounted AC drive, equipped with control and power cabinet, with torque and speed
controlled operation when used in combination with the test bed controller AVL BME or EMCON
Power section with IGBT converter for the direct connection to the mains supply (please see
installation instructions for details). Preselectable switching frequency provides nearly sinusoidal
currents to the mains and to the electric motor.
Equipped with a hybrid interface to the test bed controller, to allow the execution of torque or
speed control loops. The dynamometer can be upgraded to dynamic tests.
Best AC motor efficiency with lowest mains distortion by latest state-of-the-art IGBT
technology.
Highest torque response by rotorflux-vector-control of the stator current.
High speed gradient by optimised inertia
Robust industrial design for operation under extreme ambient and environmental conditions.
Easy installation and commissioning.
Technical Insight:
ASYNCHRONOUS MACHINE
Foot mounted AC machine with squirrel cage rotor, prepared for mounting of T10FS 1kNm
torque flange.
AVL Type
Performances generator operation:
Nominal torque
Nominal power
Maximum speed
DynoRoad 202/12SL
525 Nm
220 kW
12.000 rpm
473 Nm
198 kW
12.000 rpm
25%
90%
Mass inertia:
AC-Motor alone
0,31 kgm
AC-Motor with standard connecting flange but
0,32 kgm
without torque meter
AC-Motor with standard connecting flange and
0,32 kgm
with torque meter
Forced air-cooling, air quantity
approx. 2.088 m/h
Upper part white aluminium RAL
9006
Coolant
Colour
10
Temperature Monitoring
Connection Box
Blocking device
Speed Encoder
Weight
Degree of protection
Ambient temperature conditions
Ambient humidity conditions
3 x 400 V +10%/-15%
315/394 A, with 400V supply
50 Hz 5 %
Forced air-cooling, air quantity
approx. 3.000 m/h
RAL 7032 pebble grey
820 kg
2226x1906x620mm
IP 23
+5 to +40 C
max. 95%, non-condensed
Colour
Weight
Dimensions (LxHxD)
Degree of protection
Ambient temperature conditions
Ambient humidity conditions
Technical Notes:
Dimensions Motor
Power diagram generator
PLP 103/003
PLP 525/220/12 gen
11
720
360
640
320
560
280
T
240
P
400
200
320
160
240
120
160
80
80
40
0
0
2000
4000
Torque
Installation instructions:
6000
8000
Power
10000
Power [kW]
Torque [Nm]
480
0
12000
Speed [rpm]
PLP 170/002
Notes :
For service pupose via modem, a phone connection must be available at customer site close
to the power cabinet
In case of connection to a 380V mains voltage, the maximum power will be reduced by 5%
Note about packing : the indicated prices include packing, loading on trucks, weighing and
control. For transportation we recommend trucks with air suspension.
The system parts are covered with plastic sheets and packed in wooden crates.
Use: Covered transportation by rail and truck in western Europe except Great Britain. Storage in
open air is not allowed.
2.01.02
Set of cables between BME/EMCON series 400 - control cabinet (standard length 20 m) and
BME/EMCON series 400 motor (standard length 15 m).
Length up to 25m on request.
2.01.03
12
L2
PE
PE
L1
L3
PE
Technical Insight
Shielded power cables (multicore copper cable) to be installed between AC motor and
control cabinet.
Type:
Outer diameter
Minimum bending radius
fixed mounting
movable mounting
Length (quantity x1)
2.01.04
(2YSLCYK-JB 3X70+3X16) x 2
40,6 mm (+/- 0,5mm)
163 mm
609 mm
10 m
Class of accuracy
0,03
Nominal torque
1 kNm
Nominal speed
12.000 rpm
Nominal
sensitivity (range between
30 kHz
torque=zero and nominal torque)
Characterisitc tolerance, relative to the
< 0,05 %
actual value of the signal span :
Linearity deviation incl. hysteresis, related
< 0,01 %
to the nominal sensitivity:
Temperature effect per 10K on the output
signal, relative to the actual value of the < 0,03 %
signal span :
13
2.01.05
Only intended for calibration check. Additional measurement error to be considered when using
the calibration lever due to radial force applied on the torque flange.
Reduced error due to bending effects during calibration thanks to a special AVL design
Easy to handle
2.01.06
Dimensions
Calibration Weights set for AVL dynamometers with a nominal torque of 525Nm
14
Technical Insight
Set of weights to calibrate the torque measurement unit of AVL Dynamometers with a nominal
torque of 525Nm.
Intended to be used in combination with the optional AVL calibration system (arm lever and
weight trays) with a standard calibration ratio of 1kg = 10Nm
The delivered weights have the following tolerances:
Weight (kg)
0,5
1
2
Tolerance (g)
0,075
0,15
0,3
2.01.07
5
0,75
10
1,5
20
3
3.00.00
3.01.00
3.01.01
AVL Isolated Base Plates, made of a dense, steel alloyed special cast iron, allow an easy setup
of the test bed components. By using air springs with automatic level control, spring movements
caused by different load distribution or torque alteration are compensated, i. e. the air springs
provide a constant, load independent vertical position of the isolated base plate at low natural
frequency.
15
Technical Insight
Dimensions (L x W x H):
Mass:
max. Load:
Material:
Low natural vertical frequency:
Distance between T-Slots:
3.01.02
5602M02Z/D00E0
5602M02Z/D01E0
air quality class 2 DIN ISO 8573-1
Draining- Gutter f. Engine Only base plates that runs around the base plate with two drainage
outlets at the front end for "Engine-Only" and "Power Pack" base plates up to max. size of 5000
x 1900 mm
3.01.03
Galvanised surface for corrosion protection for Engine-Only & Power Pack base plates.
smooth surface
corrosion protection against high humidity (e.g. for use in climatic chambers)
3.02.00
3.02.01
The Engine Mounting System PS 800-960 for passenger car and light commercial vehicle
engines serves for mounting the unit under test onto the pallet system. The adjustable length,
width and height allow precise positioning of the supports to the engine's original mounting
points.
16
Example
Technical Insight
The engine mounting system represents the link between the pallet system and the test engine.
It consists of one crossbeam whose position can be adjusted by sliding along the base plate,
with two mounted on supports.
Note
The customer is responsible for the assembly of the engine onto the engine mounting system by
using the original motor rubber bearings. As interface a M12 or M16 female thread is available
on each support.
Technical Data
Weight
Maximum load
Width adjustment
Height adjustment
Connection thread
Material
Surface
Interface with pallet system
approx. 50 kg
200 kg
170 to 800 mm
800 to 960 mm
M12 or M16 female thread
aluminium, steel
anodized, galvanized
4 T-slot nuts DIN 508 M14x50 for each crossbeam
3.02.02
For installation of AVL research engines series 540, 580 and LEF 530 on the test bed.
17
3.03.00
3.03.01
The welded intermediate frame serves for adjusting the test bed shaft height and for mounting
the dynamometer onto an AVL base plate
18
Each frame is custom-built for the specified dynamometer and shaft height. The supporting
surfaces on top, bottom and front of the frame for mounting the frame to the base plate as well
as for the mounting of the dynamometer and the shaft guard are machined and bright.
Technical Data
Material
Surface
Colour
As supplied
steel
sandblasted, primed, painted
RAL 5008 (grayblue)
machined, unpainted areas preserved
Attention:
Exact test bed shaft height must be indicated at purchase order!
3.04.00
3.04.01
The Engine Trolley Manual Docking with spring loaded wheels is suitable for manual transport.
Technical Insight:
track width:
approx. 720 mm
3.04.02
The Engine Trolley Receiver MD is suitable for the manual engine trolley system for the
installation at AVL standard isolated base plates.
Technical Insight:
19
3.05.00
3.05.01
Drive-shaft for connecting Single Cylinder Engine Series 540 to dyno of the Single Cylinder
Compact Test Bed. For meeting the Single Cylinder Engine axis height to the dyno an additional
support is included.
3.05.02
The Coupling Shaft serves for the connection between the unit under test and the
dynamometer. These shafts are suitable for all engine test beds and are used, when higher
degrees of cyclic irregularity or high slightly changing oscillating torque are given.
Technical Insight:
The Coupling Shaft 900/4200 consists of a torsionally soft coupling and a cardan shaft.
Nominal torque
Torsional stiffness
Max. speed
Operating length
Length adjustment
900 Nm
4200 Nm/rad
7300 rpm
540 mm
-11 / +43 mm
20
The offered shaft can change during project realization for technical reasons!
Note:
The Coupling Shaft is mounted to the flywheel via an adapter flange. As this flange is UUT
dependent, is has to be supplied by the customer.
Note:
The calculation base for AVL drive shaft systems is the main exciter, the combustion process of
the engine in the dominating order.
Possibly appearing auxiliary exciters (e.g. ECU and actuator frequencies respectively, high idle
control) can only be taken into consideration if they are notified by the customer before the shaft
layout.
The appearance of such non declared auxiliary exciters might cause component failure.
AVL can not be held responsible for such occurring causes of damage and reserves a
disclaimer for direct costs and consequential damages in case of drive shaft failure.
3.05.03
The Safety Cover prevents test cell staff and measuring equipment from unintentional contact
with the rotating drive shaft system and is meant to reduce potential consequences of shaft
ruptures.
AVL Safety Cover Type 2 is meant to be used together with standard AVL shafts with torque
measuring flange or with large auxiliary couplings.
The Safety Cover consists of two hinged half- tubes closed by quick- release lock. A
momentary- contact switch checks whether the Safety Cover is open or closed. The automation
system then only permits test operations to start if the guard is closed.
Technical Data
Dimensions (l x w)
Mass
Suitable for shaft heights
3.05.04
ADAPTATION FLANGE
TP34DA001A.01
The AVL adapter flange is used to fit the drive shaft flange to the existing dynamometer
interface for AVL standard drive shafts.
21
4.00.00
4.01.00
THROTTLE ACTUATOR
THROTTLE ACTUATOR
TP00ASTA.00
4.01.01
For the adjustment of the throttle or injection pump on internal combustion engines.
Suitable for the execution of legal driving cycles according to ECE, FTP, EPA and Japan
guidelines.
Technical Insight
Actuator
Linear positioning unit with integrated brushless, convection cooled servomotor with resolver
Shifting travel: 110 mm
Shifting force: 120 N (up to 40 deg. C)
Shifting force: 110 N (up to 50 deg. C)
Shifting speed: 0,5 m/sec
Positional repetitive accuracy: < 0.05 mm
Ambient temperature: -30 to 50 deg. C
Air humidity: max. 85% without condensation
Height x width x depth: 170 x 350 x 315 mm
Colour:
Motor: ultramarin (RAL 5002)
22
4.01.02
Serves as a menue-oriented control unit for the adjustment of the final position of the throttle
acutator THA 100.
Technical Insight
5.00.00
5.01.00
AUTOMATION SYSTEM
TEST SYSTEM CABINET
TP01A.00
The new highly flexible operating room concept of AVL considers the constantly changing
requirements and work situations when executing engine and powertrain tests.
