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Feature of the Month: November 2011
ACS Drive-In Chambers Part 2: Automobile Emission Test Facility
ACS Experience in the Automotive Field
- Time to market is a must for the success of new car models, accelerating life tests help to reduce this factor.
- Quality , reliability, safety and environmentally friendly components are key points for modern vehicles, proper tests on products ensures a warm welcome into the market.
- In order to improve the efficiency of the project phase, improvements of testing devices are requested to perform the right tests and simulate the real working life of the vehicle.
- The screening of the components during the production phase helps to keep high quality level of the product.
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Car Running Simulation
Car Running Simulation Tools
Test features:
Temperature range:
Humidity range:
Dissipating load:
Main standards:
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-30°C to +60°C
15 to 80% RH
car running + blower + rolling bench
EUR04 - EURO05
US 06
ECE - US EPA
SULEV super Ultra - Low Emission Vehicles
SAE J1635
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Main tests:
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- Verifying the average tailpipe emissions after a cold start
- Carbon monoxide emission at idling speed
- Emission of crankcase gases
- Evaporation emissions
- Durability of anti-pollution control devices
- Verifying the average low temperature carbon monoxide
- Hydrocarbon tail pipe emissions after a cold start
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Comparisons:
| Diesel |
Gasoline |
| Standard |
PM(g/km) |
%Δ |
NOx(g/km) |
%Δ |
Standard |
PM(g/km) |
%Δ |
NOx(g/km) |
%Δ |
| Euro 3 |
0.05 |
- |
0.05 |
- |
Euro 3 |
0.02 |
- |
0.15 |
- |
| Euro 4 |
0.025 |
-50% |
0.25 |
-50% |
Euro 4 |
0.1 |
-50% |
0.08 |
-47% |
| Euro 5 |
0.005 |
-80% |
0.02 |
-20% |
Euro 5 |
0.075 |
-25% |
0.06 |
-25% |
Car Running Simulation Fresh Air
Emmission Check
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Engine Efficiency
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Dynamics Efficiency
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HVAC Efficiency
HVAC Efficiency Tools
HVAC Efficiency Test
Test features:
Energy evaluation:
Temperature range:
Temperature accuracy:
Humidity range:
Main standards:
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Psychometric method
-20°C to +60°C (two or three cabinets)
±0.2°C (in time)
20 to 90% RH
ASHRAE 33, 41.1, 41.2 and 41.9
JIS D 1618
ISO 917, 916
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Typical tests:
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- Cooling system performance test (dual evaporators)
- Evaporator performance test
- Heater test
- Condenser test
- Radiator test
- Condenser and radiator connection test
- Expansion valve test
- Compressor test
- Blower test (P-Q curve)
- Linearity test for hot and cold wind gate
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HVAC Efficiency Drawing
HVAC Efficiency Purpose
Reduce the impact of the HVAC running on the car engine
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Improve the environment condition into the car cockpit passengers comfort
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Sun Simulation
Sun Simulation Tools
Sun Simulation Test
Test features:
Main standards:
Radiation intensity range:
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DIN 75220
IEC 68-2-5
CIE N°85
800 → 1200 W/m²
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Temperature / Humidity:
Other typical tests:
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+42°C 60% +80°C 30%
- Environmetal tests ageing of paints and plastic materials
- Exposed to heating of the sun IR rays
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Sun Simulation Lamps
Sun Simulation Purpose
Sun effect on car parts
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Car ageing due to the sun rays
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Combined Stresses
Combined Stresses Tools
Combined Stresses Test
Test features:
- Combined mechanical and environmental stress
- Possibility to set and control the profiles
- Stress screening and accelorated ageing tests to improve DUT reliability
Main standards:
- BS 2011-2
- IEC 68-2-32/50
- JIS C 0039
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Combined Stresses Interfaces
Combined Stresses Purpose
Combined stress on car parts
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Screening on critical components
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Simulation of working condition of car parts
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Air Bag Test
Air Bag Test Tools
Air Bag Test Features
Main standards:
Door opening / trolley sliding:
Temperature range:
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Not offically classified, producer will follow his own standards based on the experience in the field
Within 10 sec
-40°C to +80°C
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Temperature accuracy:
Temperature rate:
Humidity range:
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±1°C (in time)
1°C/min ↑↓
10 to 95% RH
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Air Bag Test Purpose
Airbag reliability and its suitable working
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Check the correct deployment of the airbag
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Corrosion
Corrosion Tools
Corrosion Test
Main standards:
ASTM B117
DIN 50021
ISO 9227
DIN 50017
SAE J 1563
CCT I- IV
MCT 1M-2M
CCT (ACID RAIN)
Environmental Conditions:
T= +35°C to +60°C RH= 95% - 98%
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Corrosion Drawing
Corrosion Purpose
Simulate corrosion on car parts
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Accelarate ageing of plastic materials
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Filiform/scab corrosion check on painted sheets
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Rain
Rain Tools
Rain Tests
Test Features:
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Temperature range:
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Usually ambient temperature (not possible to control the test room temperature during the rain test)
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Main standards:
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- EN 60529 IPX3
(semicircular swivel tube spraying water on rotating table)
- DIN 400 46-50-52
(semicircular swivel tube spraying water)
- JIS D 0203
(swivel tube spraying water)
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Rain Purpose
Rain effect on car components
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Rain ingress check
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Sand and Dust
Sand and Dust Tools
Sand and Dust Tests
Test Features:
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Temperature range:
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Ambient temperature
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Main standards:
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- SAE J 575
(irregualr whiff of pressed air)
- DIN 40046
(dust circulation driven by fan)
- EN 60529
(dust cirulation driven by fan)
- JIS D 0207
(dust circulation driven by fan)
- JIS R 5210
(dust circulation driven by fan)
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Sand and Dust Purpose
Test of dust influence on the correct working of car components
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Sand and dust ingress check
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Ex Proof
Ex Proof Tools
Ex Proof Tests
Test Features:
Temperature range:
Humidity Range:
Typical D.U.T.:
Main standards:
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-40°C to +120°C
10 to 95% RH
Explosive material
DIN IEC JIS BS
Usually used in the automotive field
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Chamber construction:
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Light ex proof
- Jacketed heaters
- Blower in anti-spark material
- Electric motor in EEX-D II B IP55 execution
Fully ex proof
- Heating by intermediate fluid (indirect system)
- Any part according to ATEX std
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Ex Proof Drawings
Ex Proof Purpose
Working check of critical gasoline tank
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Emission test on gasoline tank
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Test on lead-acid car batteries
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Conclusion Safe Operation
- Professional training on test equipment is useful for the end user in order to avoid typical mistakes on the managing of test devices , it helps even to maintain the systems in good condition.
- Maintenance is the key point to allow the perfect running of test system, domestic service station with professional people is a "must" for fast feed back and proper actions.
- Periodic calibration of the test equipment helps to perform tests in the right way and to compare properly the results.
- The consultant of proper interocutor can help to achieve the required needs and make the right choice about the equipment to ise for any application.
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