Avl India Private Limited

Avl India Private Limited

Alandur, Chennai, Tamil Nadu
08048732206
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Engine Production

Leading Manufacturer of AVL PSS i60 Particulate Air Sampler, AVL AMA I60 Combi Air Sampler, Combustion Development for Commercial Vehicles, NVH Engineering For Large Engines, Humidity Measurement on The Testbed and High Temperature Can Open Pressure Transducer from Chennai.

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AVL PSS i60 Particulate Air Sampler
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AVL PSS i60 Particulate Air Sampler

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The AVL PSS i60 is a full flow particulate sampler used to collect minute particles in diluted exhaust gas for gravimetric analyses.The AVL PSS i60 particulate sampler for gravimetric particle measurement is characterized by its innovative and compact system design for exhaust certification testing. Optimized gas flow rates combined with an enhanced mass flow control and direct electronic signal processing, increase the accuracy and reproducibility of the measurements, especially with regard to the extremely low PM emissions of today. The new particle filter design and the temperature controlled sampling offer the best conditions for determining very small particles and quantities.
  • Safe investment in intelligent technology of the highest flexibility and retrofitability
  • Compliance with latest emission legislations, e.g. Euro 5/6, EPA CFR 40 part 1065
  • Compact design for particulate sampling, particle counting and H-THC measurements
  • Intelligent service and diagnostic functions reduce downtimes and increase efficiency
  • Substantially reduced expenses for installation and total cost of ownership
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AVL AMA I60 Combi Air Sampler
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AVL AMA I60 Combi Air Sampler

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The AVL AMA i60 COMBI is a high-end emission system for certification/audit and R&D testing of small off-road engines, motorcycles and ATVs. It combines an exhaust gas measurement system with a CVS dilution system, resulting in a very compact and modular design. The intuitive, interactive, graphical user interface supports all the essential service and diagnosis functions and issue warnings in case of pending maintenance intervals.AVL Approach

The AMA i60 COMBI contains analyzers with a wide dynamic measurement range for THC, CH4, NO/NOX, CO, CO2 and N2O, depending on the configuration. It is ideally suited for certifying spark-ignited combustion SORE engines with less than 19kw, in accordance with EPA 40 CFR Part 1054, as well as for developing and certifying motorcycle and ATVs on chassis dynamometers.

 

  • Fits easily to the exhaust system of any engine
  • Very compact CVS venturi unit for flexible integration
  • Optimized solution for SORE and motorcycle applications
  • Integrated maintenance planning and intelligent error handling
  • Complies with EPA 40 CFR Part 1054/1065, EU, CARB, as well as other worldwide exhaust emission regulations
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Combustion Development for Commercial Vehicles
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Combustion Development for Commercial Vehicles

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AVL has the in-depth knowledge for developing combustion concepts ranging from Euro III or similar up to EU VI or similar and for on-road as well as off-road engines. Due to the high focus on alternative fuels AVL has built up significant know-how in the area of gas engines complying up to EU VI or similar. AVL's solutions are customized for specific boundaries (e.g. SCR only, DPF applications,…) To be prepared for future market requirements, research is done on technologies as waste heat recovery systems, hybrid technologies, innovative technology concepts and alternative fuels.
AVL Solution
Combustion development has always been one of AVL's key disciplines. For commercial vehicles AVL provides solutions for conventional diesel as well as for natural gas application and alternative fuels. As well as conventional development work, AVL supports customers in their strategic decisions by means of studies based on AVL consolidated knowledge. Combustion development for commercial vehicles covers the following items:Layout and definition of combustion system and fuel injection equipmentPerformance developmentEmission developmentHardware definition as turbocharger, turbo compound and EGR strategy in close collaboration with AVL applied thermodynamicsAVL Approach
AVL Powertrain Engineering is your expert partner for the development of innovative powertrain systems. From diesel engines to electric drives, from alternative fuels to control software, from transmissions to batteries, we have been supporting the automotive and mobility industries for more than 60 years. Unique synergies with AVL Instrumentation and Test Systems and AVL Advanced Simulation Technologies lead to highly creative, mature and application-specific solutions for our customers to meet their future market challenges.Market RequirementsCustomer BenefitsReferencesEngine development focuses on the optimization of emission behavior, engine efficiency and power density. However, the development process has recent been primarily driven by emission legislation. For future applications engineers will concentrate more on fuel efficiency and the fulfillment of greenhouse gas emission targets, also by integrating alternative technologies in existing powertrain configurations.
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NVH Engineering For Large Engines
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NVH Engineering For Large Engines

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Mainly vibrations are the big topic for large engines. Especially for singly cylinder setups the testing layout has to be designed carefully to allow operation over the complete targeted engine speed range without running into resonances. Additionally NVH could be used for monitoring large engines and detect necessary maintenance before the engine is damaged.AVL ApproachThe AVL Acoustic Engineering team is prepared to support our customers and to provide latest NVH development tools and methodologies, NVH facilities and engineering capabilities to develop individual solutions for and together with our customer. The major services of AVL focusing on NVH development are:
  • Single Cylinder Engine Setup
  • Engine Monitoring and Detection of Possible Malfunction
  • Large Engine Development
  • Vehicle NVH Refinement
  • NVH Powertrain Integration
  • Vehicle and Powertrain NVH Simulation
  • Sound Engineering
  • NVH Software and Methodology Development
The excellent know-how and innovative ideas as well as the strong link of the NVH team to other skill teams within AVL, enforces the outcome of every single project individually and generates an additional benefit for our customers.
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Humidity Measurement on The Testbed
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Humidity Measurement on The Testbed

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The AVL Humidity Measuring Equipment is designed to measure relative humidity and air temperature for different applications. Duct mounting (e.g. intake port) and wall mounting are supported. The AVL Central Weather Station METEOR Measuring Equipment is able to measure barometric pressure, air temperature and relative humidity. For a test field or a group of testbeds, one weather station hardware can be used to centrally capture environmental data. The AVL Central Weather Station software acquires environmental data like temperature, humidity and ambient pressure via the network from the weather station hardware. This data, stored in the central SANTORIN Host System, can be distributed automatically across the entire AVL PUMA Open™ test field to each AVL PUMA Open™ test bed.AVL Approach

The objective of AVL´s Instrumentation and Test System division is to optimize our customers' workflow processes by providing reliable and accurate instrumentation, open hardware and software systems and consistent user interfaces throughout.

AVL provides all necessary sensors for monitoring the engine and measuring various parameters.

Benefits at a Glance
  • Easy installation, use and maintenance
  • Sensors with excellent long-term stability, resilient to moisture and resistant to dirt and most chemicals
  • Calibration certificate referable to international standards (NIST)
  • Reliable and accurate measurements
  • Central environmental data management and data distribution to each test bed
  • Analog or digital data transfer
Technical Data

Humidity Measuring Equipment ES
For the measurement of relative humidity and air temperature in the intake port.

Humidity Measuring Equipment IS
For the measurement of relative humidity and air temperature in the test cell.

Central Weather Station METEOR / analog
For the determination of barometric pressure, air temperature and relative humidity. Communication to the host computer is done via analog signals.

Central Weather Station METEOR / TCP-IP
For the determination of barometric pressure, air temperature and relative humidity. Communication to the host computer is done via TCP/IP. This environmental data can be distributed automatically across the entire AVL PUMA Open™ test field via the Central Weather Station software.

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High Temperature Can Open Pressure Transducer
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High Temperature Can Open Pressure Transducer

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A high-end digital transducer for undamped dynamic pressure measurement directly at the measurement point without the need of any pressure measurement hose.This small-sized, lightweight sensor permits direct mounting at the pressure measurement point, eliminating any damping effect due to the absence of a measurement hose. It makes the exact recording of dynamic pressure signals possible.


HT-C-FEM-P pressure transducers acquire the pressures of liquid and gaseous media. The HT-C-FEM-P allows dynamic pressure monitoring and recording (up to 1,000 Hz per transducer). In addition to the internal calibration, CANopen pressure transducers support PUMA Open's semiautomatic calibration (SAC) with 16 calibration points. The values between the calibration points are determined by means of linear interpolation.

The C-FEM-P's high level of integration in AVL PUMA OpenTM ensures fast real-time processing of data transferred from the pressure transmitter to the automation system. The acquired signals are transferred in physical units to the AVL PUMA OpenTMsystem by means of a CANopen interface.

Typical application: Racing or drivetrain testbeds

  • Benefits at a Glance
  • Technical Data
  • High-end technology
  • Thanks to its small (2cm) and light (13g) design, the pressure sensor can be directly mounted at the pressure measurement point
  • Specified for ambient temperatures of up to 200°C and a shock resistance of up to 1.000g (electronic: -25°C to +85°C)
  • As no measurement hose is required, damping effects and measurement errors caused by the hose are completely eliminated
  • Fully compatible to C-FEM-P pressure measurement
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AVL HSS i60 Heated Sampling System
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AVL HSS i60 Heated Sampling System

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The AVL HSS i60 is a highly flexible pre-filter and sample selection module for raw exhaust emission measurements. The AVL HSS i60 removes particulate contamination from the exhaust probe and prevents contamination of heated sample lines as well as of emission measuring systems. The heated sampling systems switch an emission bench to different sample points and sample lines.
AVL Approach
Pre-filters remove particulates from the exhaust gas and prevent contamination of sample lines and emission measuring systems. Heated sampling systems offer the possibility to switch an AVL AMA i60 or an AVL SESAM i60 FT to different sample points or lines. Sample points are, for example, single cylinders of an engine, whereas sample lines could be different testbeds that share one emission measuring system.Sample selection modules come with 2 to 4 inlets or up to 10 inlets and 1 outlet. In addition, dual stream modules with up to 9 inlets can be chosen.The heated boost pump is required to overcome the pressure drop if very long heated sample lines are used.Benefits at a Glance
Extendable with pressure drop sensors, pressure regulation, etc.Minimized delay time for transient measurements due to innovative valve manifold layoutOptimized design to minimize wall effects (hang-up)Sample point and sample line switching (up to 10 inlets)Boost pump with controlled recirculation circuit – no bypass requiredStand alone pre-filter to be connected to 3rd-party equipmentFunctionsOptionsTechnical DataApplicationsAvailable TypesFiltering techniques: 
Deep-bed filters: The mean pore size of filter media is larger than the mean diameter of collected particles. Such filters collect particulates very well, which have a diameter much smaller than the mean pore size of the filter. These small particulates are collected on the internal walls of the filter. Particulates with a diameter fractionally smaller than the pore size will pass best through the filter.  Surface filters: These filters collect all particulates whose diameter is larger than the pore size, and do not filter particulates whose diameter is smaller. A loaded surface filter may also collect smaller particulates, since the collected particulates work like as a deep-bed filter.
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AVL High Dynamic Engine and Powertrain Racing Testbeds
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AVL High Dynamic Engine and Powertrain Racing Testbeds

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High dynamic engine test beds or high performance 2WD/4WD power train test beds either stand-alone or are combined as part of a multi-configuration tested with a dyno system and summing gearbox.he AVL high dynamic engine and powertrain testbeds use low inertia dynos with permanent magnet technology for highest acceleration rates. Multi configuration testbeds are configured  with either 2 or 4 high performance wheel dynos which are matching the inertia of the wheels of the racecar. This makes the system ideal for any kind of race simulation, including race start optimization. With a summing gearbox the system can be used as high dynamic engine testbed, providing acceleration rates needed for realistic gearshift simulations. The top speed in the engine testbed configuration can be tailored according to the particular needs.Benefits at a Glance
  • High dynamic engine testing with realistic gearshift simulation due to capability of high acceleration rates
  • Test of full power train under realistic conditions
  • Possibility to combine high performance 2WD/4WD tested and high dynamic engine tested in one system
  • Flexible use of the test room due to short configuration change
  • Cost efficient investment due to multiple use of high performance equipment
  • AVL High Dynamic Engine Testbed with single dyno and integrated gearbox (i=3)
    Power (nominal / peak): 800 / 1300 kW
    Torque (nominal / peak): 1,062 / 2,228 Nm
    Speed (nominal / max): 7,200 / 15,000 rpm
    Free acceleration rate: > 80,000 rpm/s
    (Other gearbox ratios available)
     

    Powertrain Testbed
    Power (nominal / peak): 420 / 920 kW
    Torque (nominal / peak): 2,000 / 4,200 Nm
    Speed (nominal / max): 2,000 / 3,500 rpm
    Rotor Inertia: < 0.6 kgm^2
    (Data per wheel dyno)
     

    Engine Configuration (AVL Multi Configuration Racing Testbed - Engine / Powertrain)
    Power (nominal / peak): 840 / 1,840 kW
    Torque (nominal / peak): 444 / 933 Nm
    Speed (nominal / max): 18,000 / 22,000 rpm
    Free acceleration rate: > 150,000 rpm/s
    (Other speed / torque ranges as required)

    Other Wheel Dyno systems for different power / torque ranges available

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AVL Blow By Flow Meter
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AVL Blow By Flow Meter

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Blow-by measurement nowadays is standard on engine testbeds. To be able to comply with the emission legislation for new combustion engines today and in the future, the requirements for crankcase ventilation systems will continue to increase. In order to design these systems, knowledge of engine blow-by mapping is also required. This and the possibility of continuous measurement of the blow-by flow to monitor the engine condition make the AVL Blow By Meter an indispensable instrument for engine testing.AVL Approach

On the basis of the interchangeable measurement ranges between 0.2 and 2,400 l/min, the AVL Blow By Meter can be used from small-scale and single-cylinder engines up to diesel engines for ships. The areas of application cover engine research and optimization of the piston-cylinder assembly. Furthermore, this system is used when designing crankcase ventilation systems and on quality and endurance testbeds.