Because of the process orientated design of the system components a flowing transition
between test stand operation, data post processing and office area is now no problem.
The modular and variable system can simply be adapted at any time also to new workflows or
spatial requirements.
Beyond that, compact and intelligent solutions are available particularly for cramped space
conditions (e.g. container test beds).
An optimal product design, honoured with the highest Austrian Design price Staatspreis
Design, secures a harmonious attractive appearance and the fulfilment of ergonomical as well
as functional requirements.
23
5.01.01
For mounting of PUMA system units as well as of control, monitoring and measuring
insturments.
Modular design, offering many possibilities for system extension.
The industrial and easily accessible construction offers optimum conditions for installation,
commissioning and service.
Cabinet
hinged frame
detachable side panels
detachable hinged frame plate, serves for mounting of system specific units such as
switches, etc.
EMC suitable mounting panel, passivated, yellow
EMC suitable 19" hinged frame profiles, passivated, yellow
cable feeding via ceiling and floor
Desk
hinged table plate
Technical Insight
Cabinet
19" mounting area for electronics 41 HU
Desk
19" operating area (2 x 3 HU)
24
operator's room
Temperature range:
Relative humidity:
5 ... 35C
20 ... 80 %
Supply voltage:
Frequency:
Power consumption:
5.01.02
Planning for the production of an Engine Only test system (1 x Dyno,1 x Combustion Engine),
typical for R&D or endurance run .
5.01.03
The modular built cable boom 2.5 m for wall mounting, with integrated separated cable and air
ducts, serves for mounting the Boom Box(es) FEM and other additional parts. To enable an
ideal positioning of the measurement transducers in the UUT area, the cable boom is executed
tiltable.
Easy positioning of the measurement transducers above the unit under test via swivel arm
1 or 2 Boom Box(es) FEM mountable
Integrated separated cable and air ducts
Separated cable ducts (measurement and control lines)
Technical Insight
Boom length
Displacement
Max. permissible load
2.5 m
approx.: 85
240 kg
25
Air flow
Colour boom
Material boom
Note:
The boom has to be mounted on a vertical wall with max. 2 inclination.
In case of low room ceiling contact with GPM or HCP is required.
5.01.04
The BOOM BOX FEM accommodates AVL Front End Modules, 19" racks and top hat rail
modules. The BOOM BOX FEM consists of two halfes of identical design, which can also be
mounted separately on the AVL swivel arm in the test cell.
The sensors of the test unit are connected to the FEM modules accommodated in the Boom
Box via short connection lines. The sensor lines and pressure hoses are sealed using sealing
lips.
The purpose of this arrangement is to ensure the fast digitalization of the analog signals and to
reduce the electric wiring in the test cell.
Symbolpicture
Technical Insight:
A Boom Box FEM consists of two equally designed halves.
In addition to the rails for 19-rack mounting, a DIN TS35 standard profile for the integration of
non-19-FEM modules is provided.
One Boom Box half can accommodate the following units:
5 pcs. 19-F-FEMs and 2 pcs. non-19-F-FEMs, or, alternatively:
9 pcs. non-19-F-FEMs.
FEM_Ps are accommodated in the second Boom Box half, separately from the other F-FEMs
(separation of media).
Further technical features:
Sponge rubber seal at the line entrance into the housing.
26
Colours:
Housing cover: Naturally anodized aluminium, ultramarine (RAL5002)
Frame: Gray-blue (RAL5008)
Design according to drawing no.: P25BF000A
5.02.00
5.02.01
This package includes the system hardware for operating an automation system that uses SW
package PUMA Open Engine Testing
Basic System Hardware
The components included are the basic hardware of the automation system.
The basic hardware provides processing capacity for parts of the automation software as well
as serial interfaces (RS232) for measuring devices, operating panel and maintenance. It also
includes the interface hardware for the AVL I/O- and control systems.
27
5.02.02
Via the CAN Interface Board the PUMA Open system can exchange data with control units and
other nodes via CAN (Controller Area Network).
Possible applications include
recording of data from control units (ECU)
control of automatic test runs using data from the ECU
simulation of CAN nodes
acquisition of data from AVL CAN Open pressure transducers
integration of CAN based devices or I/O
I/O and communication is handled in the real-time system of PUMA Open.
Notes
The use of the PUMA Open Software V 1.2 or higher is the precondition for the function of the
High-Performance CAN-Interface Board with 2 Lines.
5.02.03
Technical Insight
28
5.02.04
Extension cable for the Pt100 sensor. The connectors for the connection to a Front End Module
Analog in (F-FEM-AI*) are included.
Technical Insight
Length: 15m
5.02.05
Thermocouple sensor NiCrNi (K-type) for the measurement of temperatures up to 1000 deg.C.
Technical Insight
5.02.06
Extension of the compensation line cable of the thermocouple NiCrNi (K-type). The connectors
for connection to a Front End Module Analog in
(F-FEM-AI*) are included.
Technical Insight
Length: 15m
5.02.07
Set of connectors (Bajonet-type) for connection of analog signals to the Front End Module
Analog In B-FEM-AIN or F-FEM-AI*.
5.02.08
29
5.02.09
For the protection of the PC in case of variations or breakdown of the power supply (also
functions as a filter). In case of a breakdown, all active PC-applications will be terminated, open
files closed and the PC shut down in a controlled manner.
Technical Insight
Double Conversion On-line UPS with 1500 VA / 1350 W
230 VAC +/- 10%, 50/60 Hz +/- 3 Hz (120 V on request)
H x W x D: 2 HU x 19 inch x 450 mm (rackmount)
Capacity at load with one PC, two TFT Monitor, one Interfacebox / PCI and one Power Supply
24 VDC / 20 A: approx. 8 min
Environment temperature: 0-40 Deg. C
Relative humidity: 0-95% (non-condensing)
Note
When using the UPS together with PUMA Open the PUMA Open SW option "Power Fail
Handling" is additionally required.
5.03.00
5.03.01
Hardware and software for the control and manual operation of the combustion engine and
dynamometer on an engine test bed.
The basic configuration of the EMCON 400 is a complete digital test bed control and monitoring
system. The system uses proven algorithms to control hydraulic and eddy current
dynamometers as well as DC and AC machines from AVL and other suppliers. The
dynamometer conditions are fully monitored with definable responses. Up to 16 additional
system conditions can be monitored with definable delay time and response type.
The EMCON 400 has an ergonomically designed operating panel. Incremental encoders permit
the exact setting of demand values and ensure bumpless transfer of control modes. The LCD
shows both demand and actual values as well as parameter settings and operating menus.
Alarm and warning messages are also displayed. Function buttons with LED status are
available for selecting operating modes and control functions.
The EMCON 400 is completely integrated in the AVL PUMA automation system.
30
Precise operation through excellent torque and speed control stability over the whole
performance range
User-friendly handling through ergonomic design of operating elements and flexible
parameter adjustment via display
5.03.02
5.04.00
5.04.01
The application package PUMA Open Engine Testing allows the customer to perform typical
tasks e.g. the development of state-of-the-art engines based on new technologies (e.g.
gasoline direct injection or HCCI, Common Rail, VVT and TCI diesel based technologies) on a
flexible test bed system with an open integration platform.
The application package PUMA Open Engine Testing is used to carry out typical testing tasks
for basic engine development. It is also the basis for engine application (ECU data loading, lookup table tuning.
Intelligent measuring device management especially for emission measurement systems is the
basis for unmanned development test operation also during weekends.
31
Powerful interfaces to the engine electronic system and optimization tools allow the user to
make time-saving variations of ECU look-up table values.
The deep integration of indicating measurement systems into the automation system provides
higher data transmission rates, fast limit monitoring and direct control of engine electronics
quantities.
The scope of functions of this package has been tailored to the requirements of the application
and can be extended at any time by additional functions and software modules.
Additional support and know-how in the form of consulting options can be obtained from AVL, if
required.
Your benefits at a glance
Technical information
Application-specific Functions:
Device Interfaces
In its function as test bed integration platform, PUMA controls and coordinates a large number
of devices. For details about the scope of supply, please refer to the fact sheet "PUMA Open
Engine Testing".
ASAM Standard Interfaces
PUMA supports state-of-the-art and powerful standard interfaces which comply with the ASAM
standard (Association for Standardization of Automation and Measuring Systems).
The ASAP3 interface is used to link an ECU application system (APS) with the AVL PUMA
system in accordance with the protocol standard V2.1. Via the ASAP3 interface, the PUMA
system can access up to 400 values.
The SANTORIN ASAM-ODS server provided with additional tools (SPACE) ensures the quick
and convenient administration of parameters and results.
Media Control
Reproducible ambient conditions on the test bed (coolant, oil, intake air, air humidity, fuel)
drastically reduce the measured result scatter. It is also possible and recommended to control
media conditioning systems for coolant (AVL 553), oil (AVL 554), combustion air (AVL ACS) and
fuel (AVL 753) directly from the PUMA system by using 12 PID and/or 12 2/3-point-controllers.
Comparable to a PLC, the Test Cell Controller / 1 TCC function is used for the startup,
shutdown, control and monitoring of peripheral test bed equipment. The included function
Scripting Basis / 1 Context provides the possibility to create application or customer specific
VBScripts.
Basic Functions:
PUMA Operating System
The PUMA operating system is the core of the test bed software, the powerful platform for all
automation tasks.
Simultaneously Usable Normnames
Within a testrun 1000 Normnames in total can be used simultaneously.
Local Test Bed Administration
With the editors included the user can change parameters directly from the test bed computer.
Local Parameter & Result Administration
32
The database management toolbox SPACE (local license) is used for the easy administration of
parameters and result data in the local test bed database.
Local Test Order Preparation
This package includes the editors and functions for the definition or adaptation of the testing
tasks. In addition, using Temporary Norm Names, predefined reserved quantities of the PUMA
system can be assigned temporarily and test bed specifically to measured quantities, without
having to change the central normname directory.
Control and Automation Functions
The functions included allow the user to operate the automation system in manual and
automatic mode.
Graphical User Interface
Test order, automation functions, process values, user dialogs and system messages are
displayed well-structured and clearly using the PUMA Operator Interface (POI).
Measurement Data Acquisition & Storage
All quantities in the PUMA system can be acquired in measurement requests and the results
can be stored permanently.
Steady-state measurements with 200 channels and continuous recording by means of 3
recorders with 96 tracks each are supported.
Result Presentation
PUMA supports local, automatic printouts of measured results and system messages.
Multi Level Safety Monitoring
PUMA provides multi-level safety monitoring tools to ensure the optimal safety of operator, unit
under test and test bed in all operating states. Up to 128 channels can be monitored by the
PUMA - System.
Formula Calculation
Formula calculations can be performed cyclically or on demand using the formula compiler
included (suitable for 256 calculated values and up to 16 groups of formulas).
