Mahle aftermarket supplies a broad portfolio of products and services. Investigate mahle turbulent jet ignition benefits on a rangeextender application expand ornl peemrc testing of remys induction machine to include generator mode and transients test mahle engine and remys machine as a range extender using hardwareintheloop test cell optimize range extender as a system. From the outset, it was important to fully understand the functional requirements of the range extender engine by defining the appropriate boundary conditions. Mahle range extender project video long version youtube. It converts chemical energy into electrical energy by means of a combustion process and linear generator. Development of a dedicated range extender unit and. Range extender and integrated battery provide sufficient power. Mahle powertrain have developed a reev demonstrator using a 900 cc 2cylinder, 4 stroke petrol engine to assess and demonstrate the characteristics and capabilities of their range extender in a. Hummer h3 range extended electric vehicle the other end of the spectrum in respect to vehicle size is the fiat 500 city car figure 4, which was also developed as a. The global electric vehicle ev range extender market demand was pegged at 247,285 units in 2017 and is likely to exhibit a cagr of 10.
Design and experimental development of a compact and. The mahle range extender engine has been sized to be suitable for a. Having successfully developed its own compact range extender engine inhouse, a fully functional demonstrator vehicle has now been built to provide convincing proof of this approach. Thanks to our expertise in electric and electronic components and systems, we can offer integrated system solutions for the future of mobility. Request pdf the development of a dedicated range extender engine. This range extender is based in the addition of a small internal combustion engine to be attached only when the electric autonomy cannot fulfill the trip. Cabin air filter caremetix cabin air filter caremetix. The test vehicle, based on the fiat 500, has already undergone comprehensive tests at rheinmetall automotive. Examples are the mahles 900cc twin cylinder re 28 and. Therefore this publication deals with the explanation of the concept and the characteristics of a free piston linear generator and a. Mahle range extender excels in all three performance levels. Evo electric and mahle partnering on 2cylinder range. Traction motors from mahle make emobility reliable and affordable. The development of a dedicated range extender engine.
The overall dimensions of this engine are shown in fig. Mahle expands thermal management portfolio for the vehicles of today, and tomorrow with behr hella integration. Mar 24, 2015 it is convenient to use the generator of a range extender also for starting the engine. In order to compare the range extender systems, fuel cells, micro gas turbine and ottowankel. The range extender engine from mahle starts in response to both the applied load and the state of charge, but the battery in the prototype uses only around 80% of its capacity. Application of the internal combustion engine as a range extender for electric vehicles abstract. In the 2019 financial year, the automobile component supplier intensified its strategic and technological realignment despite challenging conditions.
Jan 29, 20 mahle powertrain has developed a production feasible solution for a range extended electric vehicle reev powertrain. Investigate mahle turbulent jet ignition benefits on a range extender application expand ornl peemrc testing of remys induction machine to include generator mode and transients test mahle engine and remys machine as a range extender using hardwareintheloop test cell optimize range extender as a system. C28012 design and development of a dedicated range extender engine 3 m d bassett, j hall, d darkes, n a j fraser, m warth, mahle powertrain ltd, uk c28004 multiple injection and boosting benefits for improved fuel consumption on a spray guided direct injection gasoline engine j king, l schmidt, j stokes, j seabrook, ricardo, uk. Key attributes for the engine have been identified and the appropriate engine technology selected. The advantage of this is that the motor can be kept compact and simple, yet remains highly efficient due to its operation at optimum speed points. The sum of the torques developed by the startergenerator and the rotational inertia including the flywheel, have to be sufficiently large in order to overcome the compression torque so as to ensure a successful start of. Pdf application of the internal combustion engine as a. The design started from a completely clean sheet, and working prototypes were being tested 9 months after the start of. Mahle and behr have addressed these needs with a whole lineup of new products and technologies. The bmw i3 allelectric car with at least 22 kwh battery capacity offers an optional gasolinepowered range extender apu. Phev advanced series genset developmentdemonstration activity.
The range extending engine, including the generator, tips the scales. Starting from a cleansheet, the mahle range extender has been designed to. The duke output shaft, being intrinsically geared down to 56 of the piston reciprocating speed, allows the engine out torque to be higher and maximum torque to be developed at lower speeds. Iwoc one button charging port protected by a rubber. Cranfield university, mk43 0al whittle building 52 gold lecture theatre.
