ISO/DIS 23828-1

Fuel cell road vehicles - Energy consumption measurement

Véhicules électriques routiers hybrides avec pile à combustible -- Mesurage de consomation d'énergie

Standards Content (sample)

DRAFT INTERNATIONAL STANDARD ISO/DIS 23828-1
ISO/TC 22/SC 21 Secretariat: DIN
Voting begins on: Voting terminates on:
2007-01-11 2007-06-11

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION • МЕЖДУНАРОДНАЯ ОРГАНИЗАЦИЯ ПО СТАНДАРТИЗАЦИИ • ORGANISATION INTERNATIONALE DE NORMALISATION

Fuel cell road vehicles - Energy consumption measurement —
Part 1:
Vehicles fuelled with compressed hydrogen

Véhicules électriques routiers hybrides avec pile à combustible — Mesurage de consomation d'énergie —

Partie 1: Avec hydrogène comprimé
ICS 43.120

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ISO Central Secretariat work of editing and text composition will be undertaken at publication

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© International Organization for Standardization, 2007
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ISO/DIS 23828-1
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ISO/DIS 23828-1
Contents Page

Foreword ............................................................................................................................................................iv

1 Scope......................................................................................................................................................1

2 Normative reference..............................................................................................................................1

3 Terms and definitions (after the terminology Discussion) ...............................................................2

4 Measurement accuracy.........................................................................................................................2

5 Hydrogen consumption measurement................................................................................................3

5.1 Pressure method ...................................................................................................................................3

5.2 Gravimetric method...............................................................................................................................3

5.3 Flow method ..........................................................................................................................................3

6 Test procedure.......................................................................................................................................3

6.1 General condition..................................................................................................................................3

6.2 Vehicle condition...................................................................................................................................3

6.3 Chassis dynamometer conditions.......................................................................................................4

6.4 Fuel consumption tests ........................................................................................................................5

6.5 Measurement over scheduled driving test .........................................................................................5

6.6 Correction of the test results for FCHEV ............................................................................................6

7 Presentation of results..........................................................................................................................6

Annex A (normative) Test procedure in Japan...............................................................................................7

Annex B (normative) Test procedure in Europe...........................................................................................12

Annex C (normative) Test procedure in the U.S.A.......................................................................................16

Annex D (normative) Pressure method.........................................................................................................22

Annex E (normative) Gravimetric method ....................................................................................................24

Annex F (normative) Flow method ................................................................................................................26

Annex G (informative) Current method.........................................................................................................27

Annex H (informative) Estimation of interior temperature of tank.............................................................29

Annex I (informative) Test results of hydrogen consumption of test vehicle...........................................32

Annex J (normative) Allowable energy change.............................................................................................34

Annex K (normative) Linear correction method using a correction coefficient (not applicable for

PFCEV)..................................................................................................................................................36

Annex L (informative) Procedure to obtain correction coefficient for FCHEV .........................................37

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ISO/DIS 23828-1
Foreword

ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies

(ISO member bodies). The work of preparing International Standards is normally carried out through ISO

technical committees. Each member body interested in a subject for which a technical committee has been

established has the right to be represented on that committee. International organizations, governmental and

non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the

International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.

International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.

The main task of technical committees is to prepare International Standards. Draft International Standards

adopted by the technical committees are circulated to the member bodies for voting. Publication as an

International Standard requires approval by at least 75 % of the member bodies casting a vote.

Attention is drawn to the possibility that some of the elements of this document may be the subject of patent

rights. ISO shall not be held responsible for identifying any or all such patent rights.

ISO 1 was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 21, Electrically

propelled road vehicles.
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ISO/DIS 23828-1
Introduction
Fuel Cell Vehicles (FCV) include the following types:

⎯ Pure Fuel Cell Vehicle (PFCV), in which the fuel cell system is the only on-board energy source for

propulsion and auxiliary systems

⎯ Fuel Cell Hybrid Electric Vehicle (FCHEV), in which the fuel cell system is integrated with an on-board

rechargeable energy storage system (RESS) for electric energy supply to propulsion and auxiliary

systems
FCHEV design options include:
1) Externally chargeable or non externally chargeable.
2) Rechargeable Energy Storage System (RESS): battery or capacitor

3) Driver-selected operating modes: If the FCHEV has no driver-selected operating mode, it has only

a FCHEV mode.
Table – FCHEV Classification
Chargeability Operating mode
FCHEV mode
Externally chargeable
EV mode
FCHEV
FCHEV mode
Non externally chargeable
EV mode

