“Road vehicles — Endurance braking systems of motor ... … · Getriebe: ZF S6-90 n....

Pittius 2004-02-03

ISO 22/2/6/SWG 6 / Retarders / Test procedures for type approval / WD 12161

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Presentation to GRRF, 55th Session, Geneva Febr. 3rd, 2004

ISO CD 12161 Doc TC22/SC2 N 597

“Road vehicles— Endurance braking systems

of motor vehicles and towed vehicles— Test procedures”

byISO TC22/SC2/WG6

SWG 6 „Endurance braking systems“

Dr. Reinhold Pittius (VOITH TURBO)

Ramos

Informal document GRRF -55-23

Pittius 2004-02-03


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1. Structure of ISO Working Group

Subworking group SWG 6 „Endurance braking systems“Chairman Dr. Reinhold Pittius

• reporting to ISO 22/2/WG6 „Braking Systems“ Chairman Prof. v. Glasner

• Active members of SWG 6:

• Status- Working Draft agreed by TC22 Committee Draft (CD)- Distribution as ISO DIS in Dec. 2003- Balloting until May 2004

TELMAVOITH TURBOZF

DaimlerChryslerIVECOMAN

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Contents

1. Structure of ISO Working Group2. The Target3. Basic legal requirements4. Basic understanding of equivalent energy5. Specific properties of different types of retarders6. Test methods7. Conclusion

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2. The Target

Standardization

• of testing procedures• of vehicles

- equipped with endurance braking systems- to be type approved

• according to existing legal requirements

Detailed description of different test methods such thatresults are

• objectiv, • realistic and • compatible

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3. Basic legal requirements (1)

ECE-R 13, Annexe 4

para. 1.6 Type II

para 1.8 Type IIAservice brakesmust not be used !

6 %

6 km

30 km/h

7 %

6 km

30 km/h

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in thesame time

Equivalentenergy !

=same

averagepower

!

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4. Basic understanding (1)

in thesame time

Equivalentenergy !

=same

averagepower

!

Key philosophy of ISO CD 12161with regard to the standardization of

performance tests of endurance braking systems

t = L / vP = W / tW = m*g*∆H 1)

= m*g*L*tan α1) rolling resistance to be considered!

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- Downhill test (preference IVECO)

- Towing test (preference MAN)

- Test bench(preference DC)

Equivalent Energy in time ?

Yes Approval !

4. Basic understanding (2)

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Engine brake vs secondary (hydrodynamic) retarder

5 Specific properties of different types of retarders (1)

Getriebe: ZF S6-90 nMot-min/max 1200 / 2000 min-1Rdyn 0,502 m Masse 18000 kg

iHa 3,33 fr 1,0 %

Type IIa

1. Gang

2. Gang

3. Gang

4. Gang

5. Gang

6.Gang

Voith Retarder 133-2 (3750Nm)Average (engine = 1600 min-1)

600 kW300 kW 500 kW400 kW200 kW100 kW

0

500

1.000

1.500

2.000

2.500

3.000

3.500

4.000

4.500

5.000

0 10 20 30 40 50 60 70 80 90 100 v [km/h]1,0

3,0

5,0

7,0

9,0

11,0

13,0

15,0

17,0

19,0

Bremsmoment [Nm]

Comparison Exhaust Brake vs Secundary Retarder

Verzögerung [%]

Source: Voith Analysis

●

• Torque vs speed

• Power vs speed

• controllability

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Electromagnetic vs hydrodynamic retarder

Thermal performance

rotorstator

oil


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Service Brake Electromagnetic Retarder Hydrodynamic Retarder

capacitiveabsorption

time limited

radiationviasurface

continus braking capability

time limited


radiationviasurface

eliminationthroughcoolingsystem

continus braking capability

time limited

radiationvia surface


eliminationthroughcoolingsystem


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6.1 Test methods – Downhill test (1)

Specific criterias:

There is no real downhilltrack having exactly7% and 6km length

Perhaps the height differenceis available, but notexactly the length (resp. the slope)

Even if the height and thelenght are correct, theslope may vary along thetrack.

CD 12161Only small tolerances on

equivalant energy and time !

• tolerances on slope variation

• compensation on average slope

• compensation on heightdifference

but

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4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11.5 12Length [km]

350

400

450

500

550

600

650

700

750

800

850

Hei

ght

[m]

. . .. . .

. .. .. .. .. .. .. .. .. . .

. .. . .

. . . .. . . . . . .

. . . . .. . . . . . .