Benefits at a Glance
  • The accuracy of 1 % FSO and the reproducibility of 0.1 % comply with the strict requirements of engine measurement technology
  • Due to the minimal pressure drop, the original blow-by behavior of the engine is almost unaffected
  • High reliability and constant measurement readiness are realized through low dirt sensitivity
  • Correct detection even of reverse blow-by flows
  • Simple integration and installation on the testbed
  • Technical Data
  • Measuring Principle
  • Downloads

Type

AVL 442

Measurement principle

Differential pressure

Measurement ranges

0.2 … 10 l/min

1.5 … 75 l/min

3 … 150 l/min

6 … 300 l/min

12 … 600 l/min

24 … 1,200 l/min

48 … 2,400 l/min

Measurement accuracy

≤ 1 % FSO fine linearization (option)

≤ 1.5 % FSO standard linearization

Interfaces / output signal

RS232 (AK-compliant),

analog I/O, - 10 … + 10 V

Power supply

24 V DC

Power consumption

35 W

Ambient temperature

- 10 … 55 °C

Dimensions (W × H × D)

Approx. 330 × 350 × 75 mm

(MR: 3 … 150 l/min)

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AVL Flowsonix Air Samplers
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AVL Flowsonix Air Samplers

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The AVL FLOWSONIX™ Air determines the intake air mass flow with high accuracy, large turndown ratio and fast response time.AVL Approach

Along with the fuel consumption, the air consumption is another important parameter when developing combustion engines. In emission certification, the air consumption is taken as reference value. Thus, the air consumption is an integral part of AVL testbed solutions.

The AVL FLOWSONIX™ Air consists of the components of measuring head, evaluation unit and two very short inlet- and outlet pipes (<5* DN each). Due to the large measuring span of 1:70, only two different pipe diameters are needed (DN 100, DN 150) to cover the full application range of up to ± 2,600 kg/h.

Benefits at a Glance
  • The unique AVL FLOWSONIX™ Air is not sensitive to contamination, which enables long maintenance intervals
  • Marginal influence on the combustion engine due to small pressure drop in the measurement head
  • Quick and easy installation for any engine type
  • High availability of the measurement device due to extended calibration interval of one year
  • One size fits all. Due to the wide measurement range only 2 different instrument versions are required:
    Light Duty or Heavy Duty
  • Little space required - just < 5 × DN up-stream and down-stream tubing
  • Technical Data
  • Measuring Principle
  • Downloads

Measurement principle

Ultrasonic transit time

Measurement ranges

0 (± 20) … ± 1,400 kg/h (LD Version)

0 (± 40) … ± 2,600 kg/h (HD Version)

Response time

T90 = < 10 ms

Reproducibility

± 0,25 % of reading

Measurement uncertainty

< ± 1 % of reading

Temperature of air

- 20 … + 80 °C

Operating pressure max.

250 kPa abs.

Pressure drop of Measuring Head

0.25 kPa

Ambient temperature of Measuring Head

- 20 … + 60 °C

Ambient temperature of the Evolution Unit

- 20 … + 60 °C

Interfaces

AK interface Ethernet (TCP/IP)

AK Interface RS232

CAN Bus Interface

Analog 0 … 10 V, 4 … 20 mA

Digital I/O

Power consumption

25 W

Power supply

110 / 230 VAC ± 15 %

50 / 60 Hz ± 5 %

Normal size DN

LD Version 100 mm

HD Version 150 mm

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AVL Fuel Balance and Fuel Temperature Control
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AVL Fuel Balance and Fuel Temperature Control

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The combination of AVL Fuel Balance and AVL Fuel Temperature Control is a highly precise fuel consumption measurement and conditioning system.ombined with the AVL Fuel Temperature Control, the AVL Fuel Balance measures the fuel consumption of engine- and chassis dyno test beds for transient and steady state measurement where highly accurate temperature control of fuel is needed.
  • Time-saving ISO9001 testing due to calibration within a few minutes
  • Universal measurement system for different injection systems and engine sizes
  • Minimization of test bed times due to high reliability and long maintenance intervals
  • Easy and fast integration into the engine test bed due to compatible interfaces
  • Direct determination of the fuel mass
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AVL Fuel Mass Flow Meter and Fuel Temperature Control
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AVL Fuel Mass Flow Meter and Fuel Temperature Control

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The AVL Fuel Mass Flow Meter and AVL Fuel Temperature Control combine high accuracy and excellent temperature stability even with short measurement times.The AVL Fuel Temperature Control and the AVL Fuel Mass Flow Meter with a pressure control system patented by AVL, provide constant, adjustable fuel pressures and temperatures. This allows for reliable and easy utilization for engines sizes up to 600kW with state-of-the-art mixture preparation systems.AVL Fuel Mass Flow Meter and Fuel Temperature Control
Technical Details AVL Fuel Mass Flow Meter and Fuel Temperature Control
Type:AVL 735S/753C
Measurement principle:Mass flow
Measurement ranges:
Mass

0 … 125 kg/h
Measurement uncertainty: 
Mass

≤ 0.12% (acc. to DIN 1319) 
Interfaces / output signal:RS232, analog I/O, 0 … 10 V
digital I/O 
Measurement frequency:20 Hz (analog)
Response time:< 125 ms
Fuel types:Standard*) and 100% bio fuels
Engine feed pressure:< 0 … 600 kPa
Fuel circulation quantities:Optionally 240/450/540 l/h
Control range:10 … 80° C
Stability:Better than 0.02° C
Heating / cooling:1.6 kW / 1.6 kW
Power supply:230 V, 50 Hz, 220 V, 60 Hz
100 V, 50–60 Hz, 115 V,
60 Hz
Power consumption:0.4 kW (without heating)
Ambient temperature:5 … 50° C
Dimensions (W x H x D):770 x 1,630 x 345 mm
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AVL Oil Consumption Meter
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AVL Oil Consumption Meter

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The AVL Oil Consumption Meter permits rapid, professional and clean measurement of oil consumption, as well as oil refilling.AVL Approach

The AVL Oil Consumption Meter is a compact, mobile measurement system that allows quick automatic measurement of IC engine oil consumption with little effort. An important additional function is the integrated refill unit. On endurance test beds it can be used to replace the consumed oil.

Benefits at a Glance
  • Up to 50% time saving compared to conventional methods
  • Integrated oil refilling unit allows for extended test cycles
  • Minimum downtimes due to easy integration into the automation system
  • Stand-alone operation possible thanks to integrated operating panel
  • No handling of oil and clean test bed operation because of automatic measurement
  • Technical Details AVL Oil Consumption Meter
    Type: AVL 406
    Measurement principle: Gravimetric
    Measurement media: Mineral, vegetable and
    synthetic oils, including
    additives (fresh and old oils)
    Oil quantities: 
    Measurement quantity
    Residual quantity
    Refill quantity

    Max. 10 l
    0.5 l
    Max. 9 l
    Measurement accuracy: 1% of the measurement
    value ±5 g (at an oil surface
    in the oil pan of 600 cm²)
    1% of the measurement
    value ±10 g (at an oil surface
    in the oil pan of 4,000 cm²)
    Interfaces / output signal: RS232 (AK-compliant),
    analog I/O, 0 ... 10 V
    Voltage supply: 230 V, 50 ... 60 Hz,approx.
    0.8 A, optional 110 V,
    50 … 60 Hz
    Ambient temperature: 0 … 40° C
    Dimensions (W x H x D): 60 x 104 x 60 mm
    Weight empty: Approx. 60 kg
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AVL Micro Soot Sensor
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AVL Micro Soot Sensor

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The new AVL Micro Soot Sensor Generation MSSplus is a system for the continuous measurement of lowest soot concentrations in the exhaust gas from internal combustion engines.The MSSplus is the only measurement system on the market that is able to measure the concentration of soot directly and without cross-sensitivity to other exhaust components. The MSSplus operates based on the photoacoustic measurement principle. Thanks to the measurement cell design and enhanced electronics of the MSSplus, a particularly low detection limit of 1 μg/m3 in combination with a reduced signal noise is achieved. However, the MSSplus has not only been refined for low emission measurements, but also for the measurement of raw exhaust gas with the integration of an automated thermophoretic loss compensation (TLC). The TLC function compensates the particle losses resulting from thermophoretic deposition at the sample point and enables an automatic calculation, display and logging of the loss corrected soot signal.
  • Benefits at a Glance
  • Technical Data
  • Measuring Principle
  • Transient measurement of soot concentration [mg/m3]
  • Sensitive to soot (not interference to other exhaust components)
  • High sensitivity (resolution 0.01 µg/m3, detection limit 1 µg/m3)
  • Wide measuring range (1-1000 mg/m3)
  • Measurements upstream and downstream of DPF (back pressures up to 2000 mbar, temperatures up to 1000°C)
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AVL Smart Air Sampler
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AVL Smart Air Sampler

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The AVL Smart Sampler is a partial flow dilution system intended for gravimetric sampling of exhaust particulates from internal combustion engines under both steady state and transient conditions. The Smart Sampler is fully certified to the U.S. EPA 40-1065 regulation as well as the current European regulations and is approved for a pre-diluter under ECE regulation No.49 for the purpose of particle number counting. It is also designed and proven to work under US 1066 light duty chassis dyno testing.AVL Approach

The AVL Smart Sampler takes a partial flow from the engine's raw exhaust for dilution with filtered air, and then collects the particles
on a dedicated filter. It allows the transient simulation of CVS dilution tunnels by fast control of the flow rates and the dilution ratio.

Technical Data

The system meets the following global regulations:

US. EPA CPR 40-1065, EPA 40-1066
ECE regulation No. 49, Rev. 3, 04 series /ECE regulation No. 49, Rev. 4, 05 series,
ECE Regulation No. 49 Rev. 5,05 Series, Global Technical Regulation (GTR) No. 4. Directive 97/68/EC at last amended 2011/88/EC, ECE regulation No. 96, Rev. 2, 01 series ISO 16183 (2002), ISO 8178-1 (2006), ISO 8178-11 (2M6), Japan JE05
Directive 88/77/EEC as amended by 1999/96/EC and 2001/27/EC

Measurement value output g/kW-hr, g/bhp-hr, #/kW-hr
(when used with an AVL Particle Counter
Main applications Certification (HD) and R&D (HD and LD)
Certification under ECE regulation No. 49, GTR No. 4
Research and development of diesel aftertreatment systems
Measurement range Detection as low as 0.0 g/kW-hr
47 mm filter media for CFR 1065 compliant testing
Available 70 mm filter for ISO 16183/8178 compliant testing

System operation parameters
Maximum optional distance of main cabinet and filter cabinet 12 m
Transformation time (t50) <150 ms with 2m interconnect
<240 ms with 12m interconnect
Exhaust temperature range 25-500°C
(800°C with Option High Pressure)
Exhaust pressure range Ambient ± 20 millibar
0-1000 millibar gauge with optional high pressure

Facilities requirements
Size Main cabinet (HxWxD) 86x79x38 cm 80 kg
Filter cabinet (HxWxD) 86x79x38 cm
70-85 kg (depends on configuration)
Stacked system (main+filter+trolley)
190x79x66 cm ˜260 kg
Test cell temperature range 10-50°C
Voltage requirement
Compressed air requirement
100-240 VAC 50-60 Hz 1/PE. Automatic voltage detection
580 kPa absolute (70 psi Gauge) minimum
790 kPa absolute (110 psi Gauge) maximum
450 SLPM peak
200 SLPM typical
Interface requirement
Communication protocol
Stand alone mode:
Fully integrated control via AK interface or stand-alone mode

(RS232 or Ethernet) digital input for start/stop
0-10 V scaled to engine air flow
0-10 V scaled to fuel flow
Optional Add on Sampling 0-10V scaled to total exhaust flow
Full integration to AVL Particle Counter via dedicated communication link
Other Instruments may be integrated using analog scaled inputs
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AVL Smoke Meter
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AVL Smoke Meter

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The AVL Smoke Meter is a filter-type smoke meter for the measurement of the soot content in the exhaust of diesel and GDI enginesAVL Approach

The AVL Smoke Meter uses the filter paper method to determine the Filter Smoke Number (FSN defined according to ISO 10054) and the soot concentration in mg/m³. The variable sampling volume and the thermal exhaust conditioning ensure an extremely high reproducibility and a wide range of application. The instrument can be used not only on large engines but also on light duty engines independent of their generation. In addition, raw exhaust measurements (e.g. upstream a DPF) or measurements up to 5000m altitude can be carried out by using device options.