The present standard is applicable to the PFCV and to the FCHEV non externally chargeable with FCHEV

mode only (see in bold).
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COMMITTEE DRAFT ISO/CD 23828-1
Fuel cell road vehicles - Energy consumption measurement —
Part 1:
Vehicles fuelled with compressed hydrogen
1 Scope

This International Standard specifies the procedures for measuring the energy consumption of fuel cell

passenger cars and light duty trucks that use compressed hydrogen and are not externally chargeable,

operating in the regions as defined in annexes.
2 Normative reference

The following publications form a part of this International Standard to the extent specified herein. For dated

documents, only the edition cited applies. For undated references, the latest edition of the referenced

document (including any amendment) applies.
ISO 1176:1990, Road vehicle – Masses – Vocabulary and codes
ISO 3833:1977, Road vehicles – Types – Terms and definitions
ISO 8713: 2005, Electric road vehicles - Vocabulary

ISO 8714:2002, Electric road vehicles – Reference energy consumption and range – Test procedures for

passenger cars and light commercial vehicles
ISO 8715:2001, Electric road vehicles – Road operating characteristics

ISO 10521:1992, Motor vehicle road load – Determination under reference atmospheric conditions and

reproduction on chassis dynamometer

ECE-R 83, Uniform provisions concerning the approval of vehicles with regard to the emission of pollutants

according to engine fuel requirements

ECE-R 101, Uniform provisions concerning the approval of passenger cars with regard to the emission of

carbon dioxide and fuel consumption and/or the measurement of the electric energy consumption and electric

range, and of category M1 and N1 vehicles powered by an electric power train only with regard to the

measurement of electric energy consumption and electric range

United States Code of Federal Regulations, Title 40, Protection of the Environment, Part 86, Control of air

pollution from new and in-use motor vehicles and new and in-use motor vehicle engines: Certification and test

procedures, Appendix I

United States Code of Federal Regulations, Title 40, protection of the Environment, Part 600, Fuel Economy

of Motor Vehicles, Appendix I

TRIAS 5-3-1996, Fuel consumption test method of gasoline engine vehicle on 10 · 15 mode driving cycles

Safety Regulations for Road Vehicles (Ministry of Transportation Ordinance N. 67 of 1951) (for Japan test

procedure) USA procedure
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ISO/DIS 23828-1

SAE J 2572-Aug2006, Recommended practice for Measuring the fuel Consumption and Range of Fuel Cell

and Hybrid Fuel Cell Vehicles fuelled with compressed Gaseous Hydrogen
3 Terms and definitions (after the terminology Discussion)

For the purpose of this document, the terms and definitions given in ISO 3833:1977 and ISO 1176:1990 the

following apply.
3.1
battery state of charge (SOC) (apply to FCHEV)

residual capacity of battery available to be discharged normally expressed as a percentage of full charge

3.2
charge balance of battery (apply to FCHEV)
change of charge in battery during test period normally expressed in Ah
3.3
EV operation mode (apply to FCHEV)

mode of an FCHEV in which only the RESS is used for the vehicle propulsion and possibly auxiliary systems

3.4
FCHEV operation mode (apply to FCHEV)

mode of an FCHEV in which both RESS and FC system are used sequentially or simultaneously for vehicle

propulsion
Note: The FC system may also charge the RESS during propulsion or standstill.
3.5
Fuel cell vehicle (FCV)
vehicle that receives propulsion power from an on-board fuel cell power system
3.6
Fuel cell hybrid electric vehicle (FCHEV)
fuel cell vehicle with RESS
3.7
Pure fuel cell vehicle (pure FCV)
fuel cell vehicle without RESS
3.8
rechargeable energy storage system (RESS) (apply to FCHEV)

system that stores energy, for example, batteries or capacitors, and is rechargeable by on-board and/or

external energy sources, and associated controls, if any
3.9
test mass
mass of a vehicle prepared for a defined test procedure
4 Measurement accuracy

Test apparatus shall assure the accuracy of measurement of ± 1 % for the total mass of hydrogen

consumption during the test cycle, unless otherwise specified in the relevant annexes.

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ISO/DIS 23828-1
5 Hydrogen consumption measurement

According to the present status of the studies various methods for the measurement of hydrogen consumption

have been developed. Those listed below have shown to give sufficiently equivalent results. They are reported

in detail in Annex D, E, and F (normative). One of the methods shall be used. Other methods may also

become applicable if they show comparable equivalence and reliability.
5.1 Pressure method

Hydrogen consumption is calculated by measuring the pressure and temperature of gas in the high-pressure

hydrogen tank before and after the test. The hydrogen consumption can be determined by calculating the

change in the number of moles of gas in the storage by applying the measured values of pressure and

temperature to the state equation. A tank with known internal volume that allows measurement of gas

pressure and temperature shall be used for the test.
5.2 Gravimetric method

Hydrogen consumption is calculated by measuring the weight of the high-pressure hydrogen tank before and

after the test. The tank used for the test shall be suitable for measuring weight.