. . .. . .

. .. .. .. .. .. . .

. . .

Akima-Fkt.

. gemessen

Height Profile of Fed. Road B4 nearTorfhaus

Parkplatz Steinbruch bei km 4,0 (370 m über NN)

Parkplatz Torfhaus bei km 11,3 (810 m über NN)

LZA bei km 8,0 (620 m über NN)

Height profile of a realistic test track


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Downhill test - procedure

• „Qualifying“ of desired downhill track acc. to explained criterias

• Calculation of compensation parameters such as speed, mass etc.

• nearly no instrumentation necessary

• performance of the downhill test run

• measurement of the time needed

• if less then required time DONE

m = const.

variable l

Top

Bottom

variable tan

P = const.


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6.2 Test methods – Towing test (1)

Specific criterias:

The braking force may varydue to retardercharactaristic

The speed of thecombination may due to the variation or force

If the the towed vehicle has not fully laden the rollingresistance must beconsidered at theevaluation of the test.

Only small tolerances on equivalant energy and time !

• tolerances on force variation

• tolerance on speed variation

• compensation of GVW and rolling resistance

but

CD 12161

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Towing test - procedure

• „Qualifying“ of vehicles and test conditions

• Compensation of rolling resistance and determination of requ. force

• Instrumentation of vehicles necessary

• performance of the towing test 12 min and data recording

• postprocessing of test data calculation of braking energy

• if equal to equivalent energy DONE

6.2 Test methods – Towing test (2)

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6.3 Test methods –Dynamometer test bench (1)

Specific criterias:The braking force may vary

due to retardercharactaristic

The speed of the test benchmay due to the variationor force

If the the measured vehicle isnot fully laden the rollingresistance must beconsidered at theevaluation of the test.

A cooling device mustsimulate the air streamdue to the vehicle speed

Only small tolerances on equivalant energy and time !

• tolerances on force variation

• tolerance on speed variation

• compensation of GVW and rolling resistance

but

CD 12161

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Simulation test - procedure

• „Qualifying“ and instrumentation of the test bench

• Compensation of rolling resistance and determination of requ. force

• performance of the towing test 12 min and data recording

• postprocessing of test data calculation of braking energy

• if equal to equivalent energy DONE

6.3 Test methods –Dynamometer test bench (2)

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G etriebe: ZF S6-90 nMot-m in/m ax 1200 / 2000 m in-1Rdyn 0,502 m Masse 18000 kg

iHa 3,33 fr 1,0 %

Type IIa

1. G ang

2. G ang

3. Gang

4. Gang

5. G ang

6.Gang

Voith Retarder 133-2 (3750Nm )Average (engine = 1600 m in-1)

600 kW300 kW 500 kW400 kW200 kW100 kW

0

500

1.000

1.500

2.000

2.500

3.000

3.500

4.000

4.500

5.000

0 10 20 30 40 50 60 70 80 90 100 v [km /h]1,0

3,0

5,0

7,0

9,0

11,0

13,0

15,0

17,0

19,0

Brem sm om ent [Nm ]

Com parison Exhaust Brake vs Secundary Retarder

Verzögerung [% ]

Source: Voith Analysis

●

7 Specific test parameters for engine brakes (1)

Speed tolerance 30 ± 5 km/h

All primary retarders shallbe treated same as engineretarders

• because they operatevia the gearbox as well

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The deceleration test is NOT covered by the ISO CD 12161

• because this test is not „in line“ with the general idea of the equivalent energy

Deceleration test ≥ 0.6 m/s²

7 Specific test parameters for engine brakes (2)

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6 Conclusion (1)

• ISO CD 12161

• provides detailed definitions of three test proceduresaccording to the principle of equivalent energy

• the test procedures have been harmonized based on theprinciple of equivalent energy

• allows adequate and individual decisions on the test procedure. It does not need high-end test facilities

• considers primary retarders in the same „family“ as engine retarders because all are operating via thegearbox

• does not cover the deceleration test in ECE-R 13

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ISO/CD 12161

ISO TC 22/SC 2/WG

Secretariat: BNA

Road vehicles — Endurance braking systems of motor vehicles and towed vehicles — Test procedures

Véhicules routiers — Véhicules à moteur et véhicules tractés disposant de systèmes de freinaged'endurance — Procédures d'essai

Warning

This document is not an ISO International Standard. It is distributed for review and comment. It is subject to

change without notice and may not be referred to as an International Standard.

Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of

which they are aware and to provide supporting documentation.

Thank you for your attention

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