Benefits at a Glance
  • High measurement resolution (0.001 FSN or 10µg/m3) and low detection limit (0.002 FSN or 20 µg/m3)
  • Timely paper change due to remaining filter paper indicator
  • Altitude measurements up to 5000 m above sea level and altitude simulation up to 5000 m
  • High reproducibility, improved cleaning efficiency and increased robustness against wet exhaust gas due to shop air purging of the entire gas path – optional
  • Extended application area up to 3 bar exhaust back pressure for engines with exhaust aftertreatment systems - optional
  • Remote-control service with intuitive user interface – optional
  • Technical Data
  • Measuring Principle
  • Downloads
Measurement principle Measurement of filter paper blackening
Measured value output

FSN (filter smoke number) mg/m³ (soot concentration)

Measurement range 0 to 10 FSN
Detection limit 0.002 FSN or ~ 0.02 mg/m³
Resolution 0.001 FSN or 0.01 mg/m³
Exhaust pressure ranges (-300*) -100 to 400 mbar
(-500*) -200 to 750 mbar with the special sampling option
0 to 3000 mbar with the high-pressure option
(*) with activated altitude simulation
Maximum exhaust temperature 600 °C with standard 340 mm sample probe (800 °C with 780 mm long sample probe)
Interfaces 2 serial RS232 interfaces with AK protocol
Digital via Instrument Controller 4210
1 Ethernet interface with InPort option installed with AK protocol
Power supply 100 – 115 VAC or 230 VAC, 50/60 Hz
Power consumption 700 VA (heated version)
Compressed air consumption (for shop air option) ~150l/min during purge
Compressed air quality required Grades 1.1.1 to 1.4.1 according to ISO 8573.1:2001(E)
Recommended connection pressure on the AVL Smoke Meter: 5 to 8 bars at the measurement device input
Weight basic unit <40 kg (without options)
Dimensions basic unit 560 x 620 x 300 mm (W x H x D)
Sample flow ~ 10 l/min
Ambient conditions

5 to 55 °C
max. 95 % relative humidity, without condensation

Repeatability

(as standard deviation)  σ ≤ ± (0.005 FSN + 3 % of the measured value @ 10 sec sampling time)

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Dynamometer Control Unit BME 400
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Dynamometer Control Unit BME 400

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The BME 400 offers hardware and software for the control and manual operation of an eddy current dynamometer, an AC machine or a hydraulic dynamometer and for the control of a combustion engineAVL Approach

The BME 400 has an ergonomically designed operating panel. Incremental encoders allow the exact setting of demand values. Proven algorithms ensure bumpless change of control modes. The LCD shows demand and actual values as well as parameter settings and operating menus.

Benefits at a Glance
  • Precise operation through excellent torque and speed control stability
  • Standalone operation
  • Bumpless change-of-control modes
  • Communication with a host system via hybrid or digital interfaces like CAN, Ethernet, RS232
  • Reliable and approved safety concept
  • Technical Data
  • Problem Solutions
  • Control and monitoring of a load unit
  • Real-time control system running at 1 kHz
  • Data acquisition via F-FEM-CON and F-FEM-DIO
  • Standard dyno interfaces to all AVL dynos (all other dynos on request)
  • Remote interface using RS232 (CAN and hybrid on request)
  • Interface to throttle actuator, clutch actuator, gear shift robot using RS232 (other interface on request)
  • Demand value setting via 3 incremental pulse encoders
  • LCD display for visualization of demand values, actual values, parameters and messages
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AVL Particle Generator
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AVL Particle Generator

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The AVL Particle Generator (APG) is the solution for on-site quality checks of advanced particle measurement devices.AVL Approach

The AVL Particle Generator (APG) is a stand-alone device that generates a highly stable and repeatable combustion aerosol.

The intelligent design of the AVL Particle Generator, with three sample outlets, permits smooth installation and versatile utilization in a variety of different applications:

  • On-site quality checks of particle counting devices:
    • PCRF (particle concentration reduction factor) check
    • Particle number counter linearity check
    • Particle number counter cut-off check
  • Relative comparison measurements between two different particle measurement devices, e.g. AVL MSS
Benefits at a Glance
  • Generation of pre-conditioned combustion aerosol
  • Wide range of applications due to integrated dilution stages providing scalable concentrations
  • Pre-defined operating points for straightforward on-site quality checks of particle counting devices and particle measurement devices
  • Utilization as stand-alone device
  • Integrated touch-screen for simplified operation
  • Low total cost of ownership
     
    Technical Details AVL Particle Generator
    Output Combustion soot particles
    Particle size range 10-100 nm
    Concentration range Up to 1x107 particle/cm3
    Dilution Ranges - Dilution rate burner: up to 4 (adjustable)
    - Dilution rate stage 1: up to 20 (adjustable)
    - Dilution rate stage 2: 4 (fixed)
    - Dilution rate stage 3: 4 and higher (adjustable)
    Sample Outlets - Burner out (undiluted)
    - VPR out (after stage 2)
    - Dilution bridge out (after stage 3)
    Temperatures Up to 400 °C (1st dilution and evaporation tube)
    Output flow Up to 15 l/min (thermally pretreated)
    Fuel gas Propane (99.9%)
    Dilution air Filtered compressed air (up to 40 l/min depending on the dilution, 1 bar gage pressure)
    Quench gas and mixing gas Nitrogen (99.9%)
    Flow control High precision mass flow controllers
    Power supply 90…240 V AC, 50/60Hz, 450 W
    Dimensions (WxHxD) 550 x 320x 440 mm
    Weight < 30 Kg
    Touch-screen 5.7" 640x480
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Crank Angle Encoder of 365-Series
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Crank Angle Encoder of 365-Series

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Angle Encoders 365C/X/R are highly accurate optical pickups for angle-based indicating measurements and torsional analyses on IC-engines.AVL Approach

365C for standard mounting at the free crankshaft, 365X for mounting at the shaft between engine and dynamometer and 365R "mass free marker disc" designed for racing applications, small sized engines or engines with limited access to the crank shaft.

Benefits at a Glance
  • Small and compact design for easy handling and minimum influence to crank shaft
  • High resistance against vibration, temperature and electrical interference
  • Only one mark trace with integrated trigger
  • Suitable for racing application
  • The marker disk at 365X is manufactured to customer's specification
  • Technical Data
  • All Products
  • Key Features
  • Downloads

CRANK ANGLE ENCODER OF 365-SERIES

Product Family

365C

365X

365R

Engine Speed

Up to 20.000rpm

Up to 28.000rpm

Up to 28.000rpm

Permissible load

500g (overload 1000g)

500g (overload 1000g)

500g (overload 1000g)

Temperature range at mounting surface

-40°C to 100°C

 

 

Output pulses

LVDS, RS422, TTL
Up to 0.025 deg CA

LVDS, RS422, TTL
Up to 0.025 deg CA

LVDS, RS422, TTL
Up to 0.025 deg CA

Dimensions of multiplier / converter

W x H x D (mm)

110 x 35 x 85

11

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Gas Exchange and Combustion Analysis Software
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Gas Exchange and Combustion Analysis Software

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AVL GCA is a high sophisticated tool for thermodynamic analysis of IC-engines. It is both a "virtual sensor" and a design tool for the whole engine process.AVL Approach

AVL GCA consists of two calculation steps: 
First, combustion analysis is executed and subsequently gas exchange analysis is done, whose result is in turn supplied to the combustion analysis, which is then calculated for the second time for higher accuracy.

  • Benefits at a Glance
  • Key Features
  • Downloads
  • GCA providing e.g. residual gas content / energy balance / mass flow balance
  • Based on BOOST: detailed consideration of the whole engine process
  • Integrated into AVL IndiCom in online operation at the test cell
  • Integrated into AVL CONCERTO in the office
  • Plausibility Check in stationary and transient operation
  • Consideration of gas dynamics in intake and exhaust
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Avl Throttle Actuator Compact
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Avl Throttle Actuator Compact

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The AVL Throttle Actuator Compact is a linear rotary screw (LRS) type throttle actuator used for controlling the mechanical throttle on an engine. The linear rotary screw type technology gives the Throttle Actuator excellent speed, force, and accuracy capabilities. The integrated controller allows for improved stability and accommodates a large input voltage range. The integrated mechanical flex-ball connection to the throttle and a pre-defined electrical connection to the automation system make it an excellent solution for engine control. The hardware component of the AVL Throttle Actuator Compact consists of the actuator with a push-pull cable and an integrated controller. All of the required power components and motion processors are contained in the actuator housing.Benefits at a Glance
  • RS 485 connections for advanced configuration.
  • Integrated LED indicators for actuator status.
  • No external controller required
  • No tuning required for different load ranges connected
Options

The THA-LRS Setup box allows a quickly and easily set of the zero and end position of the throttle actuator THA-LRS by using simple and reliable push buttons. It offers:

  • Quick, safe setup of the throttle actuator THA-LRS
  • Industrial device with reliable push-button operation
  • Technical Data
  • About COMPACT
  • Downloads

Throttle Actuator Design

Linear, Planetary lead screw design

Max force

890 N

Linear stroke

76.2 mm

Speed

1000 mm per second (full stroke in 0.076 seconds)

Flexball Cable

l = 1.5 meter, 101 mm bend radius, ball cage PTFE

Certification

UL and CE

Input Voltage

100 to 240 Volts AC nominal, single phase, speed specifications based on 230V line voltage

Dimensions (width x height x length)

140 mm x 182 mm x 418,6 mm

Maximum Operating temperature range

-20° to 65 °C

Degree of protection

IP 54

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Indicating Amplifiers
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Indicating Amplifiers

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Modular amplifiers for high-end conditioning of cylinder pressure, manifold pressure, rail pressure, or timing signals for the purpose of combustion analysis.Our indicating amplifiers portfolio is suitable for most application fields and test environments. The different form factors of the FI/FlexIFEM and MicroIFEM amplifier families cover stand-alone usage as well as full integration into the test facility.Benefits at a Glance
  • Quick sensor swap and best traceability due to AVL Sensor Data Management SDMTM
  • Easy integration in various environments due to robustness and signal filtering
  • Compatibility with a large range of sensor types
  • High transient accuracy due to intelligent drift compensation for piezoelectric sensors
  • User-friendly parameterization due to full integration in IndiComIndicating amplifiers and signal conditioning

    Product Family

    MicroIFEM

    FI

    FlexIFEM

    Number of channels

    2 or 4

    1 or 2

    1 or 2

    Power supply

    9.5…36 VDC

    9.5…36 VDC

    9.5…36 VDC

    Dimensions WxHxD

    4.75'' or 9.5'' x 1HU x 230 mm

    86x112x270 mm

    86x112x270 mm

    Weight

    0.75 or 1.5 kg

    1.6 kg

    1.6 kg

    Signal output

    -11…+11 V

    -11…+11 V

    -11…+11 V

    Parameterization

    Remote via RS232 interface

    Via front-keypad, or remote via RS232 or USB interface

    Via front-keypad, or remote via RS232 or USB interface

    Integrated LCD

    no

    yes

    yes

    Sensor Data Management

    SID & SDC

    SID(*) & SDC

    SID(*) & SDC

    Peak firing pressure measurement

    yes (optional, only for MicroIFEM 2P5)

    yes (optional)

    yes (optional)

