exhaust systems and emissions - kst motorenversuch · 2019-11-30 · testing of exhaust systems hot...

January 2014

Exhaust Systems and Emissions

Source: BMW

January 2014 | Exhaust Gas System.ppt | Slide 2 © All rights reserved

Testing of Exhaust Systems

Hot Gas Bending Cycle Test

Measurements of Mass Flow Rates

High Temperature Oven

DPF Development

Urea Injection Systems

Catalyst Development

Thermal Imaging

Stream Lab

Contents

Structure

Emissions



Vehicle-Compliant Setup

Engine

Engine fitting position

Transmission

Engine carriers and mounting

brackets

Exhaust Gas Systems

No mechanical modifications

Original suspension components

Leveling according to vehicle

coordinates

Stiff construction of mounting

suspension



Vibration Analysis

Measurement system

Müller-BBM

Up to 160 channels

simultaneously

Vibration, strain, acoustics,

temperature, analog

variables

3 measurement systems for

220 V and 12 V operation



Vibration Analysis

Measurement system Müller-BBM,

(max. 160 channels, setup with 3-axis miniature sensors)



Vibration Analysis

Frequency [Hz]

Am

plitu

de [

mm

]



Thermal Shock Testing on Engine Test Bench

Phase of Hot Operation:

Operating points with maximum

exhaust gas temperature

(dynamic driving cycles)

Phase of Cold Operation:

Standstill or idle

(cooling down with or without

test bench blower)

Phases of coasting with overrun

cut-off

(internal cooling of catalysts and

mufflers)

0

1000

2000

3000

4000

5000

6000

0 100 200 300

Zeit [s]

Dre

hzah

l [1

/min

]0

200

400

600

800

1000

1200

Tem

pera

tur

[°C

]

400

Drehzahl

T-Oberfläche

T-Abgas

T-Monolith

Runtime [s]

En

gin

e S

peed

[rp

m]

Tem

peratu

re [

°C

]

Surface Temp.

Gas Temp.

Engine Speed

Monolith Temp.



Thermal Shock Testing / Hot Gas Generator

Gas temperature : Max. 1200 °C

Operating

supplement : Natural Gas

Exhaust gas

mass flow rate : Up to 1200 kg/h

Exhaust gas

back pressure : Max. 500 kPa

Truck Application : Increase of Mass Flow Rate via Interconnection


Hot Gas Reverse Bending Cycle Testing

2-Axis Stimulation

Traction : Max. 15 kN/Cyl.

Amplitude : 0.1 - 150 mm

Vibration frequency : Max. 100 Hz

Gas temperature : Max. 1000 °C

Fuel : Diesel

Exhaust gas mass flow rate : Max. 250 kg/h


High Temperature Oven

Preconditioning

Stabilization

DPF regeneration

DPF and catalyst ageing

Artificial atmosphere

Technical data:

Up to 1200 °C

Usuable space: 50x50x70 cm

Injection of N2, O2 and H2O

Te

mp

era

tur

[°C

]

0

200

400

600

800

Laufzeit [h]

0 8 16 24 32

N2

/ O

2 [

l/m

in]

/ H

2O

[m

l/m

in]

0

10

20

30

40

0 8 16 24 32

Temperatur

O2

N2

H2O

Temperature Characteristics at DPF Preconditioning

Runtime [h]

Tem

peratu

re [

°C

]

N2,

O2 [

l/m

in],

H2O

ml/

min

] Temperature

N2

H2O

O2


DPF Development

DPF Testing / Ageing

Regeneration behaviour at

different soot and ash

accumulation conditions

Regeneration options under

worst-case conditions


DPF Development

Cycles according to

customer specification

Automated ageing and

regeneration cycles

Event-related program

sequence via Inca

communication

Soot Accumulation

0

200

400

600

800

1000

1200

0 200 400 600 800

Zeit [s]

Tem

pera

tur

[°C

]

Temperature Gradients during Uncontrolled Regeneration

Runtime [s]

Tem

peratu

re [

°C

]


Ash accumulation cycles with

accumulation-related regeneration

Characterization according to

defined ash accumulation

Rating of regeneration behaviour

Certification according to ECE, US

and further guidelines

DPF Development

Dre

hza

hl

[1/m

in]

200

600

1000

1400

1800

Laufzeit [s]

0 100 200 300 400

Dre

hm

om

en

t [N

m]

400

1200

2000

2800

3600

0 100 200 300 400

Drehmoment

Drehzahl

Section of ETC Cycle

Runtime [sec]

En

gin

e T

orq

ue [

Nm

]

En

gin

e S

peed

[rp

m]

Engine Speed

Engine torque


Urea Injection Systems

Temperature Characteristics at Top of DeNox Nozzle

Te

mp

era

tur

[°C

]

0

50

100

150

200

Laufzeit [s]

0 2000 4000 6000

N [

1/m

in]

0

1000

2000

3000

4000

0 2000 4000 6000

Ventil-temperaturen

MotordrehzahlEngine Speed

Runtime [s]

Tem

peratu

re [

°C

]

En

gin

e S

peed

[rp

m]

Nozzle Temperatures


Urea Injection System

Cooling Element of a DeNox Injector with Thermocouples

Equipment of Exhaust Gas System with several DeNox Injectors


Catalyst Testing

Catalyst Ageing of several Samples within one Exhaust Line


Development of driving

cycle with lambda leaps

Air injection for increase in

temperature

Testing of several samples

within one exhaust line

Exhaust gas analysis via 2-

line exhaust gas

measurement device


Measuring Cycles with additional Air Injection and Lambda Leaps


Te

mp

era

tur

[°C

]

700

750

800

850

900

950

1000

Laufzeit [s]

0 100 200 300

Lu

ftm

en

ge

[l/

min

]

-200

200

600

1000

1400

1800

2200

0 100 200 300

Katalysatortemperaturen

Luftmenge

La

mb

da

[-]

/ O

2 [

%]

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

Laufzeit [s]

0 100 200 300

Lu

ftm

en

ge

[l/

min

]

0

250

500

750

1000

O2

Lambda

Luft-menge

Runtime [s] Runtime [s]

Lam

bd

a [

-],

O2 [

%]

Tem

peratu

re [

°C

]

Air

Qu

an

tity

[l/

min

]

Air

Qu

an

tity

[l/

min

]

Catalyst Temperatures

Air Quantity

Air Quantity

O2


Temperatures at Nominal Output

Thermal Imaging

Thermal Imaging of Exhaust Gas Components


Stream Lab

Adjustment of exhaust mass flow rate

and exhaust gas back pressure

Optimization of geometry of flow

Spatial twist and tumble measurement

Maximum mass flow rate: 400 kg/h

Tippelmann Test Bench


Contact

Bad Dürkheim

KST Motorenversuch GmbH & Co. KGBruchstraße 24 - 36D-67098 Bad DürkheimTelefon : +49 6322 - 799 0 Fax : +49 6322 - 799 353 E-Mail : [email protected]

Internet : www.kst-motorenversuch.de

exhaust systems and emissions - kst motorenversuch · 2019-11-30 · testing of exhaust systems hot...

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