Homologation process of a EuroVIe heavy-duty diesel engine

This thesis work, carried out in cooperation with FPT Industrial, focuses on the description of the homologation process of a new diesel engine for heavy-duty on-road applications, in compliance with the EURO VI step E emission regulation. After an overview of the main pollutants that affect human health and the environment, the emission legislative framework of the most important world market regions will be presented, with a focus on EMEA and NAFTA. It follows a detailed description of the EU pollutant emission standards for heavy-duty vehicles, together with the next emissions targets in terms of CO2. The respect of the current norms has been granted by an high technological content provided on the engine project and the calibration effort, without neglecting the innovative strategies and layout developed for the after-treatment system. These refined product characteristics are the result of the product development process adopted by FPT Industrial, which has as its main objective the full satisfaction of the customer’s requests and the leverage on improvement and innovation. The homologation process for HD engines requires the execution of specific dyno tests (WHSC, WHTC, and WNTE) as well as road tests performed in real driving conditions on a reference vehicle. The latter are performed using the PEMS equipment, and they are required both for type approval and in-Service conformity (ISC). Conformity of Production tests (CoP) are performed after the engine launch on the market, and they are used to monitor its emission performances. Going further to the homologation requirements, when a new product enters the market, there is a need to find a procedure that ensures customer satisfaction, stability of production, and performance in the immediate post-launch phase. For this purpose, The Early Warning Team process and the tutorship program, aimed at analyzing and solving promptly the quality issues relating to the launch of a new engine, have been examined.