    Additional time-based measurements

    • Engine speed for MicroIFEM 2P5
    • Engine speed
    • Engine speed
    • Combustion noise
    • Knock peaks
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Particle Measurement Device
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Particle Measurement Device

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The APCplus - AVL Particle Counter offers a unique solution for the measurement of particle number concentration not only in research and development, but also for certification.Increased test effort and RDE challenges ahead
Legislation:RDE and WLTP will significantly increase requirements for measurement equipmentNew introduction of particle number limits combined with RDE for China, Korea, IndiaGasoline:Stricter particle number limits and RDE for gasoline vehicles a particle filter ahead?Efficiency:Continuously rising test efforts and shorter development phasesThe AVL Solution
APCplus - The industry standard for particle number measurement: Now even better with AVL Condensation Particle Counter (CPC) inside.The APCplus fulfills 100% of current and in-work legislation with the highest calibration quality according to ISO 17025. The new core sensor with enhanced functionality improves performance up to 20% by simultaneously optimizing service and calibration. APCplus now enables frontloading of RDE cycles on engine and chassis dyno test beds.Unique combination APCplus & AVL Smart Sampler

Standards/InterfacesRelated AreasTechnical DataDownloadsOptions / Add-Ons:Trolley with/without Conditioning UnitMobile 19-inch rack with optional, integrated climate and compressed air conditioning for extended ambient temperatures up to 45 °C.Tailpipe Sampling Kit (APCplus Advanced)The tailpipe sampling kit enables tailpipe measurements at exhaust temperatures up to 600°C for R&D purposes.High Pressure Option (APCplus Advanced)The High Pressure Option enables the measurement at exhaust backpressures up to 2000mbar and temperatures up to 1000°C, such as engine out raw exhaust measurements upstream of diesel or gasoline particle filters.External Flow Check KitThe flow check kit enables the monthly flow verification of the device as required by legislation UN/ECE R83 and R49.CVS i60 Sampling KitThe CVS i60 Sampling Kit is a complete solution for installation of the APCplusprimary diluter on an AVL CVS dilution tunnel VT i60.CVS Mounting KitThe CVS mounting kit is a flexible solution for installation of the APCplus primary diluter on various CVS dilution tunnels.Euro Norm Probe KitUN/ECE R83 and R49 standard probe kit for various CVS tunnels.Cyclonic separatorAlternative to the standard probe. The cyclonic separator removes particles with a size range of 2.5 μm to 10 μm in accordance with the UN/ECE R83 and R49 regulations.Gas Check ValveThe automatically switchable 3-way valve enables the verification of the gas dilution ratio of the instrument.PND1 Mounting Frame The mounting of the primary diluter (PND 1) of the APCplus is relieved by means of a specially designed mounting frame.Analog cableThe analog interface on the APCplus is used to retrieve an analog voltage signal of the measurement values.Digital Cable HybridInterface cable to integrate the APCplus into the test bed system via digital input/output (I/O) (hybrid integration in combination with analog cable).Compressed Air PreparationTo supply compressed air of the required quality regarding minimum particle content as well as oil and water content for the APCplus.PND1 exchange UnitTo minimize the down time of the test facility, AVL proposes the storage of a hot-swap PND1 exchange unit including heating line.
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Pallet Systems
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Pallet Systems

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Pallet systems meet customer demands for reduced unit under test changing and mounting times, thereby shortening test bed downtimes and lowering cost through automation.AVL Pallet Systems are suitable for almost every application, from passenger car engines via commercial vehicle engines to racing engines. The Pallet Systems enable simple and easy pre-mounting and aligning of the unit under test and instrumentation in a separate setup room. Even pre-testing of the unit under test outside the testbed is possible with an appropriate level of automation.Benefits at a Glance
  • Reduced setup times due to the mounting of the unit under tests on pallet systems
  • Comfortable preassembly and alignment of the unit under test and the measuring equipment in separate setup rooms
  • Quick and easy fixing of the pallets on the testbed
  • Quicker connection of the media supply by quick couplings or docking plate systems
  • Easy movement of the unit under test by hand or fork-lift
  • Functions
  • Options

The engine trolley enables an easy movement of the unit under test from the rigging / pre-test area to the test cell by hand or by means of a forklift truck like the engine pallets.

The engine pallet for automatic docking enables shortened engine changing times through automatic and easy fixing of the pallet on the base plate as well as leakage free connection of the media supply per push of a button.

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AVL Compact I Or O Cubes
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AVL Compact I Or O Cubes

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The AVL COMPACT I/O Cube is designed as a versatile I/O module for the test cell to allow data acquisition and control of a wide variety of I/O devices. The Cube provides various input and output channels. The channel assignment is software-configurable by the user. Depending on the required I/O configuration, there are different I/O cubes available, an all-in-one I/O cube or dedicated cubes for temperature or pressure channels. Additional cubes can be easily added to the system.Benefits at a Glance
  • One software-configurable measurement cube for all signal types.
  • Output of demand values.
  • Modular design: additional cubes can be added.
  • High accuracy and resistance to noisy signals by use of front end technology.
Technical Data

 

Acquisition rate

Selectable for each channel (1 Hz, 10 Hz, 100Hz) depending on the channel type

Universal Channel

16 universal measurement channels for the measurement of voltages, currents, resistances and measuring bridges

Temperature Channel

24 temperature measurement channels for measurement of thermo couples (types K, J, R, S, T, B, E and N) 8 temperature measurement channels for measurement of RTDs (Pt100, Pt1000)

Analog Channel

8 analog outputs for voltages or currents (for demand value setting)

Digital Channel

16 digital outputs (8 relay, 8 transistor outputs for digital or PWM) 16 digital inputs

Power Consumption

62Watt typical and 208 Watt maximal

Dimensions (with x height x length)

215 mm x 464 mm x 320 mm

Weight

8,2 kg

Supply voltage

24 V DC +-20% Reserve batterie protected

Degree of protection

IP 20

 

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Drive Shaft System
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Drive Shaft System

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Drive shafts not only provide the connection between the unit under test and the dynamometer on stationary up to high dynamic test beds, they also influence the vibrational behavior of the entire system.Drive shafts not only provide the connection between the unit under test and the dynamometer on stationary up to high dynamic test beds, they also influence the vibrational behavior of the entire system.
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Isolated Base Plates
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Isolated Base Plates

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The Isolated Base Plate allows for an easy set-up and mounting of the unit under test, the dynamometer, and additional test bed equipment and enables the vibrational decoupling of the mechanical installation from the building.By using an air suspension with automatic level control, base plate movements caused by unequal load distribution or torque alteration are compensated, so that the air suspension always provides a constant and load independent horizontal position of the isolated base plate at a low natural frequency of approximately 3Hz.Therefore, reproducible measurement results are guaranteed. The compact and rigid design allows for easy integration in the test cell floor due to its low height.Benefits at a Glance

High level control accuracy ± 0,1 mm (load independent), even in the case of critical measuring tasks.Simple setup of all testbed applications via standardizedT-slots.High vibration decoupling rate between base plate and building at low natural frequencies.Easy integration in test cell floor via compact design.
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Avl Fuel System Compact
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Avl Fuel System Compact

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The AVL FUEL SYSTEM COMPACT™ is designed to meet the demands of basic R&D, endurance, quality and end-of-line applications. 
AVL Approach
Fuel efficiency and CO2 reduction are key topics in the automobile world. To ensure minimum fuel consumption, engines are validated on testbeds.The AVL FUEL SYSTEM COMPACT™ with a measuring range from 0 to 125 kg/h and a conditioning unit with integrated heating, covers applications for small engines up to heavy-duty diesel truck engines with 600 kW. The AVL FUEL SYSTEM COMPACT™ can be used with a range of fuel injection systems.More than 10,000 AVL fuel measurement devices in the field stand for proven technology. In a complex testing environment, AVL FUEL SYSTEM COMPACT™ provides a simple, precise, and robust solution to measure fuel consumption.Benefits at a Glance
Unique AVL fuel measurement sensorFlexibility in term of engine type & size - one size fits all.Simple mounting for fast installation.Optimized hydraulic design for high measurement quality and repeatability.Measurement diagnosis functionsDesigned in AUSTRIA - built in INDIA

Measurement range

0 …125 kg/h

Systematic measurement uncertainty

≤ 0.10 %

Maximal measuring frequency

(analog output) 2 Hz

Fuel circulation capacity

240 L/h or 540 L/h @50 Hz w/ alternative Pump

Max. temperature control range

15°C ... 60°C

Temperature stability

≤ 0.5°C

Heating / Cooling power

1.6 kW / 2.2 kW

Step response time

T90 < 1 s

Rise time

T10…T90 < 1 s

Fuel type

Gasoline (EN228), Diesel (EN590)

Fuel supply pressure from facility

10…80 kPa

Fuel supply temperature

-10…+40°C

Outlet (return) pressure

≤ 50 kPa @240 L/h

Maximum engine feed pressure with external pressure regulator

600 kPa

Interfaces

RS232 (AK protocol), analog 0… 10 V, digital I/O

Ambient temperature

5 … 50°C

Power supply

230V 60 Hz

Power consumption

2.2 KW

Dimensions FUEL SYSTEM COMPACT

600 x 1580 x 415 mm (W x H x D)

Weight (dry)

140 kg

 


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Boost Air Conditioning
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Boost Air Conditioning

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The boost air conditioning unit AVL ConsysBoost conditions the boost air temperature at a predefined set value and keeps it within a tight tolerance range mainly for steady state and dynamic applications with constant demand values.AVL Approach

AVL offers two standard sizes of AVL ConsysBoost for precise boost air control using a industrial air/water heat exchanger. Alternative solutions, such as spray variants, are available for following a dynamic temperature profile.

Benefits at a Glance
  • The precise adherence to a pre-defined boost air temperature significantly improves the repeatability of measuring results on turbo-charged combustion engines and therefore increases the testbed efficiency
  • The ability to simulate different pressure losses for different vehicle intercoolers enables use on a wide range of engines
  • The compact and mobile unit can be moved to different testbeds, reducing investment costs by eliminating the need for another unit
  • Space-saving installation close to the engine by separating the conditioning part from the heat exchanger
  • Options
  • Technical Data
  • References
  • Control Principle

If the use of the engine's intercooler is required, AVL offers ConsysBoost Spray. The intercooler is mounted inside a box with spray nozzles. By controlling the water flow, which is supplied via the spray nozzles, a very good temperature control dynamic is achieved.

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AVL Data Acquisition with F-FEM
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AVL Data Acquisition with F-FEM

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Test beds in the automotive industry are relatively rough environments where I/O systems are subjected to heat, vibration, fumes and EM radiation. The AVL FEMs have been designed specifically for this environment.AVL F-FEM 19" *)F-FEM-AIN, F-FEM-AIS

16 channels for the measurement of voltages, currents, temperatures, resistances and measuring bridges.

F-FEM-AIS HV

16 channels for the measurement of voltages, currents, temperatures, resistances and measuring bridges on high voltage potential (+/- 1000V DC).

F-FEM-AIT

32 channels for the measurement of temperatures and low voltages.

F-FEM-AIF

16 channels for the measurement of voltages and currents.

F-FEM-AIF HV

16 channels for the measurement of high voltages (+/- 1000V DC).

F-FEM-DDC

8 channels for output of voltages and/or currents and 16 discrete input and output channels for digital control signals.

 

*)AVL F-FEM 19" are also available as snap-in units. With the F-FEM Snap-in product family the data acquisition is shifted to the pallet in a vibration and IP65-protected manner.

 F-FEM Snap-in:
  • Flexible equipment due to clever slot system for data acquisition and pressure measurement units.
  • Sensor cabling and pressure hosing already implemented in the setup area.
  • Quick pallet replacement: connection via one multiple connector only.
  • Vibration and IP65 protection.

 

 

AVL F-FEM for DIN rail mounting F-FEM-DIO

16 discrete input and output channels for digital control signals.

F-FEM-CNT

4 + 2 counter channels for event counting, frequency or engine speed measurement.

F-FEM-DAC

4 channels for output of voltages and/or current signals as well as 2 channels for output of frequency, PWM or simulation of engine speed pick-up signals.

