|A Range Extender Module based on a rotary engine. Click to enlarge.|
AVL has introduced new range extender system technology and engineering services targeted at OEMS for short-term market introduction of range-extended electric vehicles.
The Range Extender is an autonomous auxiliary power unit added to pure electric drive vehicles to extend the operational range beyond that obtainable in the pure electric mode. AVL took a modular approach; depending on the specific customer production background and product needs, the internal combustion engine (ICE) component can be designed as a 2- or 4-stroke piston engine, or for lowest NVH and best compactness, as a rotary engine.
Because of the specific drive train system layout, the electric system and the ICE can be optimized for single point operation. Design requirements that AVL brought to the development task included:
- Lowest NVH, compact design and high power/weight ratio;
- Dependable system—i.e. available after long period of inactivity;
- Reduced system life time and load response requirements compared to standard ICEs;
- Single load point optimization for low system cost and good efficiency;
- Thermal management to protect heat sensitive e-components; and
- Low raw emissions to meet most stringent emission legislation targets at affordable cost.
|Range Extender Core Module: Rotary Engine, Generator and Power Electronics. Click to enlarge.|
All Range Extender functions are integrated in the module for to enable minimum interfaces with vehicle. The ICE, generator and power electronics are highly integrated in the single drive unit for best compactness, low weight and system cost.
The modularity also enables low part numbers and high part commonality for different performance ratings and applications.
For a demonstrator of the Range Extender system, AVL coupled a 250cc rotary engine running at 5,000 rpm with a permanent magnet synchronous machine. Electric output is 15 kW @ 320-420V, and fuel consumption is 260 g/kWh.
Dimension of the Range Extender box are 490mm x 400mm x 980, and the unit weights 65 kg. System to vehicle interfaces are high- and low-voltage, CAN bus, fuel supply, mounts and cooling.
AVL is also offering a suite of range-extender development services, including:
- Concept development and simulation
- Technical specification development
- ICE and electronic system integration
- Model-based component optimization (ICE, generator, power electronics, controller and software)
- Continuous methodology and toolchain for simulation and verification
- Operation strategies and control
- System calibration development
- Definition of testing requirements
- Prototype and production development