5.3 Flow method

The amount of hydrogen supplied to and consumed by a vehicle is measured by a flow meter.

6 Test procedure
6.1 General condition

The test shall be conducted after preparation of the vehicle and test apparatus as follows.

6.2 Vehicle condition
6.2.1 General

The vehicle shall be clean, and the windows and air entries, not needed for the correct operation of the vehicle

and the drive system, shall be closed by the normal operating controls.

The lighting, signalling and auxiliary devices shall be off, except those required for testing and usual day-time

operation of the vehicle.
6.2.2 Vehicle stabilization

Prior to testing, the test vehicle shall be stabilized, which includes vehicle mileage accumulation according to

a manufacturer-determined distance unless otherwise specified in the relevant annexes A, B or C.

6.2.3 Vehicle appendages

Vehicles shall be tested with normal appendages (mirrors, bumpers, etc.). Certain items (e.g., hub caps) may

be removed where necessary for safety on the dynamometer.
6.2.4 Vehicle test mass
The vehicle test mass shall be selected according to Annex A, B, or C.
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ISO/DIS 23828-1
6.2.5 Tires
Vehicle manufacturer's recommended tires shall be used.
6.2.5.1 Tire pressure

The vehicle tires shall be inflated, when the tires are at ambient temperature, to the pressure specified by the

vehicle manufacturer for the chosen test (track or chassis dynamometer)..
6.2.5.2 Tire conditioning

Tires shall be conditioned as recommended by the vehicle manufacturer. See Annex A, B, or C for additional

requirements.
6.2.6 Lubricants
The vehicle lubricants specified by the manufacturer shall be used.
6.2.7 Gear shifting

If the vehicle is fitted with a manually shifted gear box, gear shifting positions corresponds to the test

procedure mentioned in Annex A, B and C. However, the shift positions may be selected and determined

previously in accordance with the vehicle characteristics.
6.2.8 Regenerative braking

If the vehicle has regenerative braking, the regenerative braking system shall be enabled for all dynamometer

testing. If a vehicle is equipped with an Antilock Braking System or a Traction Control System and is tested on

a single-roll dynamometer, these systems may inadvertently interpret the non-movement of the set of wheels

that are off the dynamometer as a malfunctioning system. If so, modifications to these systems shall be made

to achieve normal operation of the remaining vehicle systems, including the regenerative braking system.

6.2.9 RESS stabilization

The RESS shall have been stabilized with the vehicle as defined in 6.2.1 or by equivalent conditioning.

6.3 Chassis dynamometer conditions
6.3.1 General

The vehicle generally should be tested on single-roll chassis dynamometer. The vehicle with four-wheel-drive

shall be tested by modifying the drive train of the vehicle. When the vehicle is modified, the details shall be

explained in the test report.

A double roll dynamometer test may be performed when a modification for single roll dynamometer test is not

possible for the specific 4-wheel driven vehicle.
6.3.2 Dynamometer calibration

The dynamometer shall be calibrated according to the specifications indicated in the service manual provided

by the dynamometer manufacturers.
6.3.3 Dynamometer warm-up
The dynamometer shall be warmed up sufficiently prior to the testing.
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ISO/DIS 23828-1
6.3.4 Determining the dynamometer load coefficient

The determination of vehicle road load and the reproduction on a chassis dynamometer shall conform to

ISO 10521. Vehicles equipped with regenerative braking systems that are activated at least in part when the

brake pedal is not depressed shall have regenerative braking disabled during the deceleration portion of

coast-down testing on both the test track and dynamometer.
6.4 Fuel consumption tests
6.4.1 General

A region-dependent procedure shall be selected from Annex A, B, or C, for Japan, Europe or the U.S.A.

respectively. Details and common procedures for each test mode are described below.

6.4.2 Vehicle preconditioning

Vehicle preconditioning shall be carried out according to the Annex appropriate for the region. In the case of

FCHEV, the RESS SOC may be pre-adjusted by charging or discharging, to obtain a suitable energy

difference in RESS between the beginning and the end of test.
6.4.3 Vehicle soak

The vehicle shall be soaked according to the regional procedure in Annex A, B, or C.

