This is the presentation accompanying an SAE paper I wrote in 2012: http://papers.sae.org/2012-01-1946.

1. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
Representative Testing of
Emissions and Fuel Consumption
of Working Machines
in Reality and Simulation
Reno Filla
Volvo Construction Equipment
2012-01-1946

2. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946

3. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946

4. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
Many different machines...

5. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
...many different applications

6. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
Which application to choose?
How to test?

7. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
How will the results be used?
Acceptable level of simplification?
“Get your facts first and then you can
distort them as much as you wish.”
Mark Twain
Imagesource:http://www.twainquotes.com/Lookalikes/AppletonsJournal4July74.jpg

8. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
How will the results be used?
• Legislative / certification
• Benchmark, external use
• Benchmark, internal use
• Design optimization
Higher demands
for practicality and
cost efficiency
Higher demands
for resolution and
representativeness

9. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
Acceptable level of simplification?
• Example: Wheel loader
Short loading cycle (real use)
vs.
NRTC (emission test cycle)

10. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
WL, bucket loading in short cycle vs. NRTC

11. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
NRTC
Nonroad Transient Test Cycle
• Compromise for testing compliance of engine emission legislation
– A huge number of greatly different machines
in greatly different applications
– Practicality issues
– Cost efficiency requirements
– “One cycle to rule them all”
• Punishes innovative, non-conventional machines (like hybrids)
(prescribes engine duty rather than machine work)
• Not to be used for testing of fuel consumption & CO2 emissions
(unlike the NEDC)
Imagesource:
http://upload.wikimedia.org/wikipedia/commons/thumb/b/b7/Unico_Anello.png/200px-Unico_Anello.png

12. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
NEDC
New European Driving Cycle
• Compromise originally for
testing compliance of emissions
of light duty vehicles (cars)
– Practicality issues
– Cost efficiency requirements
– “One cycle to rule them all”
• Misused for
– Benchmarking, external use
– Benchmarking, internal use
– Design optimizationImage source:
http://en.wikipedia.org/wiki/File:New_European_Driving_Cycle.svg

13. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
How will the results be used?
• Legislative / certification
• Benchmark, external use
• Benchmark, internal use
• Design optimization
Higher demands
for practicality and
cost efficiency
Higher demands
for resolution and
representativeness

14. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
• Extremely simplified “Dig & Dump” cycle (“Trench Excavation”)
– No digging
– Lifting an empty bucket
– All hydraulic functions at maximum speed
• The logic behind
– Operator and environment a challenge for repeatability
Conclusion: let’s neglect them
– Makes it also easier to simulate (no need for mathematical models)
Possibly good correlation between virtual and real testing
• The problem:
“Dig & Dump” cycles are about… digging and lifting in order to dump
JCMAS H020
Excavator Test Cycle

15. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
JCMAS H020
Excavator Test Cycle

16. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
• Ideal counter-balanced linkage
– Requires only energy for lifting a load
(no friction)
– Zero fuel consumption
for lifting an empty bucket
– H020 will lead to many
disappointed customers
of innovative, non-conventional
machines (like hybrids)
JCMAS H020
Excavator Test Cycle
Imagesourcebeforemodification:http://etc.usf.edu/clipart/13100/13143/pulley_13143.htm

17. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
How will the results be used?
• Legislative / certification
• Benchmark, external use
• Benchmark, internal use
• Design optimization
Higher demands
for practicality and
cost efficiency
Higher demands
for resolution and
representativeness

18. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
How to test for Design Optimization?
1. Find working cycles representative for the majority of applications
2. Standardize to minimize variations

19. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
How to test for Design Optimization?
3. Utilize recorded statistics from entire machine population
to find characteristic parameters
- Distribution of machine speed
- Mean fuel consumption
4. Measure characteristic parameters in standardized cycles
5. Determine weighing factors to approximate distribution of the
characteristic parameters of the entire machine population in the
field
6. Done! You now have a representative mix of standardized test
cycles with weighing factors.

20. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
Summary

21. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
Always consider:

22. Reno Filla (2012) “Representative Testing of Emissions and Fuel Consumption of Working Machines in Reality and Simulation”.
SAE paper 2012-01-1946. http://papers.sae.org/2012-01-1946
Thank you!
• Reno Filla, Ph.D.
Specialist Operability & Adaptive Automation
Emerging Technologies, Advanced Engineering
Volvo Construction Equipment AB
TCA 11
SE - 631 85 Eskilstuna
Sweden
reno.filla@volvo.com