 

Benefits at a Glance
  • Reduction of measurement cycles leading to shorter tests; high reproducibility of measurement results
  • Measurements on batteries, e-motors and inverters with up to +/- 1,000V)
  • No spare channels required: many different signal types are supported on one channel
  • Full synchronization of the measurement channels to each other and to the automation system with max. jitter < 0.1μs
  • Short parameterization times
  • Automatic calibration of measurement channels (option)
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Pressure Measurement Signals
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Pressure Measurement Signals

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This snap-in unit provides exact acquisition of 12 independent pressure signals in the field of automotive engine and powertrain testing.AVL Approach

The signals acquired by each pressure transducer are transferred in physical units to the AVL PUMA OpenTM automation system by means of a CANopen interface. The snap-in unit is designed for installation in the AVL Measurement Box.

The miniature CANopen pressure transducers are mounted in the 12-channel Pressure Measurement Snap-in. The snap-in unit can house transducers with relative or absolute pressure measurement ranges.

Typical applications are R&D and Emissions and Quality Assurance testbeds equipped with AVL´s Measurement Box.

Benefits at a Glance
  • Exact acquisition of dynamic pressure signals due to data acquisition rates of up to 200 Hz per channel
  • Real-time data synchronization with the AVL PUMA OpenTM testbed automation system
  • Automatic sensor detection (measuring range, serial number, type)
  • Zero offset adjustment directly in the pressure transducer controlled by AVL PUMA OpenTM
  • Vibration resistant for usage on engine pallets
  • Fast and convenient installation in the AVL Measurement Box with automatic connection to power supply and data bus for fast setup

 

Technical Data

Total error:

+/- 0.15% F.S. / 0°C...+60°C, typ.

Repeatability:

+/- 0.05% F.S., typ.

Operating temperature:

0°C to +60 °C

Media temperature:

-25°C to +100°C

Sampling rate:

5 Hz to 200 Hz in steps

Total sampling rate per CAN-Line:

5000 samples per second max. per CAN line

Data interface:

CANopen DS404 via AVL Measurement Box

Addressing:

Automatic position referred addressing by means of daisy chain during power-up

Number of transmitters:

50 Nodes max. per CAN line (6 CANopen pressure measurement boxes)

Temperature compensation:

Yes

Linearization:

Yes

Digital low pass filter:

Yes

Pressure connection:

Outside thread M14x1,5

Mounting mechanics:

Snap-in Unit (approx.19" / 1 HU) for the AVL Measurement Box

Degree of protection:

IP65

Power supply:

24 VDC via AVL Measurement Box

Vibration resistance:

IEC 60068-2-64

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AVL ICAL Emission Calibration Devices
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AVL ICAL Emission Calibration Devices

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The AVL iCAL product line includes gas dividers and NOX converter testers as well as CFO (Critical Flow Orifice) and LFE (Laminar Flow Element) devices.The accuracy of exhaust measurement systems is highly dependent on the quality and precision of the calibration devices used. In order to guarantee the highest quality, to minimize operating errors and to reduce operating times, the devices are available in a fully automated version.Benefits at a Glance
  • Pressure-independent flow stability
  • Plug and play integration
  • Simple use and operation
  • Extraordinary long-term stability
  • Factory-calibrated and individually certified, NIST traceable
  • The accuracy of exhaust measurement systems is highly dependent on the quality and precision of the calibration devices used. In order to guarantee highest quality, to minimize operating errors and to reduce operating times, the AVL iCAL devices are available in a fully automated version.
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AVL Emission Test Systems for Small Off-Road Engines
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AVL Emission Test Systems for Small Off-Road Engines

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Emissions testing for small engines, such as those in chainsaws, lawnmowers, etc. has become more and more important.AVL Approach

AVL's experience in providing and installing complete testbed systems, together with our powertrain engineering know-how, provides the ideal basis for a comprehensive product range for small off-road engine test applications - from analyzers and complete measurement systems up to test cells and automation systems.

Benefits at a Glance
  • Fully automated and highly efficient operation
  • Worldwide emission legislation fully integrated
  • Supports all R&D tasks and is prepared for future challenges
  • Highest accuracy, robustness and quality
System ScopeCertification & audit type of testing

The AVL SORE GEM-Certification test cell automation system performs - fully automatically - the required standard test cycles for each engine class. The system provides an easy-to-use user interface and integrates all the necessary devices such as the emission measurement equipment, fuel flow meter, weather station and the dyno controller.

The AVL SORE GEM-Certification offers the following features:

  • Prepares the analytical equipment before the start of a test as required by legislation
  • Records and stores all test relevant data as required
  • Test results and generates test reports
  • Graphical representation of the measurement values during and after a test
  • Loading of existing tests for post-test data evaluation
  • Configurable online calculation channels
  • Manual control of the analytical equipment through the automation system

The SORE GEM-Statistics application generates all the necessary quarterly, end-of-year and final reports as requested by EPA and CARB. The reports can be generated without the need to manually transfer the test results into the required format. This increases the quality of the reports as it eliminates typing errors.

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Combustion Development for Gasoline Passenger Cars
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Combustion Development for Gasoline Passenger Cars

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The combustion engine is still at the heart of efforts to meet the steadily increasing demands for low fuel consumption together with high power. The layout of combustion systems determines the thermodynamic efficiency as well as setting the base for achieving emission targets. The combustion system development incorporates the mixture formation as well as the combustion process. The typical tasks for combustion development are: • Thermodynamic analysis • Complete new design of ports and combustion chamber • Adaptation and optimization of fuel injection system • Evolutionary improvement of combustion system • TroubleshootingAVL Approach

In combustion development AVL follows a well-defined and proven project process to ensure the achievement of targets with very high maturity and within the shortest timeframe. The development process is driven through:

  • Design and Simulation
  • Hydraulic and flow laboratories
  • Optical measurement equipment
  • Advanced testbeds and instrumentation

Use AVL´s leading position in the development of leading gasoline combustion systems to your advantage.

Customer Benefits

AVL is a market leader and has many years of experience in combustion development for spark ignited (SI) gasoline engines.  AVL is one of the pioneers for gasoline GDI and TGDI combustion development, and can offer comprehensive experience with standard configurations as well as unconventional combustion systems (e.g. HCCI, CAI). Today we combine this key know-how with utilization of all the advanced methodology and development tools to find the overall optimum for the different kinds of future powertrain and applications:

  • Turbo charged as well as naturally aspirated
  • MPI and GDI
  • Standard gasoline and alcohol flex fuels
  • CNG, LPG and other gaseous fuels

AVL offers all the requested services for combustion development services, delivering the most overall efficient package for the development of new combustion systems for:

  • Compact engines & two-wheeler
  • Gasoline passenger cars
  • Race applications

Our locations around the world include professional project management in combination with high grade facilities.

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AVL Filter Weighing Chamber and Robot
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AVL Filter Weighing Chamber and Robot

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The AVL Filter Weighing Chamber (FWC) is a cost and space-saving alternative to a separately conditioned clean room and offers maximum user friendliness, ergonomics and functionality as well as cost effectiveness. The AVL Filter Weighing Robot (FWR) automates the weighing process from conditioning to filter disposal or archiving.AVL Approach

The AVL Filter Weighing Chamber (FWC) is a cost and space-saving alternative to a separate conditioned clean room and offers maximum user friendliness, ergonomics and functionality as well as cost-effectiveness.

The AVL Filter Weighing Robot (FWR) automates the weighing process from conditioning to filter disposal or archiving. It therefore reduces measurement inaccuracy and increases the efficiency of the entire weighing process. The capacity for particle filters ranges from 160 to max. 640 filters.

Benefits at a Glance
  • Compact and space saving solution for clean room standard 5 according to ISO 14644-1.
  • Precise control of constant climatic conditions regarding temperature, pressure and dew point in the weighing area to comply with e.g. EPA 40 CFR part 1065/1066, Euro 5/6 (LD) und Euro V/VI (HD).
  • Fully automated, movement path and time optimized weighing process via the robot.
  • Intelligent storing place management with 4 filter magazine towers and max. 640 filter storing places.
  • Sample filter identification via RFID Code with freely configurable information data.
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Oil Conditioning Unit
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Oil Conditioning Unit

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The oil conditioning unit conditions the engine or transmission oil temperature and supply pressure to a pre-definable set value and keeps it within a certain tolerance at steady state and dynamic operation of the unit under test (UUT).
AVL Approach
The main applications for AVL ConsysLube are engines up to 400 kW (customized solution for bigger engines available). Several connection modes and unit options allow different applications like oil pan conditioning, oil pressure control and pre-heating. For oil conditioning on gear boxes the AVL ConsysLube can also be used.Benefits at a Glance
High control accuracyEasy configuration, adjusted to the respective application due to modular designQuick control response due to a primary controlled media circuitVarious integration possibilities into the engine oil circuit (sump conditioning, pressurized oil conditioning, etc.)Technical DataControl PrincipleApplication  AVL CONSYSLUBEClassificationCL-25/50, CL S 50Max.  cooling capacity50 kWAdvanced1 cooling capacity120 kWTypical applicationPressure and temperature of engine and transmission oil on testbeds from pre-development up to racing applicationsStandard control rangeTemperature and accuracy70 to 140°C +/- 1°CStationary at entrance engineAdvanced1 control rangeTemperature and accuracy-30 to 155°C +/- 1°CStationary at entrance engineAdjustment time temperature< 3 minStandard control rangePressure and accuracy0.5 to 8 bar +/- 0.1 barAdvanced1 control rangePressure and accuracy0.5 to 12 bar +/- 0.1 barAdjustment time pressure< 2 minStandard flow rate range30 to 60 l/minAdvanced1 flow rate range10 to 120 l/minDimensionStarts with 610 x 350 x 550 mm(L x W x H)WeightStarts with 25 kg1Advanced = options or modifications
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Engine Production
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Engine Production

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AVL offers its services as an independent engineering partner delivering development and production expertise for our customers. Uniquely integrated and in partnership, this provides the highest quality, tailor-made manufacturing solutions for the most challenging demands.AVL‘s Plant and Production Engineering solutions encompass services that cover the entire product life cycle. In the design phase, aspects of manufacturability and costs are systematically incorporated. Optimizing and improving the productivity of manufacturing processes including the analysis of quality problems is another thrust of AVL‘s portfolio. AVL also plans and implements production lines and facilities from the customer‘s first ideas to the production launch.Our solutions include a supplier development program, which ensures that the customer receives the right product at the right time. The main objectives are reduced costs, improved quality and improved delivery performance.
  • Benefits at a Glance
  • Service Portofolio
  • References
  • Development and production hand in hand – creating synergies through simultaneous product and production development
  • Robust design and cost effectiveness – mass production aspects considered early in the design phase
  • Strong focus on quality: early Q-planning during product development and production planning
  • Continuous improvement during the whole product life cycle
  • Right-first-time design of products and faster-to-market through AVL‘s own production development process
  • High-level production expertise
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Powertrain Design for Compact Engines
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Powertrain Design for Compact Engines

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Modernization of products like motorcycles, recreational products such as watercrafts, ATVs, snowmobiles, small aircraft engines as well as handheld tools and power generators always has to start with professional design and analysis work.The products are focused on high performance, best reliability at minimum cost, fulfilling all requirements of customer expectations and legislative standards for emissions and fuel economy. The solutions of AVL are covering the complete system integration for power unit, transmission and electronic controls.
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Construction Equipment
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Construction Equipment

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Noise Vibration and Harshness (NVH) are very important topics in the development of new construction equipment. Legislative requirements for operator's ear level as well as the comparison to competitor equipment in terms of noise and vibration as well as sound quality set very challenging targets. NVH optimization of complete vehicles in conjunction with trade-off discussions between NVH, costs, emissions and durability is one of the most challenging tasks in the development process.AVL ApproachWith latest NVH development tools and methodologies, NVH facilities and engineering capabilities, the AVL Acoustic Engineering team is well prepared to support our customers in solving their development challenges. Using a combined approach of simulation and measurement, we develop individual solutions for, and together with, our customers. Important topics that AVL supports in the field of acoustic engineering for construction equipment are:
  • Operator's ear level optimization
  • Mounting system layout and refinement
  • Intake/ exhaust system layout and refinement
  • Vehicle NVH analysis
  • Driveline behavior
  • Customer Benefits
  • References
AVL has in-depth knowledge through our experts who have 40 years of know-how in continuously developing new methodologies and tools to solve this complex topic.
  • Leading edge technology and senior expertise
  • Unique tools, methodologies and processes
  • Development of complete drivelines and vehicles
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Pressure Sensors For Combustion Analysis
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Pressure Sensors For Combustion Analysis

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Pressure sensors for cylinder pressure, intake and exhaust pressure and fuel pressure measurement are important parts of the measurement chain for combustion analysis.The Challenge
Different applicationsWhich pressure sensor needs to be used for which measurement task?Which pressure sensor is typical for what kind of engine?Is there a need for water cooled cylinder pressure sensors?
Alignment of precise and robust tasksHow reliable does a sensor need to be?Which pressure sensors are suitable for highly accurate measurements?Which pressure sensors are suitable for robust monitoring and control tasks?
Usage in the measurement chainDo I need additional amplifiers for pressure sensors?How could a pressure sensor be implemented into the measurement chain?The AVL Solution
The AVL pressure sensor portfolio for combustion analysis consists of a large number of pressure sensors for various measurement tasks. The pressure sensors can be used for research, development and monitoring of internal combustion engines in the fields of cylinder pressure measurement, intake and exhaust port pressure measurement and fuel pressure measurement.
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Avl Fire M Post- Processing
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Avl Fire M Post- Processing

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The difference between real and virtual world vanishes when presenting results with the all new AVL FIRE™ M post-processor. IMPRESS™ M offers all features necessary to visualize, analyze and report simulation results. The user has the choice between interactive on-screen and template based offline operation.
  • What possibilities do I have to display result data?
  • How can I compare results obtained for different cases?
  • Do I need to create each diagram, each picture individually when post-processing large design studies?The AVL Solution

    Using IMPRESS™ M simulation results can be visualized in different types of diagrams, in planar and surface cuts or as droplet clouds. Streamlines and particle tracing is available too. Field quantities may be shown in iso-line or iso-value view or if applicable in vector plots. Transient results can be displayed as a series of “moving” images.