Look-up Table Handling
With this function, the user can create and post-process arbitrary look-up tables in the PUMA
system. These look-up tables are then available for operating point dependent limit monitoring.
5.04.02
In case of a power failure the power fail software ensures a defined stop and new start of an
automatic PUMA test run.
In case of power failure of the test bed during an automatic test run, the power fail software
ensures a defined finishing of the test run and the storage of all data which is relevant for
continuing the test run on the test bed computer. As soon as the power is back the test run will
be continued at the point of interruption or at a freely defined point.
Notes
For this function in addition an uninterruptible power supply (UPS) with suitable power for the
supply of the test bed computer is required.
5.04.03
CONCERTO-PREMIUM HARDLOCK
LICENCE
TI0CONPREA.02
33
CONCERTO Premium offers extensive possibilities and comprehensive functions for selection,
processing, presentation and correlation of various automation, measuring and simulation data
as well as for report generation and batch processing.
The nearly unlimited direct access to combustion data, recorder data, log point data and data
from ASAM ODS database systems makes data conversion tools obsolete and allows easy
comparison of different data sets.
CONCERTO Premium includes the full functionality of CONCERTO Advanced for Indicating,
CONCERTO Advanced for Test Bed as well as additional functions.
CONCERTO is available as single licence running on a PC, licensed by an USB hardlock.
Your Benefits at a Glance
Intuitive user interface, Drag and Drop, Wizards for easy, menu guided creation of diagrams,
tables and reports, context sensitive help
Data Explorer: comprehensive overview and convenient access to various data sources
(local or network drive, data bank)
Calculator: simple formula creation via predefined function and macro instructions
Formula / Script Editor: full programming environment incl. extensive library with predefined
functions for various applications
CalcGraf graphical formula editor for comprehensive creation and display of algorithm for
combustion analysis
Automated data processing via macro, script and batch commands
Open interfaces: integration into customer specific software or applications via open COMand Active-X architecture
Adaptability of user interface: complete adaptability of menu structures, integration of scripts
into existing menus, integration of object categories in the object assistant and adaptability of
CALCULATOR interface enable optimal adaptability to customer specific field of application.
Technical Insight
Access to various data : AVL PUMA files, AVL I-files (indicating data) , ASAM-ODS data
bank systems, ATF files, generic ASCII, Matlab, AVL CAMEO result files, etc.
Evaluation and comparison of test bed data: steady state, dynamic and endurance test data,
emission data, combustion data, etc.
Interactive analyzing possibilities by means of extensive cursor functions
Wide selection of visualization possibilities: line, bar, step chart, scatter plot, x-y diagram,
envelope, ISO line and 3D-diagram, 4D-objects, listings, tables, videos, statistic boxes,
waterfall diagrams etc.
Data and graphic export via ASCII, HTML or meta file
Extended data search: possibility of selected data search and navigation, based on channel
content (e.g. based on limit criteria)
Encryption functionality for customer specific formulas and scripts for increased data security
Notes
34
6.00.00
6.01.00
MEASURING SYSTEMS
CONT. FUEL MEASUR. UP TO 600KW
FLEXFUEL
TMCONT50M.00
The system combination of AVL Fuel Mass Flow Meter FlexFuel and AVL Fuel Temperature
Control FlexFuel is used for continuous measurement of fuel consumption on engine and
chassis dyno test beds in research, development and production.
With highest accuracy at shortest measuring times the mass flow is determined directly and
continuously providing permanent measuring readiness.
The measuring system with an integrated statistic evaluation method is used mainly on steadystate test beds for reduction of test times and for cycle measurement on transient, dynamic,
chassis or oil test beds with long test times.
Complete system: AVL Fuel Mass Flow Meter with AVL Fuel Temperature Control
6.01.01
FUEL METER/TEMP.CONT.
FLEXFUEL/HEATING
TMCONT50M.02
The combination of Fuel Mass Flow Meter FlexFuel and AVL Fuel Temperature Control
FlexFuel with integrated heating is a high precise and continuous fuel consumption
measurement system, which is used worldwide at almost all engine test beds where engines of
a maximum consumption of 125 kg/h are tested. The system stands out for high accuracy and
excellent temperature stability.
The fuel measurement system AVL Fuel Mass Flow Meter FlexFuel together with AVL Fuel
Temperature Control FlexFuel with integrated heating enables a high precise fuel consumption
measurement also at low flow rates and short measurement times.
35
Measurement accuracy of 0.12% through direct mass flow measurement and highest
temperature stability of the fuel conditioning system
Rapid measurements even at lowest levels of consumption
The highest level of reliability and universal suitability to the requirements of modern
measurement methods and injection systems
From a single cylinder through to a 600 kW large engine with one sensor and measurement
system
Built-in accuracy check and calibration according to ISO 9001
Technical Information
The complete FlexFuel system consists of an AVL Fuel Mass Flow Meter and an AVL Fuel
Temperature Control with integrated heating.
36
Schematic diagram: Fuel Mass Flow Meter FlexFuel with Fuel Temperature Control FlexFuel
with integrated heating
With a high accuracy mass flow sensor the fuel consumption is determined continuously and via
direct mass flow measurement in kg/h.
The density does not have to be determined in addition to the direct determination of the
gravimetric or specific fuel consumption like in volumetric measurement methods. The fuel
consumption can thus be determined to an accuracy of 0.12 % for the whole system under real
test bed conditions.
The measurement system stands out for simple installation at all gasoline or diesel injection
systems and is therefore universally applicable. This is achieved through the use of a specially
developed pressure control system that makes vehicle-like conditions possible on the test bed.
The additional measurement of the fuel density can be used for quality control or checks for the
correct fuel used. The volumetric consumption information is also available.
The measurement range from 0 to 125 kg/h covers all engine types from a single cylinder
through to a 600 kW large engine with one sensor and measurement system.
The high dynamic AVL Fuel Mass Flow Meter FlexFuel has a calibration interval of at least three
years and is therefore designed to provide a permanent availability for the test bed. In addition it
features a built-in accuracy check and calibration (see option calibration unit) according to ISO
9001 which can be performed at any time during running engine and with the original fuel (fuel
specific restrictions for gasoline fuels).
The AVL Fuel Temperature Control FlexFuel with integrated heating with its high accurate and
stable temperature regulation is an unchallenged market leader in the field of fuel conditioning
systems.
The fuel temperature can be pre-selected within the range of 10...80C. The achievable fuel
temperature, however, depends on the cooling water temperature or the amount of heat
retained in the engine return fuel.
The high precise temperature control provides a constant pre-set fuel temperature at the engine
and guarantees the high measurement accuracy of the whole test system.
37
Continuous gas bubble separation ensures that the fuel supply to the engine is free of bubbles.
The integrated monitor outputs a warning when gas bubbles occur in the measurement system.
The engine feed pressure can be controlled up to 6 bar (rel.) (pressure control on request).
Built-in service interval displays enable preventive maintenance which helps to reduce and plan
downtimes.
Technical Data
Compatibility
The FlexFuel system of AVL Fuel Mass Flow Meter and AVL Fuel Temperature Control with
integrated heating can be combined with the following systems:
Filling pump and pressure control available on request
38
6.01.02
Technical Insight
Hydraulic connections:
cylindrical inside thread R 1/2" to DIN 2999
Resistant to all commercially available petrol and diesel fuel types with a methanol or ethanol
content of up to 100% of vol. (M100, E100).
6.01.03
Technical Insight
Hydraulic connections:
cylindrical inside thread R 1/2" to DIN 2999
Resistant to all commercially available petrol and diesel fuel types with a methanol or ethanol
content of up to 100% of vol. (M100, E100).
6.01.04
To be arranged in the venting line, prevents flaming of the fuel-air-mixture inside the venting
line.
Technical Insight
Hydraulic connections:
inside thread R 1/2", cylindrical to DIN 2999
Resistant to all commercially available petrol and diesel fuel types and alcohol fuels (e.g. M100,
E100).
39
6.01.05
6.02.00
OPACIMETER 439
TM0439A.00
6.02.01
The AVL 439 Opacimeter (G004) is the 4th generation of measurement instrument for recording
exhaust gas opacity in internal combustion engines using opacimetry, i.e. the measurement of
the reduction of visible light in a measuring chamber through which the sample gas is passed.
The measurement value output will be indicated as well as in opacity N [%] or the absorption
-1
value k [m ].
Exhaust gas is passed through the measurement chamber where opacity is measured.
The AVL 439 Opacimeter is frequently used in development and certification areas. Because of
its technical design authorised testing laboratories like the RWTV in Germany or the UTAC in
France have officially accepted the 439 for statutory tryouts.
The operator interface of the 439 incorporates different algorithms for the electronics filtering of
the measured signal, which are defined and required in statutory test cycles.
40
By using the 439 tests i.e. the ELR test cycle (EURO 3, EURO 4) or the ECE R24 test cycle
then results can be easily achieved.
Flexibility:
Application on engine- as well as chassis dynamometers and also for mobile driving tests
Large application area in the fields of development and certification
Suitable for applications where purge-air into the exhaust gas duct is not permitted (e.g. in
front of exhaust gas after-treatment systems)
Simple operation:
Controlling as a stand-alone instrument via AVL cable-remote control IC4210 or PC439
SW, but also in test bed automation system using the AK generic communication interface
and PUMA operating interface (439 PUMA device driver)
Reliable zero stability
Fast signal rise time
High signal sensitivity
Extensive software functions for R&D
Less efforts on maintenance
Conforms to ISO 11614 design instructions
Technical Insight
The optical path length is 430 mm and the measurement gas temperature in the measuring
chamber will be kept constant in the range of approx. 100C by using a heater.
A constant flow of exhaust gas is drawn from the exhaust pipe through the sample line (welded
sample probe) and conditioned sampling hose by means of a diaphragm-type pump pack. The
recirculation of the sampled gas via a return line to the exhaust pipe of the test engine ensures
constant sample flow also at varying pressure conditions. Due to this feature the 439 can be
used for many different applications on the exhaust gas duct whilst still operating within the
instruments limits.
In the conditioned sampling line, the sampled gas is fed to the inlet of the measuring chamber at
a temperature of approximately 100C, i.e. for higher exhaust gas temperatures, (up to 600C
maximum), the sample is cooled and for cold exhaust gas it is heated.
An important benefit of this temperature conditioning is the reliable signal stability and high
signal sensitivity.
The standard configuration consists of a flexible 1 metre sampling line, with integrated probe
and a flexible 1.5 metre conditioning hose (optionally. a 3 metre conditioning hose is available,
i.e. total length 4 m). The sample return line is the same length.
The 439 G004 uses for the first time two zero-air-valves (one of it is included in the articles for
the 4 different sample hoses), which provides economical and safety advantages.
The air pressure consumption will be reduced and the operating safety regarding possible
damage and simplification in operation of the 439 will be increased.
