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In Fall of 2001, a new emissions test cell was installed at Ford Motor Company that was specifically designed for precise low-level measurements (as described in Reference 6). The primary design focus for this cell was to ensure that optimal measurement capability was available to test vehicles that meet the stringent Partial Zero Emission Vehicle (PZEV) tailpipe requirements (NMOG = 10 mg/mile, NOx = 20 mg/mile). Over the past four years, there have been numerous improvements to the operational and Quality Assurance (QA) practices used in the PZEV Test Cell. Several investigations have also been performed to demonstrate the quality of its emissions measurements. Finally, a number of “lessons learned” have been documented from our experiences with PZEV measurements and with testing hybrid-electric vehicles. This paper summarizes these findings as a reference for others interested in low-level emissions measurements.

The on-going regulatory emphasis on reducing vehicle emission levels and increasing fuel economy has resulting in numerous efforts to improve the technology used to obtain these measurements. For example, raw exhaust flow meters are being implemented to provide improved tailpipe (i.e. modal) emission measurements as part of the vehicle development process. In addition, new sampling system technologies (e.g. partial flow dilution systems) are being implemented that use either synthetic air or catalyzed/dried ambient air to dilute exhaust samples. With these new technologies, however, often comes an increased sensitivity to leakage from both the test equipment and from the hoses/connectors used to route the vehicle's exhaust gas to the test equipment. In the case of the exhaust flow meter, a leak upstream of the measurement zone will provide an inaccurate flow reading. With an emissions sampling system, an exhaust leak will result in inaccurate emissions and fuel economy readings.

As automakers begin to develop and certify vehicles that meet the California Air Resources Board LEV II and Environmental Protection Agency Tier II Regulations, emissions test cells must be designed and implemented that are capable of accurate low-level measurements. A new test cell has been installed at Ford Motor Company for use in testing vehicles that meet the stringent Partial Zero Emission Vehicle tailpipe requirements (NMOG = 10 mg/mile, NOx = 20 mg/mile). This test cell includes a redesigned Bag Mini-Diluter (BMD), improved analytical benches, an ultrasonic exhaust flow meter with an integrated tailpipe pressure control system, a conventional constant volume sampler (CVS), and a moveable electric dynamometer. The Bag Mini-Diluter will be used as the primary sampling system for the tailpipe measurements. The moveable electric dynamometer enables the test cell to be configured so that the vehicle is moved to the test equipment rather than moving the test equipment to the vehicle.

As automakers begin to develop and certify vehicles that meet the California Air Resources Board LEV II and Environmental Protection Agency Tier II Regulations, the study/usage of the Bag Mini-Diluter (BMD, or Mini-Diluter) sampling system continues to increase. Previous papers have provided an overview of the BMD and compared the measurements from the BMD to the measurements from a traditional constant volume sampler (CVS). These papers have suggested that the BMD approach offers new opportunities to improve the quality of vehicle exhaust measurement at very low levels, which will be crucial for accurate measurements on vehicles meeting LEV II SULEV standards (NMOG = 10 mg/mile, NOx = 20 mg/mile). This paper continues the effort to study and implement the BMD sampling system as the optimal sampling system for SULEV measurements. Based on the results from previous testing, a number of investigations have been initiated to improve the quality and understanding of BMD measurements.