    For result analysis IMPRESS™ M offers user-defined scaling and different color bars. Results of multiple individual simulations and case studies can be arranged in the same viewer making it easy to compare them.

    Presentation of results is supported by IMPRESS™ M through providing advanced features such as shading and blending or user defined object lighting and color assignment. Plots and animations can be created in different formats. Result data can be exported also as 3D PDF. Automated report generation based on user-defined templates is available, significantly simplifying and accelerating the post-processing of large design studies.

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AVL CVS i60 Exhaust Gas Dilution System
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AVL CVS i60 Exhaust Gas Dilution System

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he AVL CVS i60 is a space-saving and cost-efficient full-flow dilution system designed for engine and vehicle certification as well as R&D testing. The intuitive, interactive graphical user interface supports all essential service and diagnosis functions and issue warnings in case of pending maintenance intervals
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Stand Alone Unit Monitor
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Stand Alone Unit Monitor

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AVL AMA i60 Remote/Stand Alone Unit

The AVL AMA i60 Remote/Stand Alone Unit is a high-end mobile emission bench for emission testing of selected components such as THC, NOX, N2O or CO2-EGR.

AVL Approach

The AVL AMA i60 Remote / Stand Alone Unit has been designed for the analysis of exhaust gases from various sample points. It can be used as a remote unit (controlled by the AVL AMA i60) or as a stand alone unit (controlled manually via iGEM AMA on separate external computers or by a host computer).The iGEM AMA bench control software provides a quick overview of the bench status, including all streams and analyzers. The control software allows diagnostic functions to be performed automatically and supports trouble shooting down to sensor and valve level.

  • Compact mobile unit, which is easy to move around and to use at different sampling points
  • Allows for short sample transfer lines resulting in fast response with high accuracy
  • Optimized packages for applications like heated THC/NOX measurements or EGR determination based on CO2 measurements, SHED THC or EPA greenhouse gas (GHG) measurements
  • Substantially reduced setup time and total cost of ownership thanks to the use of proven i60 technology, the well-known iGEM AMA user interface and diagnosis functions
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Avl Sesam I60 Ft Multi Component Exhaust Measurement System
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Avl Sesam I60 Ft Multi Component Exhaust Measurement System

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The AVL SESAM i60 FT is a FTIR multi-component measurement system that measures numerous pre-calibrated gas components in a time-synchronous and dynamic way.AVL Approach

The AVL SESAM i60 FT provides optimized analysis methods for different applications and fuels. Every single FTIR comes with an individual gas calibration certificate and verified accuracy. The modular system allows for integration of optional conventional analyzers as well as a second FTIR. 

The iGEM SESAM control software allows for easy, intuitive operation of the SESAM i60 FT i60 via a touchscreen. It provides a quick overview of the bench status, including all streams and analyzers. The control software allows diagnostic functions to be performed automatically and supports trouble shooting down to sensor and valve level.

  • Every single FTIR comes with individual gas calibration certificate and verified accuracy.
  • Optimized analysis methods for different applications and fuels, based on decades of AVL's FTIR application experience.
  • Fast response times with accurate and synchronous measurement of NO, NO2, N2O, NH3, CO, CO2, CH4 as well as alcohols, aldehydes and more within one device.
  • Low operating costs due to low maintenance system with no need for regular calibration.
  • Easy operation and flexible integration into the testbed automation system.
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All-in-One Indicating Systems
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All-in-One Indicating Systems

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AVL Approach
The All-in-One indicating systems combine intelligent signal conditioning and high-end data acquisition in one housing. Through the compact design and the high level of flexibility they are suitable for a broad range of mobile applicationsBenefits at a Glance
Ideal for basis calibration of the engine, engine monitoring and developmentFlexible use due to application packages for gasoline and diesel enginesCompact design for in-vehicle useDirect integration into the application system (e.g. INCA)Functionally expandable for the measuring tasks of tomorrowTechnical DataAll ProductsKey FeaturesDownloadsALL IN ONE INDICATING SYSTEMSProductFlexIFEM IndiIndiMicroIndiSmartAnalog input channels 1 or 24(3 units cascadeable to12 Ch)8(cascadeable to 32 Ch)Amplitude resolution 16 Bit 16 Bit14 BitSampling rate 1MHz per channel 1MHz per channel800kHzper channelInput range +-10V +-10V+-10VMultipurpose inputs Not available Not available2 to 4(depending on amplifier configuration)Piezo electric inputs 1 or 2 42 to 8(depending on amplifier configuration)Input range(piezo) Up to 14,400 pC Up to 14,400 pCUp to 14,400 pCDrift   compensationCyclic or continuous drift compensation modesCyclic or continuous drift compensation modesCyclic or continuous drift compensation modesCAN interfaceCAN High-Speed output(ISO 11898 compatible)maximum Baud Rate 1Mb/s at 25 m cable lengthCAN High-Speed output(ISO 11898 compatible)maximum Baud Rate 1Mb/s at 25 m cable lengthCAN High-Speed output(ISO 11898 compatible) maximum Baud Rate 1Mb/s at 25 m cable lengthApplication Software integration INCA OHI interface INCA OHI interfaceINCA OHI interfacePC communication GigaBit Ethernet GigaBit EthernetGigaBit EthernetInternal high speed memory no no64 MB(expandable to 256 MB)Digital input channels 2 digital TTL inputs 2 digital TTL inputs8 digital TTL inputsDigital output channels 4 digital TTL outputs 4 digital TTL outputs8 digital TTL outputs, alternatively can be used as relay outputsConnector for crank angle encoder 1 socket for direct connection of AVL 364/365 encoder or AVL pulse conditioner box 379 (used for Hall sensors) or AVL inductive signal conditioner 369 (used for inductive sensors)TTL based crank and trigger signal can also be connected via adapter cable to digital inputs1 socket for direct connection of AVL 364/365 encoder or AVL pulse conditioner box 379 (used for Hall sensors) or AVL inductive signal conditioner 369 (used for inductive sensors)TTL based crank and trigger signal can also be connected via adapter cable to digital inputs 1 socket for direct connection of AVL 364/365 encoder1 socket for connection via AVL pulse multiplier box1 BNC for trigger signal1 BNC for CDM signal1 parallel socket to feed in differential digital angle marks or a trigger signal (acc. to RS422 standard)1 pickup in for connection of inductive or Hall crank angle sensorsDimensions(w / h / d) 86 / 112 / 270 mm 9.5'' / 1 HU / 270 mm19'' / 2HU / 500 mmTemperature range -10°C to +50°C -35°C to 50°C -10°C to +50°C Power supply 9.5V to 36V DC20W 9.5V to 36V DC25W9.5V to 36V DC100W (fully equipped)
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Avl Santorin Compact
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Avl Santorin Compact

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In test fields with stand alone test beds the management of result data from various sources generate great challenges:

  • Having comparable result data from test beds of different suppliers
  • Ensuring a simple restore of result data in case of data loss on the test bed

AVL SANTORIN COMPACT™ is the central platform to manage result data in a heterogeneous test field with automation systems from AVL and other suppliers. AVL SANTORIN COMPACT™ stores result data from different test beds into one ASAM-ODS compliant data base. Unified channel names are achieved by an automatic channel name alignment. This standardized result data is used for data analysis with different data post processing software tools, e.g. AVL CONCERTO.

AVL SANTORIN COMPACT™ includes a central security and user management for access to the result data stored in the AVL SANTORIN COMPACT™ data base. An automatic data backup ensures that a data recovery is easily possible in case of hardware defect or data loss.

  • Benefits at a Glance
  • Technical Data
  • Applications
  • About Compact
  • Permanent availability of result data for all users in one format
  • Easy access and analysis of standard result data from AVL and 3rd party test beds without manual conversion
  • Reduced costs for backup and restore of result data
  • Central management of user rights and project security for access of the stored result data
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Optical Combustion Analysis Systems
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Optical Combustion Analysis Systems

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With the help of optical measuring methods, deep insights into the complex processes of fuel mixture and combustion beyond the findings of the pressure indicating method can be achievedAVL Approach

AVL Visiolution technology helps the whole process to be understood in detail and thus provides the right tool for improving performance with regard to fuel consumption, mixture formation, exhaust emissions and engine power.

Benefits at a Glance
  • Measurement in highly transient operation such as cold start / tip-in
  • Best suited for exploring injection strategies
  • Engineering mixture formation and find critical emission cycles
  • Evaluate flame propagation and detect knock limit
  • Detect root causes of irregular combustion / evaluate thermal risk
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Crank Angle And Pulse Conditioning
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Crank Angle And Pulse Conditioning

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Engine indicating requires not only accurate pressure signals, but also accurate crank angle information: Absolute piston position, exact injection or ignition timings are necessary for detailed combustion analysis.AVL Approach

Our pulse conditioning solutions are compatible with a broad range of standard sensors and deliver precise digital signals to our data acquisition units or All-in-One devices.

Benefits at a Glance
  • Broad range of solutions for most sensor types (hall, inductive…)
  • Fast signal conversion adapted to engine indicating requirements
  • Easy connectivity to our data acquisition units and All-in-One devices
  • Technical Data
  • All Products
  • Downloads

Crank Angle and Pulse Conditioning

Product Family

4CA1
Crank Angle Calculator

369
Inductive Signal Conditioner

379
Pulse Conditioner

389
universal Signal Conditioner

380
Ignition Time Module

Number of channels

2 (CDM+TRG)

1
(CDM or TRG)

2 to 6

3
(ind. or hall and 2 current clamps)

1

Application

CDM/TRG

CDM/TRG

CDM/TRG
Ignition timing
Injection timing

CDM/TRG
Ignition timing
Injection timing

Ignition timing

Dimensions WxHxD

9.5'' x 1HU x 230 mm

80 x 35 x
115 mm

80 x 35 x 115 mm

80 x 35 x
115 mm

80 x 35 x
115 mm

Signal input

Hall, inductive, TTL, ECU…

Inductive

Hall, active or passive current clamp

Hall, inductive and passive current clamp

Passive current clamp
(scope of supply)

Signal output

LVDS, TTL, RS422

LVDS, TTL

LVDS, TTL

LVDS, TTL

TTL

Additional function

Angle multiplication, engine speed output, CAN/RTP output (optional)
 

-

-

-

 

-

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Coolant Conditioning
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Coolant Conditioning

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The coolant conditioning unit AVL ConsysCool is used to bring the engine coolant to a freely definable temperature and to keep it within tight limits. A coolant pressure control is optionally available.AVL Approach

The total range of ConsysCool fulfills the requirements on nearly all engine tests. The AVL ConsysCool supports research engineers in end-of-line tests, single cylinder research engines and high dynamic applications for race car engines.