Further the purge-air will not be back flushed into the exhaust gas duct, but leaded via a bypass
of the external zero-air-valve into the ambient.
The second zero-air-valve is located in the area of the exhaust gas recirculation inside the 439.
Output of Measurement Values:
The measurement results for opacity N [0 to 100%] and for the absorption coefficient k [0 to
10m-1] are available at both the serial interface and at the analogue outputs.
The measurement value can be displayed either as an unfiltered raw value or (according to the
required regulations) a filtered signal (Bessel filter, low pass, sliding average, etc.)
41
The measurement value corresponds to the measuring chamber temperature of 100C and
relates to a measurement gas pressure of 1bar, made possible by the pressure and
temperature sensors in the measuring chamber and consideration in the sequence control.
For stand alone operation where no test bed automation system is present the AVL 439 can be
operated by an optional remote control unit (IC4210). The instrument can also be operated from
a stand-alone computer or notebook using terminal emulation or optional PC439-software.
Both alternatives can be chosen as an option for the 439.
Calibration:
Automatic zero point calibration
Built in automatic calibration of the linearity of the photocell (Lin Check)
Calibration is possible with certified reference filters (different transmission filters available as
an option)
Types of Measurement:
Continuous measurement (standard measurement)
Sliding average
Bessel filtering, adjustable parameters
Peak value measurement "raw value"
Peak value measurement of free acceleration as per ECE R 24
Peak value measurement of sudden load set ups as per ELR Test to EURO III (with Bessel
filtering)
Zero gas measurement
Technical Data
Zero stability
50 Hz
Output rates
Max. 600C
Ambient temperature
5 ... 50C
Power supply
Power consumption
1 kVA (max.)
-1
-1
Compressed air supply/consumption Max. 100 l/min, 4 bar (non-oiled, dried and
filtered)
Mechanical dimensions
Weight
42
Notes
The sample hose is not part of the 439 basic unit and according to the demands it can now be
selected from 4 different types. Whereby the main difference is the kind of material (Silicon or
Viton) and the two different lengths (2,5m or 4m).
The standard configuration of the sample hose consists always of a flexible sample line with
integrated sample probe (total length 1m) as well as the flexible conditioning tube with the
length 1.5m (total length 2.5m) or with the length 3m (total length 4m) and the zero-air-valve
with the control hose. The lengths of 2.5m or 4m are also used for the return sample lines,
which are already part of the sample hose articles.
Basically it should always be considered to keep the sample hoses as short as possible, in
order to avoid deposits on the tube inner walls and thus to eliminate unwanted variations on the
measured values.
It is a must to select one of these 4 types of sample hoses (must have option), otherwise the
439 is not operative !
6.02.02
Complete sample hose with zero-air-valve and return sampling line with a total length of 2.5
meter for exhaust gas sampling with the AVL 439 Opacimeter.
Will be needed for the operation of the AVL 439 Opacimeter generation 4 (G004).
A constant flow of exhaust gas is drawn from the exhaust pipe through the sample line (welded
sample probe) and conditioned sampling hose by means of a diaphragm-type pump pack. The
recirculation of the sampled gas via a return line to the exhaust pipe of the test engine ensures
constant sample flow also at varying pressure conditions. Due to this feature the 439 can be
used for many different applications on the exhaust gas duct while still operating within the
instruments normal limits.
In the conditioned sampling line, the sampled gas is fed to the inlet of the measuring chamber at
a temperature of approximately 100C, i.e. for higher exhaust gas temperatures, (up to 600C
maximum), the sample is cooled and for cold exhaust gas it is heated.
An important benefit of this temperature conditioning is the reliable signal stability and high
signal sensitivity.
The 439 G004 uses for the first time a zero-air-valve which provides advantages in economy
and safety.
The air pressure consumption will be dramatically reduced and the operating safety regarding
damaging and simplification in operation the 439 will be increased.
The sample hose is not part of the 439 basic unit and according to the demands it can now be
selected from 4 different types. Whereby the main difference is the kind of material (Silicon or
Viton) and the two different lengths (2.5m or 4m).
The standard configuration of the sample hose consists always of a flexible sample line with
integrated sample probe (total length 1m) as well as the flexible conditioning tube with the
length 1.5m (total length 2.5m) or with the length 3m (total length 4m) and the zero-air-valve
with the control hose. Those mentioned lengths 2.5m or 4m are also used for the return sample
lines, which are already part of the sample hose articles.
Basically it should be always considered to keep the sample hoses as short as possible, in
order to avoid deposits on the tube inner walls and thus to eliminate unwanted variations on the
measured values.
Flexibility:
43
Application on engine- as well as chassis dynamometers and also for mobile driving tests
One sample probe for different engine sizes (from the small single cylinder engine up to big
ship engines)
Less application efforts:
Welding pieces for sample probe and return sampling line
Flexible sample probe (corrugated tube) works as a cooling line
Zero-air-valve to reduce the compressed air consumption and increases the operation safety
Conditioned sample line (conditioning hose) to increase the signal stability and signal
sensitivity
Techncal Data
Length: 1m
Material: Stainless steel
Zero-air-valve
Length: 1.5m
Material: Teflon
Conditioning hose
Length: 1.5m
Material: Stainless steel with silicon covering
Max. 600C
Notes
The above have to be ordered in addition to the basic article, in order to achieve an operative
and ready for measurement AVL 439 Opacimeter.
6.02.03
CONDENSATE TRAP
TM0439KOFA.01
A condensate trap in the return sampling line could avoid heavy losses on the AVL 439
Opacimeter.
Such a condensate trap will be offered by AVL.
Technical Insight
The exhaust gas return sampling line is usually laid parallel to the sampling line. If it is laid in an
ascending direction to the exhaust pipe, it is possible for collected residual moisture to flow back
44
into the exhaust pipe. To prevent this happening, we recommend fitting a condensate trap at the
lowest point in the return sampling line. To fit it, cut through the hose, connect up the
condensate trap and fix it in position.
The application instructions describe very extensivly the measures which are possible and
should be taken during the installation of the sample hoses.
6.02.04
To protect the sensible components of the diaphragm pumps of the AVL 439 Opacimeter
against soiling a soot filter insert is installed in front of it.
The filter insert should be replaced in certain intervals by a new one.
This set includes 6 pieces of filter inserts wherewith a longer and proper working of the 439 will
be ensured already.
Maintenance can be performed due the fast and easy exchange of the filter insert.
For each AVL 439 Opacimeter one piece of filter insert is required.
The average life time of one filter insert is approx. 2 to 4 weeks, but of course depends very
strongly on the kind of application, usage and composition of the exhaust gas (sampled gas).
6.03.00
6.03.01
Mass flow meter for gases according to the principle of the hot film anemometer.
The rapid response to flow changes enables the measurement of the air mass flow in stationary
and dynamic operating states.
Technical Insight
Accuracy:
Reproducibility:
Temperature influence:
Pressure influence:
Operating temperature:
Response time:
Large measurement range:
Operating pressure max:
Pressure losses at Qmax:
The stated specifications are only valid if the offered up- and downstream tubes are used.
45
6.03.02
Required accessories with open air filter for Air Mass Flow Meter 0 1200 kg/h to achieve the
specified accuracy.
6.03.03
The digital evaluation unit provides the auxiliary power for the sensing element.
Furthermore it converts the flow rate dependent signal into a mass flow linear standard signal.
Technical Insight
Power Supply:
Version A (standard):
Caution:
Ambient temperature:
Air humidity:
-25 ...+50 C
max. 85 %, not condensing
6.04.00
HUMIDITY MEASUREMENT
TP17A.00
6.04.01
For the measurement of relative humidity and air temperature in the test cell.
Technical Insight
Supply:
Ambient temp.:
Velocity of air:
20 ... 28 V DC
-40 ... +60 C
< 30 m / sec.
Relative humidity:
Measuring range:
Accuracy:
0 ... 100 % rF
2 % RH (0 .... 90 % RH)
46
Nominal temp.:
Output signal:
Temperature:
Measuring range:
Accuracy:
Output signal:
6.05.00
BAROMETRIC PRESSURE
MEASUREMENT
TP18A.00
6.05.01
Technical Insight
The pressure proportional analog signal, generated by a thin film cell made of steel is digitized
by a 16 BIT A/D converter. The digital signal is acquired and processed by PUMA Open via a
CANopen interface.
PUMA Open synchronizes the CANopen barometric pressure transducer with the defined
acquisition frequency ( synchronized transmission of the pressure value to PUMA Open ).
The calibration of the CANopen barometric pressure transducer is done in the PUMA Open
system by means of the semiautomatic calibration ( SAC ) with 16 calibration points. The values
between the calibration points are determined by means of linear interpolation.
47
Technical Data
Pressure Range:
Total Error:
IP 65
15g (20....2000Hz)
24 VDC via CAN-Bus connector
Repeatability:
Longterm drift:
Operating Temperature:
Data Interface:
Addressing:
Temperature compensation:
Linearisation:
Digital Low Pass Filter:
IP Protection:
Vibration:
Power Supply:
Notes
6.06.00
PRESSURE MEASUREMENT
TP10A.00
6.06.01
Digital transmitter for pressure acquisition in the field of engine and powertrain testing in the
automotive industry.
The signals acquired by the pressure transducer are transferred in physical units to the PUMA
Open system by means of a CANopen interface.
The temperature compensation, linearisation and digital filtering is integrated in the processor of
the sensor.
48
Typical Application
Intakemanifold vacuum
Intakemanifold vacuum
Intakemanifold vacuum
Intakemanifold vacuum
Intakemanifold vacuum/Turbo
Exhaust back pressure
Exhaust back pressure
Turbo pressure
Turbo pressure
Fuel pressure
Oil pressure
Oil pressure
1 bar
1 bar
3 bar
4 bar
6 bar
1 bar
3 bar
6 bar
8 bar
15 bar
20 bar
32 bar
Accurate recording of highly dynamic pressure curves due to high speed data acquisition of
up to 1000 Hz ,
Data realtime synchronized with PUMA Open
Highest comfort due to automatic sensor detection (measuring range, serial number, type)
Zero Offset adjustment directly in the pressure transducer controlled by PUMA Open
Position referred address assignment of the transmitter is done automatically by means of
Daisy Chain Technology
Technical Insight
With the CANopen pressure transducer you can acquire pressures of liquid and gaseous media.
The pressure proportional analog signal, generated by a thin film cell made of steel is digitized
by a 16 BIT A/D converter. The digital signal is acquired and processed by PUMA Open via a
CANopen interface.
This allows dynamic pressure monitoring and recording (up to 1000 Hz per transducer) by
means of Real-time synchronised high speed data acquisition with PUMA Open.
The Zero Offset adjustment is done directly in the pressure transducer, initiated by a command
in the PUMA Open System.
In addition to the internal calibration, PUMA Open offers for CANopen pressure transducers the
semiautomatic calibration ( SAC ) with 16 calibration points. The values between the calibration
points are determined by means of linear interpolation.
