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AVL Announces New Modular Range Extender Technologies and Engineering Services

Posted on: Wednesday, 20 May 2009, 15:05 CDT

PLYMOUTH, Mich., May 20 /PRNewswire/ -- AVL has announced 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. The modular design combines compact size, weight and packaging with competitive production costs and system efficiency. Depending on the specific customer production background and product needs, the internal combustion engine (ICE) 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. AVL Range Extender-specific requirements are:

• 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.

All Range Extender functions are integrated in the module to enable minimum interfaces with the vehicle. The ICE, generator and power electronics are highly integrated in the single drive unit for best compactness, low weight and system cost.

The modular approach allows for the use of lower part quantities and higher part commonality for different performance ratings and applications.

The AVL Range Extender employs 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.

Dimensions of the Range Extender box are 490mm x 400mm x 980mm and the unit weighs 65 kg. System to vehicle interfaces are high- and low-voltage, CAN bus, fuel supply, mounts and cooling.

Related development services offered by AVL include:

• 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

www.avl.com

SOURCE AVL

Source: PR Newswire

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