6.5 Measurement over scheduled driving test

For the measurement of hydrogen consumption, the test vehicle shall be driven on the chassis dynamometer

according to the running mode prescribed for the region (see Annex A, B, or C as appropriate). The hydrogen

consumption can be measured by one of the methods described in Annex D, E, or F, or by an alternative

method that provides equivalent accuracy.
The hydrogen consumption is determined using one of the following equations.
22.414
w x x 10
b x 10
t0 m
FC1= =
L L
b x x 10
w x10
22.414
FC2= =
L L
22.414
wx x 10 x Q
b x10 x Q
t0 H m
FC3= =
L L
wherein,
FC1 Hydrogen consumption per unit distance (Nm /km) referred to volume
FC 2 Hydrogen consumption per unit distance (kg/km) referred to weight
FC3 Hydrogen consumption per unit distance (MJ/km) referred to caloric value
L distance (km)
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ISO/DIS 23828-1
b Hydrogen consumption (l at 273 K, 101.3 kPa)
w Hydrogen consumption amount (g)
m Molecular weight of hydrogen (2.016)
Q Lower calorific value of hydrogen (10.8 MJ/Nm )
6.6 Correction of the test results for FCHEV
6.6.1 General

After the FCHEV has been tested, the hydrogen consumption shall be corrected if the energy difference in the

RESS between the end and the start of the test is above the limit described in 6.6.2.

6.6.2 Allowable limit for RESS energy change for FCHEV
The allowable limit for RESS energy change is
where
ΔE is the energy change in RESS over the test cycle;
RESS
ECF is the energy of consumed fuel over the test cycle.

Energy change in the RESS and maximum allowable energy change in the RESS are described in Annex J.

Correction procedure by correction coefficient for FCHEV

The vehicle manufacturer shall provide the correction coefficient for calculation of hydrogen consumption at

ΔE = 0. The correction coefficient can be obtained according to Annex K.
RESS
7 Presentation of results

Test results should be recorded according to the Annex I. The fourth significant digit should be rounded off to

provide the hydrogen consumption rate to three significant digits.
Other data should be recorded as required by the regional regulations.
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ISO/DIS 23828-1
Annex A
(normative)
Test procedure in Japan
A.1 Scope

This Annex describes the typical procedures and related conditions in Japan to measure fuel consumption of

the passenger cars and light duty trucks defined in Japan regulation. .
A.2 Accuracy for determining vehicle road load and others
Accuracy of determining road load shall conform to the ISO 10521.
A.3 Driving procedure

The gear manipulation in each operational condition specified in Tables A.1 and A.2 shall be performed

smoothly and quickly according to the following instructions.
A.3.1 Vehicles with manual transmission

A.3.1.1 The idling operation refers to a condition in which the accelerator pedal is not depressed, with the

transmission gear in neutral.

A.3.1.2 The transmission gear shall be shifted to the low gear position (or such a gear in instances where

the “low” gear position should read otherwise in Table A.1 and A.2) five second before the idling operation

mode is switched to the acceleration mode.

A.3.1.3 For deceleration, the clutch shall be disengaged at a speed of 10 km/h during the 20-0 km/h

deceleration operation and at a speed of 20 km/h during the 40-0 deceleration operation as specified in Table

A.1 and A.2. In the same way, the clutch shall be disengaged at a speed of 30 km/h during the 70-0

deceleration operation as specified in Table A.2.

A.3.1.4 On vehicles with a 6-speed transmission in which driving by operating the shift lever in respective

gear positions as specified in Table A.2 can not be performed because of the running performance of the

vehicle, driving may be carried out according to the example of the 5-speed transmission specified in Table

A.2.

A.3.1.5 If the revolutions of the motor of the test vehicle exceed the revolution speed at which the motor

delivers its maximum output during the operation of the test vehicle, the gear position that is one step higher

than the original gear may be used. In this case, the vehicle speed at which the gearshift takes place shall be

the vehicle speed corresponding to the revolution speed at which the motor delivers its maximum output.

A.3.2 Vehicle with automatic transmission

The selector position shall remain in drive position. No further manipulation shall be made.

A.3.3 Vehicles with other transmissions

Gear changes shall be made considering the running characteristics of the tested vehicle with transmissions

other than those described in A.3.1 and A.3.2.
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ISO/DIS 23828-1
A.4 Vehicle test mass

The test vehicle shall have a mass obtained when two persons (assuming that the mass of one person is 55

kg) or mass of 110 kg are loaded on the test vehicle under the “unloaded state” prescribed in Item (3) of

Paragraph 1 of Article 1 of the Safety Regulations for Road Vehicles (Ministry of Transportation Ordinance No.