Technical Data
Total Error
Repeatability
Longterm drift
Operating Temperature
Media Temperature
Sampling Rate
Total Through-put-rate per CAN-Line
Data Interface
Addressing
Number of Transmitters per CAN Line
49
IP 65
Outside thread M14x1,5
15g (20....2000Hz)
24 VDC via CAN-Bus connector
Temperature compensation
Linearisation
Digital Low Pass Filter
IP Protection
Pressure connection
Vibration
Power Supply
Notes
System Requirements :
Software PUMAopen 1.2 or higher
Interface Requirements :
PUMA CANopen Interface board
PUMA CANopen driver software for pressure transducers
The pressure tubing from pressure transducer to the measuring point is part of the customer.
The PUMA System covers the CPU-performance demand of a typical set up with 16
CANopen pressure transducers of 100Hz a piece in one CAN-line. Extended configurations
can be realized after a performance check of the complete system has been carried out.
6.06.02
Is used to connect and disconnect the engine pressure channels quickly at the transducers.
The Quick Release Coupling includes a non-shutoff connector on the transducer and a shut-off
coupling on the Teflon hose. After opening the Quick Release Coupling, the shut-off coupling on
the Teflon hose prevents the media from flowing out. The non-shutoff connector on the
transducer connects the pressure transducer with the ambient pressure, thus creating the basis
for PUMA supported offset compensation.
6.06.03
50
6.06.04
TEFLON HOSE 5M
TP10DB002A.01
Connects the transducer to the measuring point on the unit under test.
Technical Insight
7.00.00
7.01.00
EMISSIONS ANALYZER
FTIR SESAM APPLICATION PACKAGE
TEFFP.00
7.01.01
AVL SESAM-FTIR Application Package - General 5Hz 240V provides an optimized, robust, and
user-friendly emission measurement system for most typical emission measurement application.
It contains all the required hardware and software components and exhaust gas evaluation
methods.
Furthermore, its extensive factory calibration makes the system ready to be used without any
further calibrations. In conjunction with the background recording, re-calibration of the FTIR is
not needed for several years.
An intuitive operator interface makes the system easy to use and frees the operator to focus on
his development work and not the operation of the measurement system.
The AVL SESAM-FTIR has proved outstanding performance for such application already in
many installations worldwide.
Application task: Gasoline, CNG and LPG
This application package tailored for the emission measurement requirements of Positive
Ignition (PI) engines.
Application task: Diesel
This application package tailored for the emission measurement requirements of Compression
Ignition (CI) engines.
Application task: Diesel SCR
51
Extremely low emission limits for diesel powered Light Duty (passenger cars) and Heavy Duty
(trucks and buses), like EURO-IV, US2007 and 2010, require the development and calibration
of advanced exhaust gas after-treatment systems to reduce NOx and particulate matter. For
these reasons several technologies exists for the NOx reduction, like Hydrocarbon Selective
Catalytic Reduction (HC-SCR), NOx Storage and Reduction (NSR), Plasma Techniques, and
Selective Catalytic Reduction (SCR).
The Urea-SCR technology will be mainly used in for Heavy Duty and Light Duty Diesel
applications. The NSR is already now the preferred solution for lean burning direct injection
gasoline passenger cars and to some extent also with diesel powered vehicles.
The Urea-SCR technology uses urea from a tank as a reducing agent. The reduction of NOx is
accomplished through a controlled injection of the urea solution into the hot exhaust gas. This is
combined with one or more catalytic converters. The urea breaks down into NH3, HNCO and
CO2. NOx is reduced when it reacts with NH3, on the surface of the catalyst, to produce nitrogen
and water vapor. The Selective Catalytic Reduction (SCR) is a complex chemical process,
which consists of several reactions, running simultaneously in the exhaust gas after-treatment
system. The primary reaction when using NH3 is the removal of NO and NO2. This process
forms nitrogen and water. Additional secondary reactions take place, like an increase of NO2
content (from enhancing the removal of NO), the generation of ammonia from injected urea, the
removal of remaining NH3, and the formation of nitrous oxide (N2O, laughing gas).
Development and calibration of such vehicles with SCR technology are focused on managing
exhaust gas temperature, urea dosing strategies, and being sensitive to certain undesired gas
components. This makes it almost mandatory to measure several gaseous components such as
NO, NO2, NOx, N2O, NH3, HNCO, HCOOH, H2O, CO, CO2 and others. All these gas
components must be measured and managed at different sampling locations, like pre-cat, mid
bed, post- cat. Due to the chemical interaction of all these gas components, it is crucial to
measured all components simultaneously, perfectly time aligned, and at a fast response time.
This necessitates the need to measure all the gas components in the same measuring cell with
the same measurement technology. Only the FTIR analytical measurement technology is able
to meet these demands. The FTIR is capable of measuring simultaneously, all the relevant
gases, in one measuring cell with one analytical technology.
Application task: Bio Fuel
Modern fuels very often contain a certain fraction of Bio-fuel, like Ethanol. This application
package also measures gaseous components for such applications.
Measured and calculated gas components
All exhaust gas evaluation methods are installed and configured. All gas components are
factory calibrated accordingly to this application. The calibration is valid for several years.
Chemical
Formula
CO2
CO
NO
NO2
NOx
H2O
NH3
N2O
CH4
C2H2
C2H4
C2H6
Range in ppm
0 200 000
8 000 100 000
0 8 000
0 10 000
0 1 000
0 10 000
0 250 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
52
C4H6
C2H5OH
IC5
NC8
AHC
NC5
HCHO
CH3CHO
COS
SO2
HNCO
HCN
HCOOH
1,3 Butadiene
Ethanol
Iso-Pentane
n-Octane
Aromatic hydrocarbons
n-Pentane
Formaldehyde
Acetaldehyde
Carbonyl sulfide
Sulfur dioxide
Isocyanic Acid
Hydrogen Cyanide
Formic Acid
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 200
0 1 000
0 1 000
0 1 000
0 1 000
53
AVL SESAM-FTIR has been designed and developed to be operated by technicians who have
no previous experience with FTIR based systems. No knowledge of software programming or
FTIR spectroscopy is required. It is easier to operate than a conventional emission bench!
With the longtime stable factory calibration it does not require regular calibration, check and
linearity processes. Without the need for calibration gases, it is the most cost effective emission
analysis system on the market. Combined with the minimal maintenance effort and its
robustness it delivers the lowest total cost of ownership.
Multi-component analyzer system with the ability to detect regulated and non-regulated
emission components
Optimized signal to noise ratio
Excellent dynamic behavior rise time t10 - t90 within 1 sec
Perfectly time aligned signals
Complete software automation with easy to use intuitive operation
Full integration into test bed automation systems standard AK protocol to host
Low total cost of ownership (TCO)
Factory calibration stable over years
No calibration gases required
Minimal service and maintenance requirements
Works much more reliably than conventional analyzers
19 closed cabinet
Industrial-type FTIR spectrometer, installed within the cabinet
Optional expanded software packages available for advanced stand alone operation
Technical Insight
The Fourier-Transform Infrared (FTIR) spectroscopy enables time-resolved (modal) on-line
measurements. This method is highly suitable for in depth investigation of transient processes in
combustion engines. It is capable to determine up to 25 gaseous exhaust components
simultaneously.
The AVL SESAM-FTIR has been designed to be operated by technicians who have no previous
experience with FTIR based systems. No knowledge of software programming or FTIR
spectroscopy is required. Actually it is easier to operate than a conventional emission bench, or
any other analytical system. All operation is done via the advanced software package.
Within the cabinet all components for required to perform the measurement are located,
including the FTIR analyzer module itself. The cabinet is mounted on castors and can easily
move around.
FTIR spectroscopy
Unlike conventional infrared (NDIR) analyzers, which use a single wavelength of infrared light to
measure a single gas component, FTIR spectrometers use a wide range of infrared wave
lengths to detect simultaneously all spectral information available from the gas sample.
54
The AVL SESAM-FTIR uses a Michelson interferometer with two mirrors, one fixed and one
moving. A wide band infrared radiation from the light source is split into two beams by a beam
splitter. One of the beams passes through the beam divider onto the moving mirror and the
other is reflected onto the fixed mirror. Both beams are then recombined to one beam again
along with an interference effect depending on the optical path length difference (retardation)
caused by the actual position of the moving mirror relative to the fixed one. If the retardation is
zero, the two beams are perfectly in phase and all light from the source will be transmitted into
the measuring cell. If the retardation is unlike zero, the beams will be out of phase and less light
(up to zero) will be transmitted into the measuring cell. Consequently, at every mirror movement
(scan) between its turning points the detector will record an "interferogram" (intensity vs. time)
as result of the varying interference of the beams.
When the sample gas cell is filled with exhaust gas, each single exhaust gas component will
absorb infrared light at different wave length and depending on its concentration. This spectral
absorption will change the interferograms, which then comprise the total information of the
complete spectral absorption of all gas components contained in the exhaust sample.
By the Fourier Transform (FT) method interferograms are converted back via mathematical
procedures into an infrared spectrum (intensity vs. wavelength), which is the absorption
spectrum of the relevant exhaust sample. This enables the determination of the concentration of
all infrared-active components of the exhaust gas sample.
Just like standard evaluation methods, as used for general purpose laboratory FTIR analyzers,
the AVL SESAM-FTIR uses specially developed evaluation methods. These methods have
been developed over the last 15 years and are continuously being optimized and improved.
These methods combine the specific requirements for exhaust gas measurement of internal
combustion engines and specific mathematical functions to minimize cross interferences.
The factory calibration of all measured gas components on each single AVL SESAM-FTIR
system ensures the highest possible analytical performance combined with the long time
stability of the calibration.
Optionally, conventional analyzers as well as all necessary sampling compounds can be
integrated. The analyzers just as all other functions are controlled via the software.
The following analyzers can be integrated, the integration of conventional analyzers require to
use the Basic Unit Large Cabinet:
Heated FID (THC) module
NDIR (CO2-EGR) module
PMD (O2) module
The conventional analyzers are operated in the usual way like any conventional emission
bench. A supply with the typical operation gas and calibration gas is required. See the analyzer
data sheet for the detail specifications.
Technical Features
The gas cell is easy to remove and clean and does not require special optical alignment after
cleaning.
All optical parts of the FTIR are mechanically auto-aligned, this means they can easily be
exchanged or repaired. The final optical adjustment is performed by the automated optical
alignment function.
Sample purging time of 1 second due to the optimized gas cell.
No loss of concentration in the sample, because condensation is prevented (important
especially for hydrocarbons and all other components, that resolve in water). Sample lines
and gas cell are heated to 190 C (gas cell 185 C).
55
Synchronous measurement for all components (no individual delay times). This makes time
synchronization easier, especially for pre / post catalyst measurements.
Excellent long term stability, FTIR comes with factory calibration for all measured gases. The
calibration remains stable during life time of the FTIR.