Benefits at a Glance
  • Stainless steel tubing avoids dissociation of rust particles and guarantees long time value
  • Excellent control accuracy and dynamics for various applications
  • Easy to use visualization software, integrated in PUMA Open automation. This Graphical User Interface (GUI) with an interactive flow diagram allows a user friendly handling and monitoring of all active control components.
  • Faster control response due to a primary controlled media circuit (coolant) compared to a secondary (cooling water) controlled device
  • Fast installation/setup time due to the 'plug & play' function. The configuration of the connected unit is automatically identified by the PUMA automation
  • Minimized commissioning time due to simple configuration and parameterization of controllers by using preset basic parameters
  • One unit for a wide application rangeThe coolant conditioning unit AVL ConsyCool can be used as an intermediate circuit conditioning unit for oil and boost air conditioning, as it is very frequently applied in conjunction with pallet systems. A special addition to the AVL ConsysCool allows for the simulation of dynamic temperature profiles on engine testbeds.
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Stands and Supports
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Stands and Supports

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Stands and Supports ensure a quick installation of the dynamometers and unit under tests on the isolated base plate.rowing demands for a quick installation and a simple setup of the dynamometer and the unit under test require frames and mounting systems with standardized mounting possibilities.

INTERMEDIATE FRAME

The AVL Intermediate Frame serves to mount the dynamometer on the base plate at the respective specified shaft height, as well as the mounting of the safety cover. Each frame is custom-built for the specified dynamometer and shaft height. It' s torsional stiff design enables an easy and quick alignment of the dynamometer.

 

PORTAL FRAME

The AVL Portal Frame enables the use of the original customer engine exhaust system on the testbed. Each frame is custom-built for the respective configuration of the dynamometer, its decoupling, base plate, required space for the customer specific exhaust system(s), and the desired shaft height.

Benefits at a Glance
  • Warp resistant vibration-optimized design.
  • Usage of vehicle's own exhaust system possible.
  • Easy alignment of dynamometer and unit under test.
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AVL Media Conditioning
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AVL Media Conditioning

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AVL Media Conditioning Systems are responsible for exact adherence of controllable parameters of the engine‘s combustion air, coolant and oil, thus allow a high reproducibility of the test runs.AVL Approach

The performance of combustion engines strongly depends on the media conditions. For a better reproducibility under almost real conditions there is a need of a high dynamic control of the media conditioning units. For 25 years, AVL has intensively developed different compact conditioning systems and technologies which are used in high-end engine test cells. If standard systems are not sufficient, customer-specific units are designed by AVL.

Benefits at a Glance
  • A modular design makes it usable in a wide range. For different applications, various modules are available
  • High control accuracy in steady state and dynamic mode ensures exact data from the test procedure and increases the testbed efficiency
  • Extreme temperature and pressure ranges for simulating conditions at the test bench which are hard to achieve on the road
  • Easy integration to the automation system enables a quick initialization (plug & play)
  • Good repeatability allows a fast achievement of the development goal
  • Minimized downtime with robust and reliable design
  • Short commissioning time
  • Flexible use due to a mobile design
  • Less maintenance work requiredHigher market and legislative requirements for combustion engines have increased the complexity of engine control and combustion systems. In order to reach the high quality standards (e.g. legislation for emission) and optimize development time, media conditioning systems are needed which are able to simulate constant ambient conditions as well as extreme environmental conditions.
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Pressure Measurement Box
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Pressure Measurement Box

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  • A digital measurement box for the acquisition of eight independent pressure signals for automotive engine and powertrain testing
  • AVL Approach

    The signals acquired by each pressure transducer are transferred in physical units to the AVL PUMA OpenTM automation system by means of a CANopen interface. The temperature compensation, linearization and digital filtering are integrated in the processor of the sensor.

    Each pressure transducer can be individually exchanged. Pressures of liquid and gaseous media can be acquired. By means of sampling rates of up to 200 Hz per transducer even dynamic pressure signals can be monitored and recorded. 
    The zero offset adjustment is done directly in the pressure transducers.

    Benefits at a Glance
    • Exact acquisition of dynamic pressure signals due to data acquisition rates of up to 200 Hz per channel
    • Real-time data synchronization with the AVL PUMA OpenTM testbed automation system
    • Automatic sensor detection (measuring range, serial number, type)
    • Zero offset adjustment directly in the pressure transducer controlled by AVL PUMA OpenTM
    Technical Data

    Total error:

     +/- 0.15% F.S. / 0°C...+80°C , typ.

    Repeatability:

     +/- 0.05% F.S. , typ.

    Operating temperature:

     0° … +85°C

    Media temperature:

     -25 … +100°C

    Sampling rate:

     5 Hz … 200 Hz in steps

    Total sampling rate per CAN-Line:

     5'000 samples per second max. per CAN line

    Data interface:

     CANopen DS404

    Addressing:

     Automatic position referred addressing by means of Daisy Chain during power-up

    Number of transmitters:

     50 Nodes max. per CAN Line (6 CANopen Pressure Measurement Boxes)

    Temperature compensation:

     Yes

    Linearization:

     Yes

    Digital low pass filter:

     Yes

    IP protection:

     IP 65

    Pressure connection:

     Outside thread M14x1,5

    Power supply:

     24 VDC via CAN-Bus connector

    Weight:

     Approx. 2,1 kg (with 8 transducers)

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AVL Test Cell Mechanics
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AVL Test Cell Mechanics

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Besides intelligent measuring technique and automation, the mechanical automation of testbeds can increase productivity by minimizing the setup and testbed downtimes and by enhancing the quality of the results due to an appropriate design.AVL Approach

The pursuit of increased productivity and efficiency also requires a rethinking of the configuration and the operating processes of the testbeds and will be guaranteed by process-oriented design and the high functionality of testbed equipment. The demand for short installation times and easy adjustment of the testbed equipment requires modular concepts with standardized mounting possibilities.

Unproductive duties like engine commissioning and decommissioning, rigging, unit under test alignment, system checks, calibration, service, maintenance and repair tasks have to be shifted out of the test cell to ensure optimal test cell utilization.

A prerequisite for smooth and efficient test processes is sophisticated test bed mechanics in combination with mobile pallet systems for the shortest possible unit under test changing times.

AVL's modular concepts allow for a high degree of scalability from simple durability testbeds to highly sophisticated and complex powertrain development testbeds.

  • High functionality due to process oriented design
  • Short installation times via standardized mounting possibilities
  • High flexibility by modular design
  • Wide range of standardized and customized solutions
  • Professional partner for complex and individual customer specific requirements
  • Low maintenance and high availability through sturdy design
  • Global service & support
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Calibration on the Virtual Vehicle Engine Test Bed
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Calibration on the Virtual Vehicle Engine Test Bed

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The Virtual Vehicle Engine Test Bed (VVETB) is designed to enable the engineer to observe the engine under its real cyclic behavior where at the same time the mechanical influence of the testbed is eliminated. Such setup allows improved development and calibration and the frontloading of traditionally on-road vehicle tests to the engine test bed. An integration of models to represent vehicle and driving environment completes the VVETB.AVL Approach

The AVL VVETB Test System comprises a base system for high dynamic testing. It can be extended with modules for exhaust emission measuring, automatic calibration tools and special instrumentation like AVL DRIVE™ on engine test bed.

Benefits at a Glance
  • Realistic cyclic rotational behavior of engine is not influenced.
  • Realistic engine start and stop.
  • Dual mass flywheel simulation model available.
  • Featuring up to 40Hz powertrain behaviour.
  • Wide range of engines with only one driveshaft.
  • Functional features

    • Powertrain simulation: up to 40 Hz at crankshaft of engine.
    • Realistic engine start and stop.
    • Dual mass flywheel simulation.
    • Misfire detection possible.

    Load System: Dyno Spirit

    Pemax 370 kW
    Mdmax 785Nm 
    nmax 10 000 rpm
    delta nmax 54 100 rpm/sec
    Inertia 0.208 kgm2

    With the portal frame of DynoSpirit the original exhaust system can be mounted in the space below the dynamometer (small adaptions may be necessary depending on the space available).

    Mechanical Setup

    Driveshaft: 60Hz layout for a wide range of engines:
    1.3l 4-cylinder up to .35l V6 and 4.2l V8

    The unique combination of the driveshaft layout with the VVETB control system allows relaxed alignment criteria and hence fast engine exchange times.

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AVL Canload Canister Conditioning System
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AVL Canload Canister Conditioning System

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The AVL CANLOAD pneumatic unit is designed for all standard applications based on butane/nitrogen or fuel vapor handling. It provides all required functions including individual valve matrix control, canister interface and mass-flow regulation.
AVL Approach
AVL CANLOAD systems constitute a state of the art test system by providing specific test solutions for a wide range and supporting standard certification up to individual R&D and durability testing.Benefits at a Glance
Uniform and flexible system design for synthetic gas and fuel vapor testingSubstantially reduced expenses for installation and total cost of ownershipImproved flexibility, quality and reproducibility accelerating R&D processesLook and feel user interface designed for simple operation and service-friendlinessMSR stand-alone architecture for independent and self-sufficient online test automationMarket RequirementsFunctionsApplicationsAvailable TypesCurrent trends and future demands concerning alternative fuels and various drive concepts require adequate and flexible test systems.
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AVL iGEM Offline - Emission Test Data Evaluation
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AVL iGEM Offline - Emission Test Data Evaluation

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AVL iGEM Offline test data evaluation is an innovative solution for the efficient data analysis of exhaust emission tests according to legislative requirements.AVL Approach

AVL iGEM Offline complies with all current worldwide emission legislations and is also prepared for future legislations/regulations, new measurement methods, alternative fuels and other potential developments. It provides intelligent (support) tools to create individualized calculations and reports.

Benefits at a Glance
  • Central formula database of all legislative calculation formula
  • Reduction of costs and time through simple system customization and expansion.
  • Save time and support through quick error and problem localization
  • Wide scope of usage through easy integration of third party automation systems
  • Online references to the texts of the corresponding regulation/legislationAVL iGEM Offline includes a range of effective tools and offers the possibility for authorized users to change or expand an existing record configuration. The formula editor helps change calculation variables and formula and add them into the database. The configuration can be adapted to comply with new legislation or modified technical conditions. Report templates can be created and modified easily via drag and drop operations in the report layout editor. Several different types of reports can be created besides the typical standard reports such as online and modal reports; specimen, equipment and consumable data record sheets; statistics COP and audit reports; testing series reports, and also combinations of different types of reports.
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AVL Combustion Measurement Equipment
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AVL Combustion Measurement Equipment

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Complete combustion analysis platform covering pressure and optical signal measurement and conditioning, data acquisition and online and offline data evaluation - all crank angle based and cycle per cycle!
AVL Approach

Based on detailed knowledge and experience in the methodology of combustion analysis, AVL has developed practical tools and devices to make the complex thermodynamic processes of an engine visible and understandable. In order to support all phases of development, AVL offers different solutions for different tasks in combustion development, application and calibration.

Benefits at a Glance
  • Full combustion measurement platform with consistent communication, unique in the world
  • Flexible solutions for multiple applications
  • Perfect integration and communication with testbed and application system
  • Data security through integration into the testbed data management system
  • High precision of measurement through inbuilt plausibility checks
  • Open, homogeneous solutions for user-specific adaptations
  • Fast but reliable combustion results as basis for engine development, calibration and optimization decisions

    These days, legislation acts as a major driving force on the automotive market and brings about current development needs and trends.

    Effective drive systems with the lowest emissions possible at moderate costs will be in high demand for all engines sizes. At the same time, the market is changing rapidly as a result of new manufacturers of engines/models appearing on the market and intensifying the competitive pressure on all OEMs.

    All these circumstances lead to a trend of radically shortened development cycles in general. The combustion analysis will increasingly become a central test focus again, because future engines will have to incorporate several combustion concepts in parallel. Therefore, all test engineers, calibration engineers and development engineers as well as test-field managers are facing increasing complexity.

    Engineers are facing new challenges again as they need stronger interaction and correlation between combustion analysis results in engine automation and control systems faster than ever before.

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Avl Particle Scale
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Avl Particle Scale

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The AVL Particle Scale is a universal solution for managing sample filters as used for particle measurement in emission tests. The intelligent particle filter management supports the user in the weighing process and offers easy handling of test and reference filters as well as reference weights throughout the whole life cycle.AVL Approach

With AVL Particle Scale, AVL presents a universal solution for the management of sample filters as used for particle measurement in emission tests. The intelligent particle filter management supports the user in the weighing process and offers easy handling of test and reference filters as well as reference weights throughout the whole life cycle.