An electric vehicle ev range extender includes a variety of components such as generators, battery packs, power converters, and electric motors that enable range extension for electric vehicles. Mahle compact range extender engine mahle powertrain. Apr 25, 20 mahle has developed a range extender engine to identify the requirements, and challenges for csegment extended range electric vehicles erev. Mahle traction motors are suitable for all applications.
Starting requirements of a range extender for electric vehicles. The germans are know looking into the field, and mahle, the engine specialists have unveiled a new range extender ice. The mahle range extender is a twocylinder inline engine that charges the battery of a primarily electrically powered vehicle when needed, which may occur after a specific cruising range has been reached, or when high current. The range extender engine developed by mahle was installed in a demonstration. Birmingham, mi automotive supplier mahle harnesses global positioning system technology to an extendedrange electricvehicle. Air is delivered by a small electric supercharger maximum electric power. Starting from a cleansheet, the mahle range extender has been designed to be light 65 kg including generator and compact. Free piston linear generator in comparison to other range.
The detailed design led to the 900 cc twin cylinder 4stroke gasoline engine layout presented here. Few people know mahle outside of the auto industry, but if one looks closely on fords latest ecoboost engine, the pistons, the bearings, the camshafts and all the small internal parts are built by mahle. Mahle powertrain recognised the potential benefits in the application of range extenders and set out to design and develop its own unit inhouse. If the downsized combustion engine is used as a range extender, the total range is extended to. Fleet vehicle drive data was analyzed, using a drive style analysis toolset developed by mahle powertrain, to identify the typical daily usage pattern of such passenger cars. A dedicated range extender powertrain has been developed from a clean sheet and applied to a standard production vehicle in an effort to prove the technologys maturity and potential n. Stuttgart, april 30, 2020 in the current coronavirus crisis, the mahle group can rely on a sound financial position and liquidity. The lotus range extender engine has been conceived from the outset specifically as an engine for a plugin series hybrid vehicle, therefore being free of some of the constraints placed on engines. Pdf application of the internal combustion engine as a range. Lownoise range extender dispels battery runtime angst together with fev gmbh, rheinmetall automotive is currently and successfully testing a range extender developed for electric vehicles. The development of a dedicated range extender engine request. Mahle has developed a range extender engine to identify the requirements, and challenges for csegment extended range electric vehicles erev.
Design of a dedicated range extender engine request pdf. The free piston linear generator is a new range extender technology. The key players analyzed in this electric vehicle ev range extender market report are avl, ballard power systems, bmw, ceres power, delta motorsport, magna international, mahle, nissan motor. Based on a small size 4stroke engine article pdf available in international journal of automotive technology 164 august.
Mike bassett corresponding author mahle powertrain limited, costin house. Electric vehicle range extender market industry report. Extended range electric vehicles erevs offer a viable solution using an onboard generator range extender, enabling a significant battery size reduction. The engine is a clean sheet design optimized for cost, weight, nvh, package size and installation flexibility. Over the past 3 years, mahle powertrain has designed and developed an engine specifically for the use as a range extender. It can therefore be integrated almost anywhere on the electric vehicle. Current focus on techniques to reduce the tailpipe carbon dioxide co2 emissions of road vehicles is increasing the interest in hybrid and electric vehicle. In order to make a qualitative comparison between the proposed 2stroke engine and a 4stroke one, the mahle range extender may be considered. Application of the internal combustion engine as a rangeextender for electric vehicles abstract. Stuttgartgermany, february 12, 2020 mahle and sap have decided to cooperate closely on the implementation of the mahle groups digitalization strategy. A range extender is chosen by means of a comparison between different electric engines sold in the market. Development of a dedicated range extender unit and demo vehicle. This analysis enabled the requirements for electrical components and the range extender to be determined. Mahle powertrain recognised the potential benefits in the application of range extenders and set out to design and develop its own unit inhouse, which has now been installed in a bsegment.