No regular calibration necessary, only daily background sampling using zero gas is needed.
SESAM-FTIR Air Conditioning Features
SESAM-FTIR Air Conditioning unit allows the SESAM-FTIR cabinet to be installed inside an
engine test cell.
Conditions for the Basic SESAM-FTIR cabinet with Air Conditioning Package are 15C to
55C (59F to 131F)
Software features
The AVL SESAM-FTIR has been designed to be operated by technicians who have no previous
experience with FTIR based systems. No knowledge of software programming or FTIR
spectroscopy is required. Actually it is easier to operate than a conventional emission bench, or
any other analytical system. All operation is done via the advanced software package.
The software is installed on a PC, with a Microsoft Windows operating system. It uses the
Windows operation conventions as well as the AVL look and feel of the other products. In this
manner each test bed operator is quickly familiar with the basic functions.
The normal measurement operation is reduced to simple and easy to understand
instrumentation operation. All results displayed are already the final result as needed by the
operator.
All the controls for the system, like sample preparation (solenoid valves, temperatures, etc.), the
data evaluation of the Fourier Transform calculations, conversion into quantitative units and
spectra management (FTIR Control Computer), Interferometer control (lasers, light source,
detector, etc.) and monitoring is done by the FTIR specific software in the background.
System diagnostics and maintenance screens are available for system maintenance or for a
possible need to take a deeper look into. In addition the operator is supported with easy to
understand and operate screens showing the actual flow diagrams and online graphics. If
needed the data source for the analytical data evaluation, like the absorption spectra, is
available.
The integration into any test bed automation system is done via the standard emission
measurement protocol, as defined by the AK standard. If needed, optional analog output signals
can be delivered, for simple analog based interfacing to test bed automation systems or data
recorders.
Optional software package can be installed on the system PC to advance operation, especially
for stand alone operation. Such options starts with simple data recorder and can expand up to
test run automation systems, with full data evaluation routines.
56
Technical Data
Data Sampling
Scanning Rate
Number of simultaneous measured or calculated gas
components
Spectral Region for Analysis
Wavenumber Resolution
Measurement Cell
Detector cooling
Liquid Nitrogen consumption
Time between refills
Material in Contact with Sample
5 Hz at 25 measured
components
1 scan per second
up to 25
gas
Weight
Power supply
Operating Environment
Warm Up Time (95% heated)
Notes
AVL SESAM-FTIR Application Packages are optimized for certain common and popular
measurement applications. In this manner we can standardize the manufacturing and calibration
processes as well as to automate it. Therefore, we can offer such application oriented solutions
at an optimized price, too. With this article not all options are available. All FTIR articles, which
can be used with such packages, have an indication. This indication can be found in the article
information (see Notes).
AVL SESAM-FTIR Basic Units are used to realize customer specific configured systems. The
AVL SESAM-FTIR Basic unit can be combined with any other FTIR article. There are three
Basic Units, one with a small cabinet, one with a large cabinet and one with a X-large cabinet.
Not all hardware options can be integrated in the small cabinet, like additional conventional
analyzers. In that case the Basic Unit Large Cabinet or the Basic Unit X-Large Cabinet must
be ordered.
57
7.02.00
consisting of:
7.02.01
Technical Insight
16 outputs
0 - 10 V or 0 - 20 mA, configurable
7.02.02
The heated Pre-filter is used to remove particulates from the exhaust sample to avoid
contamination in the sample stream as well as contaminations in the measurement cell of the
FTIR system, and any integrated analyzer module. It supplies a back flush functionality.
This pre-filter is especially design and made to prevent measurement artifacts. Such artifacts
can be chemical or physical reactions of the gases with the surface of the filter module or the
filter material itself, or time delays and hang-ups for certain gases. Especially NH3, which is a
limited emission component in the European emission legislation, can be strongly affected,
when not done properly.
Especially the measurements of critical gas components, which are not measured in
conventional emission systems, like NH3, are taken care by this special pre-filter. In addition it
has been designed to avoid long delay times and smoothening effects of the gases, which
would reduce the dynamic of transient measurements.
58
Technical Data
Filter holder
Stainless steel
Temperature controlled
190C
Start up time
15 min
Notes
7.02.03
FTIR heated line provides heated routing of exhaust gas from the sample probe to the FTIR
sample inlet.
Technical Data
Length
4m
Temperature controlled
190C
Notes
7.02.04
7.03.00
INSTALLATION &
COMMISSIONING/TRAINING
TE86A.00
7.03.01
59
7.04.00
7.04.01
The packaging has been designed to ensure the immaculate operation of the shipped exhaust
gas analysis instruments at its final destination.
Notes
60
8.00.00
8.01.00
The AVL Indi-Advanced series is the new generation of high performance AVL Indicating
Systems.
The IndiModul 621 is a modular high speed indicating equipment for research and development
of engines and components. It is designed for use at test beds and in vehicles.
Highest flexibility in functionality and application is guaranteed due to modularity and powerful
options.
The included software for PUMA connection and the optional software Communication Interface
allow remote operation from test beds and direct communication with other equipment. The area
of application of the basic system can be extended by various software packages (see options
CalcGraf, FlowGraf, "Recorder Function", "Real-time knock analysis, Driver software for NIPC cards, etc.").
The IndiModul 621 is controlled by the PC operating software package AVL IndiCom. This
software package assists the user in the parameterisation of the measurement and data
evaluation, in the fast and direct data access, all this with minimum training efforts.
For detailed and convenient analysis of all combustion related data the post processing
software IndiCom-Offline is recommended. IndiCom-Offline has been optimised for fast data
access, versatile calculation, flexible display and report generation with a single tool. It allows
also to configure the IndiModul 621 in the office (in off-line mode while not connected) and to
test the set-up with already measured or with predefined data.
The data format is also compatible for the AVL data post processing software CONCERTO-I or
Top-CONCERTO.
8.01.01
The IndiModul 621 is a high speed 8-channel indicating system, for crank angle related
measurements on internal combustion engines, injection systems etc.
The innovative graphical user software AVL IndiCom supports the user during parameterization,
measurement and data processing.
The described IndiModul 621 also provides a firewire connection (IEEE 1394) to the notebook
(FireWire PCMCIA-Card included in scope of supply).
61
Real time data acquisition system with extensive on-line combustion analysis:
Crank angle based data acquisition with simultaneous real-time evaluation of indicating and
knock results (option: real time knock monitoring)
Oscilloscope mode and single measurement in real-time, multi-channel digital voltmeter
Continuous or single measurement on time base (recorder function)
Event monitoring
Event triggered measurement with pre and post history
Channel individual measurement windows and measurement resolutions
PUMA connection: remote control from an AVL PUMA automation system via serial link (RS
232) or TCPIP (need PUMA Open 1.1 or higher)
Technical Insight
8 analogue differential inputs with individual 14Bit / 800 kHz ADC per channel:
- Input voltage +/-10V
- On-board data memory 8Mbyte
(extendible to 20 MByte by means of memory extension)
Angle- and measurement resolution : 0.025 to 1.0 deg. c.a.
Time-based measurement resolution: 0.00125ms 5000ms
8 digital outputs: TTL level (alternatively to be configured as 4 open collector and 2 relay
outputs)
Sockets for connecting AVL Angle Encoder 364 or 365
Integrated CDM-multiplier incl. 60-2 logic (TTL level required) for a measurement resolution
up to 1.0 deg. c.a.
PC-connection via IEEE 1394 interface (firewire)
Extension by cascading further IndiModul (8 channels each), up to maximum 4 IndiModul
can be cascaded.
Technical Data
Power supply
Power consumption
Ambient temperature
Relative humidity
Dimensions (width x height x
depth)
Design
Complying with legal regulations
10.5...36 VDC
45 VA
0 50 C
10...75 % (not condensing)
19 x 1 HU x 280 mm (320 mm including cable
connectors)
Table or rack version
CE
Notes
62
Hardware requirements: Pentium 4 Notebook with 1.8 GHz and minimum 512 MB RAM, CDROM drive and free PCMCIA slot (an IEEE1394/FireWire PCMCIA-card is included in the
scope of supply)
PC Operating System: Windows XP
For connection with a notebook the use of the integrated firewire (IEEE1394) plug of the
notebook is recommended. If the notebook is not supplied by AVL, a list of positively tested
notebooks can be supplied by AVL.
8.01.02
Memory Upgrade from 8MB to 128MB for one IndiModul 621 with FireWire.
If the memory upgrade is ordered for an existing system, the installation has to be carried out by
a qualified AVL service technician.
Allows the acquisition and storage of indicating raw data over a very long measurement
duration with high crank angle resolution
Application example: recording of 4 cylinder pressure signals on one data acquisition module
over 15.000 cycles (typical FTP cycle) with a resolution of 0,2CA from 10...70 CA and a
resolution of 1CA from 360...360 CA
Technical Insight
Hardware extension auf 128MB dynamic memory for the installation in an IndiModul 621 with
FireWire.
Notes
The option is valid for one IndiModul 621 with FireWire and necessitates IndiCom 1.3.
The IndiModul including all cascaded units require minimum a Pentium 4 PC with a RAM size
larger 256MB plus the sum of memory size of all the acquisition modules.
Currently a maximum acquisition memory of 768MB per IndiModul system is supported.
Because of the memory extension the memory for the oscilloscope is limited to 8MB.
8.01.03
The software option Cold Start Measurement enables the combustion analysis starting from the
first movement of the angle marks, as well as the acquisition of engine start measurement on
time base with following conversion to crank angle base.
In mode Cold Start the data are recorded from the very first movement of the engine without
waiting for synchronisation by the trigger pulse. The TDC correction is performed automatically
after stopping the measurement. Therefore, convenient check of all signals will be possible
immediately after measurement.
In the time based engine start measurement, an analog CDM trace (i.e. 60-2) is recorded in
addition to the measurement signals. After the measurement, the time based signals are
converted into CA-base and can consequently be used for calculation of CA or cycle based
63
results. A benefit of the time based start measurement is the recording of values before the
actual engine start.
8.01.04
The Notebook consists of a DELL Latitude notebook D600 (or similar type with equivalent or
better specification) and includes also the installation of the operating software IndiCom.
Technical Data
Microprocessor
RAM
512 MB
Floppy Drive
3 1/2
CD/DVD Drive
Ethernet Adapter
Ports
Operating System
Windows XP preinstalled
Housing
Notebook
Accessories
Support
Notes
Suitable for Indiset Advanced 631, IndiModul 621 with Link, Indiset 620 and Indimeter 619
For use with IndiModul 621 with FireWire, Indiset Advanced Plus 641 or Indimaster
Advanced 671 a PCMCIA-Firewire card is mandatory, we recommend Margi 1394-to-Go or
Unibrain FireCard400
64
8.01.05
Angle Encoder Unit with integrated marker disk, mounted optical cable and opto-electronic
converter but without Pulse Converter Box (Angle Encoder 365C), suitable for mounting to a
free shaft end or belt pulley.