Benefits at a Glance
  • Increased efficiency and quality assurance thanks to intelligent particle filter management
  • Central administration of all used test and reference filters as well as weights in the test facility
  • Climate data monitoring as well as calculation and storing of the exhaust test measurement results according to current legislation (e.g. Euro 5/6, EPA 40 CFR part 1065, World-Harmonized/UNECE)
  • Clearly structured and intuitive graphical user interface with extensive configuration and customization options
  • Secure identification of filter sets by RFID or barcode labeling
  • Easy integration into an external system based on a flexible .NET architecture
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Tractor NVH Analysis and Assessment
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Tractor NVH Analysis and Assessment

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Noise, vibration and harshness (NVH) are very important topics in the development of a new tractor vehicle. Legislative requirements for operator ear level, the comparison to competitor vehicles in terms of noise and vibration as well as sound quality set very challenging targets. NVH optimization of complete vehicles in conjunction with trade-off discussions between NVH, costs, emissions and durability is one of the most challenging tasks in the vehicle development process.With the latest NVH development tools and methodologies, NVH facilities and engineering capabilities, the AVL Acoustic Engineering team is well prepared to support our customers in solving their development challenges. Using a combined approach of simulation and measurement, we develop individual solutions for - and together with - our customers. Important topics that AVL supports in the field of acoustic engineering for tractors are:
  • Vehicle NVH analysis
  • Pass-by noise analysis and optimization
  • Operators ear level optimization
  • Driveline/transmission behavior analysis and optimization
  • Cabin mounting system layout and refinement
  • Intake/exhaust system layout and refinement
  • Besides the legislative requirements for exterior noise (pass-by noise) and operator ear noise, the market also requires a good noise environment for the operator. Typically, this is assessed with the standing tractor at low and high idle condition of the engine. To meet the challenging market requirements for cabin noise it is necessary to apply a careful and thorough NVH development process of the tractor starting with an NVH friendly concept and layout of the main tractor components.
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Single Cylinder Research Engines
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Single Cylinder Research Engines

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For development of engines, components, alternative fuels and lubes; with transparent access into the combustion chamber. Compact test bed solution and peripherals.AVL Approach

Working with our single cylinder research engines offers the significant advantage that the prospects of success are tested under realistic engine conditions long before new concepts are applied to the full engine.

Benefits at a Glance
  • Engine versions from small passenger car to heavy duty truck engine size
  • Modular design concept allows easy conversion into customer specific engine versions
  • Versatile GDI cylinder head with highest flexibility in tumble and injector installations
  • Optical top-works for application of modern laser supported measuring techniques
  • Truck size single cylinder engines for max. combustion peak firing pressures > 300 bar
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Avl Fire Aftertreatment Module
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Avl Fire Aftertreatment Module

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The AVL FIRE™ Aftertreatment Module is part of the AVL Aftertreatment Suite, which consists of AVL BOOST, AVL CRUISE and AVL FIRE®. It comprises the most advanced and most powerful set of capabilities for emission treatment simulation on the market. Due to its outstanding performance in respect to physical and chemical modeling the module became an indispensable element in the design, development and optimization of aftertreatment devices for internal combustion engines and industrial exhaust gas cleaning.

 

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Avl Fire Ese
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Avl Fire Ese

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The AVL FIRE™ Engine Simulation Environment (ESE) offers dedicated solutions for simulating IC engines and engine components.AVL Approach

Users of AVL FIRE™ engaged in IC engine research and development value particularly a set of tools collected in the FIRE™ Engine Simulation Environment (ESE), supporting them to perform their day-to-day business: the simulation of the flow in IC engines and engine components.

Benefits at a Glance
  • Tailored solutions for most common tasks.
  • Pre-defined workflows providing re-producible, user-independent results.
  • Easy to operate.
  • FIRE™ ESE Aftertreatment comprises newly developed features and functions enabling its user to quickly setup and perform the generation of models for exhaust lines including exhaust gas aftertreatment devices. Within an automated grid generation process the tool takes care about all mesh requirements during subsequent simulations. Setting up a simulation task is based on pre-defined control files. That way the knowledge required about numerical models is reduced to a minimum. The task is now so easy that almost everybody can perform it.
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Avl Fire Eulerian Multiphase Module
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Avl Fire Eulerian Multiphase Module

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The AVL FIRE™ Eulerian Multiphase Module is used to simulate flows potentially consisting of an arbitrary number of fluids and / or phases. Its major feature is the ability to calculate for each phase its volume fraction distribution in addition to all other flow variables.

 

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Impress
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Impress

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AVL Approach

AVL FIRE™ is a modern, complete CFD solution offering pre-processing, main program as well as 2D and 3D post-processing capabilities, supporting its users in simulation monitoring, visualization, analysis and presentation of results.

2D Result analysis

2D result analysis is performed in IMPRESS™ Chart, AVL's technical graphics and analysis tool that handles two-dimensional simulation result data quickly and easily in a way that allows plots and data configurations to be reused. The user can import data in a variety of formats, perform a range of mathematical and statistical analyses, and exchange data and graphics with applications integrated in the AVL Workspace. IMPRESS™ Chart features a comprehensive set of graphical styles, giving its users total control of each individual graphics element. The user can create plots of different types and layouts. Application specific reports can be easily created based on templates.

  • 3D Result analysis
  • Related Simulation Solutions
  • Related Simulation Tools

AVL's solution for 3D result post-processing, IMPRESS™ 3D, offers numerous functions enabling detailed result visualization and analysis. During the simulation it enables monitoring the convergence behavior and the result development by visualizing the residuals of the differential equations as well as selected results. Simulation results, both vector and scalar quantities can be displayed in two and three-dimensional "cuts" as iso-lines, iso-values, iso-surfaces and vector quantities can be additionally displayed as vector plots. Calculating streamlines, particle tracing as well as the visualization of droplet clouds is possible too. In order to analyze results IMPRESS™ 3D offers support on operations on three-dimensional result data, macros, formula capabilities, import of selected reference (testbed) data, user-defined scaling and color schemes. For result presentation the post-processor provides shading, blending and texturing options, manipulation of lighting and color assignments, inserting text elements, generation of plots in different formats and the generation of animations in mpeg and avi format.

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Avl Boost Charger Expertise
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Avl Boost Charger Expertise

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AVL Approach

The drivers for the use of charged engines include increasingly stringent economic and environmental constraints, the need for low fuel consumption, a fun driving experience and a continuing trend in terms of engine downsizing to achieve improved engine efficiency.

Advanced charging/turbocharging strategies in combination with aftertreatment measures are used to optimize pollutant formation. And to improve overall engine performance as well. AVL's extensive experience enables advanced charger component design, matching and testing as part of an overall engine system. Key features include the ability to:

  • Acheieve an optimal balance between performance, efficiency and durability
  • Minimize engine out and tail pipe out emissions
  • Reduce of development costs and time-to-market
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Avl Boost  Charger Concept Investigation
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Avl Boost Charger Concept Investigation

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AVL BOOST™ is the optimal tool for charger evaluation for given engine performance and fuel consumption targets.
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Turbocharging Simulation
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Turbocharging Simulation

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AVL BOOST™, AVL EXCITE™ and AVL FIRE™ enable advanced compressor and turbine component design and turbocharger matching as part of an overall engine system. This integrated approach accommodates the complex interaction between the system components in order to create the most effective, low emission engines possible.Multilevel Simulation Depth

The basic thermodynamic matching of the turbocharger is performed for steady-state operation and continued by the optimization of the transient response. The matching calculation is iterative, based on compressor and turbine maps, as well as the most important engine data. Engines equipped with the charging system can be integrated into the vehicle simulation tool AVL CRUISE™, in order to consider the overall system of the engine and vehicle within a driving cycle.

Pressure Wave Supercharger

In contrast to standard pressure charging devices, the pressure wave supercharger process is a direct gas-dynamic transfer of exhaust gas energy to the fresh charge in the channels of the rotor via traveling shock and expansion waves. The underlying physics allow highly predictive 1D modeling where the performance is a simulation result and no maps for mass-flow or efficiency characteristics are necessary.

  • Reducing CO2 Emissions
  • Rotor Dynamics and Bearing Analysis of Turbocharging Systems
  • Increasing Engine Performance while Reducing Emissions
  • Related Simulation Solutions
  • Related Simulation Tools
  • Downloads

AVL BOOST™ and AVL FIRE™ offer an advanced pressure charging simulation system. Users benefit from the ability to:

  • Select a turbocharger to match a given engine
  • Design new turbochargers with engine matching at every design stage
  • Readily change compressor and turbine sizes and predict the effect
  • Rapidly improve the turbocharging system, and determine the impact of wastegates, variable geometry, exhaust gas recirculation and component losses
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AVL DynoPrime
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AVL DynoPrime

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The DynoPrime Series is designed to replace a combustion engine on gearbox and powertrain test stands. The mass inertia of the dynamometer is close to the inertia range of combustion engines.AVL Approach

The DynoPrime system is a synchronous motor with high nominal torque (larger than ICE) plus additional overload torque capability for simulation of speed oscillations. The specially designed dyno housing allows the substitution of the combustion engine for direct gear box testing.

Benefits at a Glance
  • Inertia similar to a combustion engine
  • High flexibility in the parameterization of various characteristics of engines
  • Cost savings due to simpler setup of transmission and driveline testbeds
  • Combined power converter - DynoPrime in combination with DynoTrain or DynoWheel - are highly cost efficient.
  • Based on the high overdrive ability the machine is able to be designed on base load and not on peak loads in the ICE emulation.
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AVL FIRE M Pre-processing
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AVL FIRE M Pre-processing

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The pre-processor of AVL FIRE™ M offers two novel grid generation solutions: FAME™ Poly, a fully automated meshing environment for geometries of all complexity levels and FAME™ Block, an interactive meshing tool for specific applications.

Effortless pre-processing

  • What do I need to make a mesh?
  • Does it require much training to learn how to make it?
  • How flexible is FAME™ M?

Precise representation of real geometries

  • Will all details of the geometry be represented in the mesh?
  • How can I get mesh boundary layers?
  • Can I control the mesh resolution?

Multi-domain model generation

  • How simple is it to make a mesh for a multi-domain problem?FAME™ M offers CAD Data readers for all common native and standard exchange formats, a comprehensive set of functionalities to manipulate and repair defect geometry data and two meshing solutions, FAME™ Poly and FAME™ Block.

    FAME™ Poly requires very little input and works fully automatic. Even for novice users it takes just minutes to prepare and to submit a meshing job. Due to the nature of the technology multi-domain problems can be meshed without additional user effort. FAME™ Poly allows generating both tetrahedral meshes and polyhedral meshes.

    FAME™ Block generates fully hexahedral meshes. The user decides the mesh topology. Even though the tool is operated fully interactively it takes little time to learn using it.

    All available meshing solutions provide boundary fitted grids with mesh boundary layers of user defined thickness and in user defined number. Arbitrary cell size selection, local refinement and re-dimension functions provide control over global and local mesh resolution.

    Offering multiple mesh generation approaches users can select the best solution for each problem. FAME™ Poly and FAME™ Block meshes can be randomly combined without arbitrary interface generation.

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AVL FIRE  M Solver
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AVL FIRE M Solver

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Simulation driven development and frontloading, investigating a large number of designs in an early development stage.

Meeting needs

  • How does FIRE™ M help to shorten my development cycles?
  • Can FIRE™ M deliver results that are reliable and accurate?
The AVL Solution

The FIRE™ M Main program is handling non-reacting, single phase fluid flows, heat transfer and solid temperatures. All of it simultaneously, efficient and effective. The combined capabilities of pre-/post-processing and main program allow easy execution of case studies supporting the integration of simulation into product development processes. This is essential to reduce development cycles without compromising on quality. It offers investigating more designs in a shorter time to get products of higher performance and maturity.

FIRE™ M benefits from lessons learned during three decades of CFD Software development, at AVL engagement in thousands of engineering projects and continuous extensive investments in simulation model development.

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Avl India Private Limited 2A-2, AMG Towers (2nd Floor), No. 28, Lawyer, Jagannathan Street, Alandur,
Chennai-600016, Tamil Nadu, India

Arun Kumar V ( Sr.sales And Service Engineer )
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