Mahle powertrain has developed a production feasible solution for a range extended electric vehicle reev powertrain. The mahle range extender demonstrator vehicle batteryelectric mobility without range limitations pdf. Request pdf development of a range extender engine family mahle has developed a dedicated range extender rex unit, focussed on meeting the requirements determined for a compactclass range. Mahle powertrain was commissioned by its parent company, mahle, to develop an engine for use as a range extender for electric vehicles. Freepiston linear generator, wankel, otto, engine, range extender, fuel cell. Mahle already offers manufacturers of electric vehicles sophisticated drive solutions with maximum performance. Fleet vehicle drive data was analyzed, using a drive style analysis toolset developed by mahle powertrain. The key attributes for the range extender engine were identified. The design started from a completely clean sheet, and working prototypes were being tested 9 months after the start of concept work in 2009. The range extender is the same 647 cc twocylinder gasoline engine used in the bmw c650 gt scooter with a 9 l 2. Comparison between 2 and 4stroke engines for a 30 kw range. The paper compares two different design concepts for a range extender engine rated at 30 kw at 4500 rpm. Ev range extender market electric vehicle that travels. The advantage of this is that the motor can be kept compact and.
Naturally, the range extender starts earlier on, especially at low temperatures, as for example, the vehicle must be heated, but even in winter provided sufficient. Development and assessment of an overexpanded engine. Range extender orbea 3 on off charging point connecting cable range extender users manual technical specifications total capacity. Development of electric and rangeextended electric. To achieve its high efficiency, the highly soundproof combustion engine is constantly operated in the optimum engine speed range. The digital backbone will serve as a new, central digital platform for mahle, with the specific aim of standardizing data and processes. Mahle aftermarket europe aftermarket of tomorrowwhat. The range extender functions as a generator used solely to charge the battery in electric vehicles. A key feature of the engine is its oiling system, which enables the range extender to be installed vertically or horizontally. Range extender requirements are fully understood and optimized. Experienced in range extender engine development and vehicle applications. Development of a range extender engine family request pdf.
Free piston linear generator in comparison to other range extender. Ten year forecast for electric cars, hybrids and their range extenders 5 1. Mahle powertrains solution to this dilemma is a compact range extender engine. Mahle, evo electric developing 2cylinder rangeextending. Some companies even offer the range extender as a standalone product, such as mahle powertrain or duke engine. New applications in the field of internet of things iot.
Mahle develops highefficiency drive systems and power electronics for electric powertrains. The torque needed by the engine at the early stage of engine cranking has been modeled. A range extender is an auxiliary power unit, usually consisting of an internal combustion engine and an electric generator, which is used to charge a battery of an electric vehicle in order to. Mahle range extender for greater cruising range in passenger cars with batterypowered electric powertrains another of the mahle highlights at the evs30 is the mahle range extender. It is extremely important that the efficiency of these range extenders be as high as. In simple terms, the range extender is an auxiliary power unit consisting of a small internal combustion engine coupled with an electric generator which is used to recharge the battery pack. Mahle has developed a range extender engine to identify the requirements, and challenges faced in the development of the components, for such future engines. However, the issue of range anxiety has become a major concern for consumers and this negative factor, coupled with persistently high battery costs, has severely limited the market penetration of these new generation, zero emission vehicles. Baseline engine comparison with mahle engine components 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 0 2000 3000 4000 5000 6000 7000 8000 engine speed rpm torque nm. The duke engine lends itself well to marine, aircraft and generatorutility, automotive and hybrid electric vehicle range extender applications. Mahle powertrain mahle compact range extender engine. The chevy volts range extender engine is an offtheshelf motor not designed for such applications and is not fully suitable for the task in hand. Having successfully developed its owncompact range extender engine inhouse. Hub and middrive motors we offer suitable drive units for every type of bicycle.
Remote control, display hmi and bespoke applications offer an intelligent user interface. The mahle range extender engine has been sized to be suitable for a typical csegment passenger car. Thereby the technology aims to have better properties than other range extenders. New mahle range extender vehicle launched car engineer. Feb 18, 20 mahle powertrain has developed a production feasible solution for a range extended electric vehicle reev powertrain. Range extender speed revmin 0 2000 3000 4000 road power rex power rex engine speed deplete battery maximiseev range load follow soc sustaining engine speedload follows vehicle speed minimisenoise and fuel consumption vehicle noise masks rex rexoff at low vehicle speeds unless soc critically low. Mahle range extender engine takes cues from gps wardsauto. Another of the mahle highlights at the evs30 is the mahle range extender. Mahle range extender engine, 20th aachen colloquium automobile and engine. Phev advanced series genset developmentdemonstration.
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