The AVL Angle Encoder 365C (flange mounting unit GG0736 and electronics BO4293, plug-in
type) will be delivered without Pulse Converter Box (3064Z05 or 365Z01) Therefore, it is to be
connected directly from elecctronics BO4293 to an indicating system of the AVL Indi Advanced
series or to an existing Pulse Converter or to the IFEM Signal Conditioning Rack 6FA1 with
CDM Interface.
For this connection of the Angle Encoder 365C the Connecting Cable BV2026 is included.
The plug connectors allow more flexible mounting of AVL Angle Encoders in combination with
Indi Advanced systems or IFEM-Rack with CDM-Interface since there is no more need to find a
proper mounting place for the bulky Pulse Converter.
Cost saving version in combination with AVL Indi Advanced system or with the AVL IFEM
Signal Conditioning Rack
Precise measurement up to n = 20,000 rpm, even in dynamic operation
Compact size with low-mass and therefore low inertia
High tensile strength materials (titanium shaft, high tensile strength housing)
Technical Insight
The angle information is transmitted by light pulses from an encoder through an optical cable,
length 2 m, to an emitter-receiver-electronics. The digital signal is generated in the plug type
electronics unit.
The necessary power supply is provided by an AVL Indi Advanced system or by CDM-Interface
or by pulse converter.
For further technical data, mounting dimensions and available accessories see leaflet or manual
for Angle Encoder 365C.
8.01.06
4-channel microIFEM 4P3G indicating amplifier for acquirement of combustion pressure signals
or other piezo electrical signals at the test bed or in the vehicle. With a switchable ground
potential also the application of mass isolated sensors is possible.
The robust mechanical design allows mounting close to the sensors, e.g. in a cable boom box.
This allows short cable distance between sensors and amplifiers and therefore allows lowest
impact of electromagnetic interference. The direct connection of piezo sensors reduces signal
drift and possible problems with polluted connectors. The wide range of temperature and the
small dimensions allow universal application.
Automatic sensor identification when using piezo-electric sensors with sensor identification
(SID). The amplifier is equipped with an additional SID board (with HF-technology), which
automatically detects the connected sensor. The allocation of all relevant sensor data is done
via sensor database. Additionally the operating time of the sensor will be registered. The
65
integrated operation time monitor updates the operation time information on the sensor data
connector in certain intervals to be set by the customer and thus enables the monitoring of the
calibration interval or a rough estimation of the sensor condition.
Alternatively the sensor identification or parameterization of sensors can be accomplished
selectively with an integrated Fischer connector using an applicable TEDS.
Your Benefits at a Glance
Remote controlled parameterization via PC-menu (sensor type and sensitivity, signal range,
amplification, offset, sensor type, etc.)
Automatic sensor identification for sensors with SID-technology
AVL Sensor Data Connector (TEDS)
Monitoring of the connected sensor only in combination with the AVL SID
On-board storage for amplifier settings and sensor parameters
Ground-loop suppression by full galvanic isolation between signal input and output
Switchable ground potential for mass isolated sensors
Robust mechanical design for use on test beds and in vehicle
Technical Insight
Dimensions W x H x D
Power supply
Sensitivity
Linearity error
Upper cut off frequency of low pass
Resolution for gain factor
Output voltage
Temperature range
8.01.07
220 mm x 40 mm x 230 mm
9.5 V ... 36 V DC
8 ... 800pC/V
< +/- 0.01% FS
12, 50 or 100 kHz; remote controlled setting
16 Bit
-10V ... +10V
-40C+60C (-40F..+140F)
The microIFEM (micro Indicating Front End Module) rack mount offers space for 2 microIFEM
modules for mounting in a 19 rack and includes microIFEM cascading cable set.
If mounting in a 19-rack or cable boom is required this rack mount allows convenient fixation of
one or two microIFEMs on a tray with 1 HU.
Technical Insight
66
Notes
If just one microIFEM is mounted the use of the MICROIFEM BLIND COVER 9,5
TI04FRCOVA.01 is recommended.
microIFEM cascading cable set serves as connection to the microIFEM. Ensure that the
maximum continuous current of the supply connector doesnt exceed 8A, (e.g. 24 V DC power
supply: 16W / 24V = 0.67A, i.e. 9 Racks can be cascaded.)
8.01.08
External 24V-power supply unit for max. 4 microIFEM amplifier modules (depending on ambient
temperature).
Technical Insight
Compatibility
In case several microIFEM second generation (.02) are used simultaneously following max.
ambient temperatures are allowed:
4 devices: Tmax = 45C
3 devices: Tmax = 50C
2 devices: Tmax = 55C
1 device: Tmax = 60C
8.01.09
Design cost for manufacturing drawings and clarification of the neccessary dimensions for Glow
Plug Adaptors AG03 and AG04 and Glow Plug Sensor GU13G.
Please advise with order the precise dimensions of the installation bore. Use the Table of
Dimensions sheet in the sensor folder or in www.avl.com/sensors Adapter for this purpose.
8.01.10
Transducer, adaptor, cables etc. for measurement of combustion chamber pressure in diesel
engines by means of Pressure Measuring Probe GH12P in conjunction with glow plug adaptor
AG03 without machining the cylinder head.
67
The transducer is mounted to the engine via a glow plug adaptor included in the set. For signal
processing a free input channel with charge amplifier must be available per indicating system.
The outer shape of the AG03 is performed according to the dimensions original glow plug and
its installation bore. When ordering a glow plug adaptor, AVL would need the precise
dimensions of the glow plug and installation bore. Please use the Table of Dimensions sheet
in the sensor folder or in www.avl.com/sensors. After check of these dimensions the drawing for
manufacturing is created.
Your Benefits at a Glance
Technical Data
Pressure Measuring Probe GH12P
Measuring Range (FSO)
Sensitivity (nominal)
Linearity
Operating Temperature Range
Mounting Thread
Glow Plug Adaptor AG03
Mounting Thread
8.01.11
Thermo Protection for use with Transducers GM12D, GH12D, GU12P, GU12S and GU13X.
The Thermo Protection PH01 is to be used in case of extreme thermal load (knock analysis at
petrol engines; highly supercharged engines) or in cases where transducer accuracy is of
utmost importance.
The Thermo Protection reduces the combustion-gas quantitiy which is pulsing in the area of the
sensor membrane and withdraws its heat, so that the thermal load of the membrane is reduced.
Thus the membrane is protected and the cyclic drift of the transducer is reduced by approx.
50%.
In sooting engines (Diesel, GDI) the catch of the small bores of the Thermo protection or the
filling of the space between the membrane and the thermal protection has to be taken into
account and can be avoided by carrying out proper cleaning intervals.
68
8.01.12
Set of mounting tools TS01 for proper installation of Miniature Pressure Transducers
GM12D/GH12D, Pressure Measuring Probes GU12P/GU12S and Dummy DG01.
8.01.13
Box spanner TA16 for proper installation of Pressure Transducers SL31D2000, SL31D200 and
Glow Plug Adaptor AG03.
8.01.14
Commissioning of an IndiModul 621 light (AVL scope of supply) and a subsequent 2 days
onsite training.
Introduction in functions and operation, on the basis of a single visit not later than 5 months
after delivery.
Notes
Travel and accommodation expenses for the AVL employee(s) are included
Interpretation/translation is to be provided by the customer (exception: German, English).
Pre-conditions
The system will be available without interruption from the time of arrival of our staff during
the entire service intervention.
The engine will be operational before arrival of our staff and correctly fitted with all the
necessary pressure and displacement transducers as well as the angle encoder.
For demonstration of the data transfer the appropriate computer system will be available and
operational.
Any additionally required extra time due to non respect of the above mentioned requirements
will be invoiced separately.
9.00.00
9.01.00
CONDITIONNING UNITS
COOLANT CONDITIONING SYSTEM
CONSYSCOOL
TP24A.00
69
9.01.01
CONSYSCOOL S 200
TP24BB000A.01
The coolant conditioning system AVL ConsysCool S 200 with secondary circuit control is used
for cooling the engine coolant to a free definable temperature within tight limits, independent
from the operating state. The control is done by the PUMA System.
The AVL ConsysCool S 200 is suitable for engine test beds with engine ratings up to approx.
230kW.
70
Technical data:
Main data:
Dimensions (L x W x H): approx. 750x600x450 mm
Dimensions with attachments (L x W x H): approx. 960x620x450 mm
Weight: approx. 90 kg
Ambient conditions:
Ambient temperature: 0 to 40 C
Air humidity (rel.): 20 to 80 %, not condensing
Primary circuit:
Nominal cooling capacity (QC): 200 kW
Operating temperature (TB): 10 to 140 C
T- control range nominal (TR): 70 to 125 C
T- control range advanced (TR): 20 to 125 C
Control accuracy (engine inlet): 0,7 C or higher *)
Control accuracy (engine outlet): 2 C or higher *)
Pressure loss at v(Nom) = 12 m/h (p): approx. 0,2 bar (excl. feeding)
Max. system pressure: 6 bar
Max. mixture ration water/glycol: 50/50
Coolant capacity in unit: 8 l
Secondary circuit (cooling water requirements):
Temperature at unit inlet: 0 to 30 C
Pressure: min. 2,5 bar, max. 6 bar
Pressure loss max. 1,5 bar
Max. glycol content: max. 5 %
Recommended water hardness: 7 8 dH
Connections engine side (primary circuit):
Nominal width (DN): 1"
Nominal pressure (PN): 6 bar
Connections cooling water side (secondary circuit):
Nominal width (DN): 1"
Nominal pressure: 6 bar
Pneumatic connections:
Nominal width hose (DN): (int.) 4 mm; (ext.) 6 mm
Minimum pressure (pmin): 4 bar
Maximum pressure (pmax): 6 bar
Electricity:
Voltage (U): ~ 2 x 400 VAC 10 %
Frequency (f): 50 / 60 Hz 1 % (permanent)
2 % (short term)
Connection power (P): appr. 0,1 kW
Protection class: IP 54
*) The coolant temperature stability might exceed the given values. Higher fluctuations might
occur due to too small engine coolant flow, typically at engine idle or with small engines.
Additional requirements:
Additional requirements for unit operation:
1 channel FEM A
1 channel FEM DAC
71
9.02.00
The AVL 576 oil and water conditioning unit is specially designed the AVL Single Cylinder
Engines series 530.
Cooling water supply system: for the automatic control of the cooling water temperature
Lubricating oil supply system for the automatic control of the lube oil temperature. Supplies
oil to the power train, valve train, gear train and balancer shafts of the research engine.
9.02.01
For coolant and lube oil supply of the AVL Single Cylinder Engines series 540 and 580 or Single
Cylinder Research Engines up to approx. 1 litre swept volume.
