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AVL Range Extender Technologies and Engineering ServicesAVL Range Extender - The Enabler for Electric MobilityMarket RequirementsThe sales volume of electric vehicles with acceptable driving range is limited by product cost and weight. An intelligent system approach utilizing Range Extender technology facilitates market acceptance and success. Based on developed technologies (e.g. ICE) the system supports short-term market introduction.
AVL ApproachThe 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. An essential criterion is the implementation of this functionality into the electric vehicle without noticeable comfort losses. 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 |
| Low raw emissions to meet most stringent emission legislation targets at affordable cost |
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AVL Strengths | Unique system definition and system integration competence |
| Highly experienced in-house development teams for ICE, generator, power electronics, software and vehicle integration development |
| Continuous methodology, toolchain and test environment available |
| Leading edge thermodynamic and electromechanic system definition for most stringent emission requirements and performance targets |
| Experience from prototype to mass production development |
Customer Benefits | Reduced development effort by reduced system complexity |
| Unique system efficiency with minimum fuel consumption |
| Tailored solution for specific customer vehicle requirements |
| Excellent volume production conditions |
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Technical Specifications of AVL DemonstratorICE concept (displacement and rated speed): | rotary engine (250ccm and 5000rpm) | | permanent magnet synchronous machine | | single circuit liquid cooling | | AVL rapid prototyping control unit | | module embedded SW with CAN interface |
Electric output power @ voltage: | | 1m averaged sound pressure: | | System box dimensions (L x H x W): | | | | | | RE-system to vehicle interfaces: | High- and low voltage, CAN bus, fuel supply, mounts, cooling |
| | | | | battery with driving range of 160km, battery cost 500,-EUR/kWh, energy density: 80Wh/kg, energy consumption 20kWh/100km, Range Extender system with pure electric range 50km) |
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Highlights of the AVL Range Extender TechnologyThe module design emphasises the criteria comfort, 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.
| All Range Extender functionalities integrated in module for minimum interfaces with vehicle |
| ICE, generator and power electronics highly integrated in single drive unit for best compactness, low weight and system cost |
| Best NVH properties by lowest excitation and module integrated damping and shielding |
| Concept modularity, low part number and highest part commonality for different performance ratings and applications |
AVL Range Extender Development Services | 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 |
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