67 of 1951).
A.5 Tire conditioning

Tires shall be conditioned as recommended by the vehicle manufacturer and shall have accumulated a

minimum of 100 km (62 miles) and have at least 50% of the original usable tread depth remaining.

A.6 Dynamometer inertia setting

The equivalent inertia mass set for the chassis dynamometer shall be the standard value of equivalent inertia

mass specified in the right column of Table A.3, corresponding to the vehicle test mass specified in the left

column of Table A.3.

However, if the specified equivalent inertia mass is not available on the chassis dynamometer being used, the

equivalent inertia mass within plus (+) 10 % of the specified standard value may be used.

Table A.1 — Operation conditions, vehicle speed, acceleration/deceleration of 10 mode

Vehicle Duration of Standard gear positions Acceleration
Cumulative
Mode Operation
speed operation or
3-speed (3+OD)-speed 4-speed 5-speed
time
no. conditions
time deceleration
transmission transmission transmission transmission
km/h s (m/s )
1 Idling 20 20 - - - - -
(0-15) Low (0-15) Low
2 Acceleration 0-20 7 27 (0-20) Low (0-20) Low 0,78
(15-20) 2nd (15-20) 2nd
3 Constant speed 20 15 42 2nd 2nd 2nd 2nd -
4 Deceleration 20-0 7 49 2nd 2nd 2nd 2nd 0,78
5 Idling 16 65 - - - - -
(0-20) Low (0-20) Low (0-15) Low (0-15) Low
6 Acceleration 0-40 14 79 (20-40) 2nd (20-40) 2nd (15-30) 2nd (15-30) 2nd 0,78
(30-40) 3rd (30-40) 3rd
7 Constant speed 40 15 94 Top 3rd Top 4th -
8 Deceleration 40-20 10 104 Top 3rd Top 4th 0,59
9 Constant speed 20 2 106 Top-2nd 3rd-2nd Top-3rd 4th-3rd -
10 Acceleration 20-40 12 118 2nd 2nd 3rd 3rd 0,49
40-20 10 128 Top 3rd Top 4th 0,59
11 Deceleration
20-0 7 135 Top 3rd Top 4th 0,78

NOTE Figures put into brackets in the column “Standard gear positions” represent vehicle speeds for respective gear positions.

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ISO/DIS 23828-1
20 42 49 65 79 94 104 106 118 128 135
Time (s)
Figure A.1 — 10 Mode, vehicle speed versus time

Table A.2 — Operation conditions, vehicle speed, acceleration/deceleration of 15 mode

Duration Cumula- Standard gear positions
Vehicle Acceleration
tive
Mode Operation
(3+OD)-
speed or
opera-
time
3-speed 4-speed 5-speed 6-speed
no. conditions
speed
deceleration
tion time
transmission transmission transmission transmission
transmission
km/h s (m/s )
1 Idling 65 65 - - - - -
(0-20) Low (0-20) Low (0-15) Low (0-15) Low (0-15) Low 0,78

2 Acceleration 0-50 18 83 (20-40) 2 (20-40) 2nd (15-35) 2nd (15-35) 2nd (15-35) 2nd

(40-50) Top (40-50) 3rd (35-50) 3rd (35-50) 3rd (35-50) 3rd
3 Constant speed 50 12 95 Top 3rd Top 4th 4th -
4 Deceleration 50-40 4 99 Top 3rd Top 4th 4th 0,69
5 Constant speed 40 4 103 Top 3rd 3 3rd 3rd -
(40-50)3rd
6 Acceleration 40-60 16 119 Top 3rd 3 3rd 0,39
(50-60)4th
7 Constant speed 60 10 129 Top 3rd Top 4th 5th -
8 Acceleration 60-70 11 140 Top 3rd Top 4th 5th 0,29
9 Constant speed 70 10 150 Top OD Top Top Top -
10 Deceleration 70-50 10 160 Top OD Top Top Top 0,59
11 Constant speed 50 4 164 Top 3rd Top 4th 5th -
12 Acceleration 50-70 22 186 Top 3rd Top 4th 5th 0,29
13 Constant speed 70 5 191 Top OD Top Top Top -
70-30 20 211 Top OD Top Top Top 0,59
14 Deceleration
30-0 10 221 - - - - - 0,88
15 Idling 10 231 - - - - - -

NOTE Figures put into brackets in the column “Standard gear positions” represent vehicle speeds for respective gear positions.

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Velocity (km/h)
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