Compact Range Extender Vehicle Brochure - Mahle Powertrain Ltd

MAHLE range extender demonstrator vehicleAs oil prices continue to rise and society becomes increasinglyaware of the environment, the global automotiveindustry is now sharply focused on electric vehicles.However, the issue of ‘range anxiety’ has become a majorconcern for consumers and this negative factor, coupledwith persistently high battery costs, has severely limitedthe market penetration of these new generation, zero emissionvehicles. MAHLE Powertrain’s solution to this dilemmais a compact Range Extender engine which can powerthe vehicle when the battery is depleted. A demonstratorvehicle has been built to showcase this technology and toassist in the further development and optimisation of theengine, associated hardware and control systems.MAHLE Powertrain set ambitious performance targets forthe demonstrator vehicle including a minimum ‘electriconly’ range of 70 km. The maximum speed will be 145 km/h with the ability for continuous (charge sustaining) drivingat 120 km/h. The vehicle will also be capable of maintaining90 km/h on a 6 % gradient.To reach all these targets, the engine was designed to produce30 kW and the generator was specified to match thisoutput. A battery pack rated at 14 kWh was required and atraction motor with 100 kW peak output was selected.The other necessary electric drive hardware also included a2-speed gear box, two motor control units with associatedcooling systems and a battery management system. TheMAHLE Flexible ECU (MFE) was implemented for both theengine and vehicle controllers.Range extender demonstrator vehicleYour contactDevelopment: Dr. Marco WarthTel. +44 (0)1604 738 001marco.warth@mahle.comSales Europe: Daren MottersheadTel. +44 (0)1604 738 226daren.mottershead@gb.mahle.comMAHLE Powertrain Ltd.Costin House, St. James Mill RoadNorthampton NN5 5TZ - United Kingdomwww.mahle-powertrain.comMAHLE Product Information 07/2012 1© MAHLE Powertrain Ltd, 2012

MAHLE range extender demonstrator vehicleThe packaging of all the hardware in a compact vehicle representeda significant challenge. MAHLE Powertrain utilisedits experience and skills in demonstrator vehicle buildto solve this challenge, especially with regard to the intake,exhaust and cooling system packaging. With the batterysituated beneath the rear luggage compartment, it waspossible to install all the other components within the enginebay and thus retain all of the original passenger andluggage space.What differentiates our concept from established hybridcars is that there is no mechanical link between the engineand the wheels. Our compact, lightweight engine (with itsintegrated generator) simply charges the battery as necessaryand so extends the range of the vehicle. For optimumeconomy, the battery should always be charged externally,whenever possible, via a standard plug in supply. However,with the car being refuelled with gasoline in the traditionalway, greater flexibility of use is available for longer journeys,with a combined battery + engine range of up to 500 km,before recharging / refuelling is required.In keeping with the low emissions philosophy of electricvehicles, the engine has been calibrated for compliancewith Euro 6 regulations and the vehicle is capable of achieving45 g CO 2 /km on the legislated NEDC test.Through building this range extender demonstrator vehicle,MAHLE Powertrain has used its expertise and knowledgeto create a viable alternative to current production EVs. Thiscar provides the optimum combination of extended rangeand flexibility of use with zero tailpipe emissions capabilityand class-leading fuel economy.This is the car of the future - today.Technical specificationsEngine layout900 cc, 2 cylinderBore/stroke:83.0 / 83.0 mmInstallation angle: Vertical or horizontalEngine control:MAHLE Flexible ECUMaximum power: 30 kW [4000 min -1 ]Vehicle specificationsCO 2 output NEDC: < 45 g/kmEmissions target: Euro 6Pure Electric Range: 70 kmCombined Range: 500 kmMaximum Speed: 145 km/hKerb Weight:1350 kgMAHLE Product Information 07/2012 2© MAHLE Powertrain Ltd, 2012