The AVL 577 oil and water conditioning unit is specially designed for Single Cylinder Engines
and allows control of the cooling water temperature and the oil temperature independently while
heating or cooling. The temperature control via set values is realised by the integrated PID
controller in the switch box. The oil and coolant connections as well as the electrical signal
connections and mains are equipped with quick All components and the switch box are
mounted on a common frame.
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Maximum operating comfort allows temperature control of both oil and coolant
independently while heating or cooling
Quick connectors for lube oil, coolant and electrical cables and mains
Small, compact cubic design
Integrated PID controller on switch box
Technical Insight
Operating range of the unit:
Oil circuit:
Temperature control range
Cooling capacity (nominal)
Heating capacity (preheating)
Coolant circuit:
Temperature control range
Cooling capacity (nominal)
Heating capacity (preheating)
* under the assumption that the temperature of the supplied external cooling water on
customers test bed is below 30 C
Supply voltage
Connecting power
Protection class
Dimensions W x H x D
Weight
Cooling water quantity
Cooling water pressure
min. 3m /h
min. 2 bar (at inlet when using an open water circuit)
max. 6bar
Cooling water hardness
< 5 dH
Maximum permitted content of suspended solid matter < 20 mg/litre
Notes
The conditioning unit with internal oil tank is designed for connecting to combustion engines
with dry sump oil circuits only. No oil return suction pump is used engine oil return line only by
natural height difference.
9.03.00
EXHAUST BACK-PRESSURE
ADJUSTMENT
TP35D.00
Kit for the remote control of the exhaust back pressure of combustion engines, suitable for use
at an engine test stand.
The remote control function will be provided by the test stand computer (e.g. AVL-PUMA
system.) Alternatively an adequate potentiometer can be used (available on request).
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9.03.01
EXHAUST BACK-PRESSURE
ADJUSTMENT 80
TP35AR000A.01
Kit for the remote control of the exhaust back pressure of combustion engines with a power of
up to 250kW, suitable for use at an engine test stand.
The control of the exhaust gas back pressure will be done manually (remote controlled) by a
control flap which is integrated into the engine test bed exhaust system. The exhaust gas
pressure is adjusted during engine full load operation typically.
The remote control function is provided by the test stand computer (e.g. AVL-PUMA system).
Alternatively an adequate potentiometer can be used (available on request).
Easy adjustment of the exhaust gas pressure at engine full load operation for different
engine sizes to be operated on the test bed
Technical Insight
The kit consists of an adjustment flap NW 80, housing GGG40, flap and
shaft 1.4301, operating temperature max. 650C, with connection flanges for the installation in a
customer supplied exhaust system.
The flap adjustment is done by an electrical actuator. A stainless steel mounting console is
provided to fix the flap onto the engine test bed base plate or the test cell floor.
Interfaces:
Input:
Adjustment signal (0-10V)
Electrical connections: 230 VAC / 15 W - 50Hz
Design and dimension similar to drawing no 5490M00A/D00V0
10.00.00
This offer describes the conversion of an AVL SCRE 5403 GDI to a standard AVL SCRE 5402
CR Diesel DI engine.
For this purpose the existing SCRE 5403 GDI which is at TU-Cluj has to be sent free of
charge to AVL Graz for conversion to Diesel Direct Injection and CommonRail Fuel injection
topworks with functional test run.
10.01.00
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The AVL 540 passenger car size single cylinder engine is an excellent tool for research and
development of combustion concepts, hardware parts, injection systems, EMS etc by highest
flexibility for realising various engine versions - standard or customised.
The Basic Unit 5400 can be used for completion with different topworks within a certain
bore/stroke range. The typical sizes are:
Bore
Stroke
Swept volume
Max. speed
Max. combustion pressure
65 100 mm
60 95 mm
0.20 0.75 litre
8000 rpm
150 bar (at bore 95 mm)
The basic unit could be offered as a standard version (AVL 5401 gasoline port injection, AVL
5402 diesel with CR or AVL 5403 gasoline direct injection) or can be completed to a single
cylinder engine with customer specific hardware parts.
10.01.01
COMPONENTS CONVERSION
RESEARCH ENGINE 5403 GDI TO 5402
DIESEL DI CR
TF540ASTA.0101
DOHC 4-valve single cylinder research engine for Diesel 4-stroke operation with Common-Rail
injection and control unit comprising the AVL Basic Unit 5400.
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Technical Insight
Crankcase:
Rigid structure in cast iron with 2 underslung main bearings. Separate aluminum housings
contain the front and rear oil seals.
Crankshaft:
Manufactured from a steel billet and nitride hardened. Flywheel flange mounted and bolted to
the crankshaft.
Cylinder block/-liner:
Cast iron cylinder block contains the replaceable cylinder liner and supports the cylinder head
assembly.
Cylinder liner:
Cast iron, design uses a top flange location and double O-ring coolant sealing at the base.
Cylinder head:
Special unit casting in aluminum. 4-valve design with a unique swirl port concept and double
overhead camshaft acc. to the AVL-LEADER engine. The valves are inclined by 3.5 degrees.
Advantages:
more space for a Unit Injector installation (if required)
less dead volume at the seat rings
bigger seat diameter possible
Two different intake ports, a helical and tangential, are used. This combination enables optimum
positioning of the ports. The cylinder head is prepared for the installation of a cooled pressure
transducer type AVL QC3XC dia 10mm or equal uncooled version.
Camshaft drive:
Special camshaft drive pulleys with internal adjustment possibility for easy changing of valve
timing, adjustable tensioner.
OPTION: Common-Rail Injection equipment (BOSCH CP1 1600 bar)
NOTE: The visualisation software INCA and a measuring and control unit ES690 for access to
the ECU are not included in this offer.
Bore
Stroke
Swept volume
Max speed
Max. BMEP
Max. output
85 mm
90 mm
510 cm3
4200 rpm
~ 14 bar at 2300 rpm / supercharged operation
~ 19 kW at 4200 rpm / supercharged operation
Note
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The engine series 540 requires external supply systems for coolant and lube oil with electrically
driven pumps for example the AVL577 oil and water conditioning unit which can be offered
separately.
10.01.02
Common-Rail Injection equipment (BOSCH CP1 1600 bar) und 3 injections per cycle (pre, main
and post). Open ECU system (AVL) with full access to injection parameters like SOI (start), DOI
(duration), PRAIL (railpressure) with maps.
NOTE: The visualisation software INCA and a measuring and control unit ES690 for access to
the ECU are not included in this offer.
1 CR injection equipment: incl. solenoid injector / rail /high-pressure pump /control unit / sensors
/ wiring loom / fuel lines / safety mechanical overpressure valve, etc
TM
1 AVL RPEMS : open ECU based on BOSCH MES-5 with AVL Software
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10.01.03
Engine conversion from AVL 5403 GDI to 5402 CR DI version with components from items
above.
The 5403 engine hast to be sent to Graz FOC for this conversion. After disassembly the Diesel
components will be assembled on the crankcase housing.
The engine will be functional tested on an AVL test bed before delivery.
The testing will be reported with measurement values as:
Power
Torque
Speed
Indicating: max. in cylinder pressure, IMEP
Injection timing parameters
Several Temperatures and Pressures
10.01.04
11.00.00
Technical University of Cluj is planning to use a single cylinder diesel engine for the
investigation of fuel injection, mixture formation and combustion events. For this purpose, AVL
has provided a quotation to upgrade an existing gasoline single cylinder engine with a diesel
cylinder head.
For the purpose of optical in-cylinder spray and combustion analysis Cluj and AVL have
identified the AVL VisioScope system as most suitable. This is offered in a separate standard
quotation.
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Illumination and View into the combustion chamber by means of 1 bore and the all in
one endoscope.
Straight view endoscope
Pixelfly color camera
Electronics
PC and VisioScope software
Thermovision advanced flame evaluation SW
All components are part of the standard VisioScope system. Therefore, any future expansion of
the system can be accomplished on basis of this economy system.
Adaptation of endoscope bore to cylinder head: is part of the deliverables in the quotation for
the diesel engine cylinder head.
11.01.00
AVL VISIOSCOPE
TFIMAGERA.00
The AVL VisioScope is a new generation of imaging system for the development of combustion
engines. The system incorporates the latest camera technology with an extended image
processing software for enhanced optical diagnosis of combustion and injection phenomena.
The high dynamic range of the camera allows observation of phenomena with low light
radiation. The system goes far beyond the pure observation of engine phenomena by providing
extensive post processing functions, thus opening up new methods of visual analysis.
AVL VisioScope
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11.01.01
VISIOSCOPE SYSTEMHARDWARE
TKSASTA.0101
The AVL VisioScope is a fully digitized triggerable imaging system for combustion research and
development. The system components are based on latest technology available for camera and
PC.
The system visualizes and records images of injection and combustion processes, in addition
mechanical motion of components can be investigated in both diesel and gasoline engines.
Proven endoscope technology provides a high degree of flexibility for adaptation and enables
optical access to almost all parts of the engine, without effecting engine operation.
Your Benefits at a Glance
Technical Insight
Picture resolution: 640 x 480 pixel, color
Dynamic resolution: 12 bit (4095 steps)
Max. shutter speed: 10 micro to 10 milliseconds
11.01.02
Software package for the calculation and display of spatial temperature distribution of a sooting
diesel flame. In addition large data sets can be evaluated automatically.
The software package Thermovision Advanced processes a number of measurements
automatically. The concise presentation of the flame temperature or the soot density versus
crank angle permits easy comparison of engine operation conditions.
The temperature is calculated offline from images of the diesel flame taken with the calibrated,
digital RGB camera of the VisioScope. The temperature and soot density calculation is based
on the 2-colour method with the model of a local homogeneous distribution of soot density.
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Technical Insight
The diesel flame temperature or soot density images created by Thermovision Advanced
Software are split into zones which correspond to different combustion regimes (spray torch,
end gas) or other regions of interest. Within these zones an integral value of the flame
temperature respectively soot density is evaluated for every detail screen. These results are
saved in a spread sheet.
Results evaluated by Software ThermoVision (ThermoVision Statistics) can be exported as IFile for evaluated by CONCERTO. So temperature and soot density distributions can be
presented versus time (CA). Individual engine operating points therefore can be compared to
each other easily
The calculation of the temperature is carried out in two stages:
calibration of the image record
thermographic analysis
During the first processing stage, an optical correction factor can be defined either automatically
or manually. The correction factor allows the local layer thickness to be unambiguously
identified in the subsequent temperature analysis.
12.00.00
12.01.00
12.01.01
COLD CHAMBER
TESIN6500.0101
Consisting of an isolated chamber with thermal panels, and access door for engine trolley, and
the cooling equipment to keep the temperature inside the room at -30C, and able to cool down
the engine from the initial temperature (estimated 25C) to the start temperature (-30C) in a
period of 30 hours. After the engine start, the inside temperature is not controlled.
Evaporator will be installed inside the chamber, hanging from the roof. Compressor and
condenser in the building terrace.
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