Range extender

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A prototype AC Propulsion tzero electric car with an external range-extender or genset trailer, 1999 Acp tzero DSC00467.jpg
A prototype AC Propulsion tzero electric car with an external range-extender or genset trailer, 1999

A range extender is a fuel-based auxiliary power unit (APU) that extends the range of a battery electric vehicle by driving an electric generator that charges the vehicle's battery. This arrangement is known as a series hybrid drivetrain. The most commonly used range extenders are internal combustion engines, but fuel-cells or other engine types can be used. [1]

Contents

Range extender vehicles are also referred to as extended-range electric vehicles (EREV), range-extended electric vehicles (REEV), and range-extended battery-electric vehicle (BEVx) by the California Air Resources Board (CARB). [2]

Many range extender vehicles, including the Chevrolet Volt and the BMW i3, are able to charge their batteries from the grid as well as from the range extender, and therefore are a type of plug-in hybrid electric vehicle (PHEV). [3] [4] Historically PHEV, HEV and MHEV were primarily powered by combustion (bigger engine and fuel tank with smaller battery and electric motor(s)). While EREV are the opposite. [5]

Motivation

The key function of the range extender is to increase the vehicle's range. Range autonomy is one of the main barriers for the commercial success of electric vehicles, and extending the vehicle's range when the battery is depleted helps alleviate range anxiety. [6]

A range extending vehicle design can also reduce the consumption of the range extending fuel (such as gasoline) by using the primary fuel (such as battery power), while still maintaining the driving range of a single fuel vehicle powered by a range extending fuel such as gasoline. The range extending fuel is generally considered to be less environmentally and economically friendly to use than the primary fuel source, so the vehicle control system gives preference to using the primary fuel if it's available. However, due to range limitations with the primary fuel source, the range extending fuel allows the vehicle to get many of the cost and environmental benefits of the primary fuel, while maintaining the full driving range of the range extending fuel source. [7] That said, the benefits (cost, carbon emissions) derived from using a vehicle with a range extender ultimately depend on how the vehicle is driven, and in particular how often the range extender is used. [8]

As an example, cars such as the Chevrolet Volt and the BMW i3 with optional range extender are equipped with sufficiently large batteries to drive 80–160 km (50–100 miles), which is enough for many trips but not sufficient to drive long distances. As such, the driver may use battery power for commuting and daily driving, but still be able to drive from New York to Boston (about 320 km, 200 miles) by using the auxiliary gasoline internal combustion engine, without stopping frequently to charge the battery (which can take hours). The vehicle owner therefore accrues the benefits of using cheaper and less carbon-intensive electric power for most driving, while maintaining the ability to embark on longer trips with the same vehicle.

When a range extender uses conventional fuels they can re-fuel at regular fuel stations, which provides them with a similar driving range to conventional automobiles. [9] [10] [11]

As an REEV is only propelled by the electric motor it can do away with the weight and cost associated with the gearbox transmission system typically used in internal combustion engine cars. Further, as the range extender does not need to increase or decrease output in line with the power needs of the vehicle (this task is handled by the electric motor) the range extender can be sized to satisfy the vehicle's average power requirement rather than its peak power requirement (such as when accelerating). The range extender can also operate much closer to its most efficient rotational speed. These design features allow an REEV to convert fossil fuel energy to electric power and vehicle motion relatively efficiently.

Generations

CARB regulation

According to 2012 Amendments to the Zero Emission Vehicle Regulations adopted in March 2012 by the California Air Resources Board (CARB), a range-extended battery-electric vehicle, designated as BEVx, should comply, among others, with the following criteria: [2]

Applications

Range extenders are commonly used in marine (autonomous underwater vehicle), aircraft and Generator/Utility, automotive [13] and hybrid electric vehicle applications. [14]

Automotive

Chevrolet Volt

The Chevrolet Volt is a series plug-in hybrid referred by General Motors as "an electric car with extended range." DCA 06 2012 Chevy Volt 4035.JPG
The Chevrolet Volt is a series plug-in hybrid referred by General Motors as "an electric car with extended range."

General Motors describes the Chevrolet Volt as an electric vehicle equipped with a 16 kWh battery plus a "range extending" gasoline powered internal combustion engine (ICE) as a genset and therefore dubbed the Volt an "Extended Range Electric Vehicle" or E-REV. [3] [4] [15] In a January 2011 interview, the Chevy Volt's Global Chief Engineer, Pamela Fletcher, referred to the Volt as "an electric car with extended range." [16] The Volt operates as a purely electric car for the first 40–80 km (25–50 miles) in charge-depleting mode. When the battery capacity drops below a pre-established threshold from full charge, the vehicle enters charge-sustaining mode, and the Volt's control system will select the most optimally efficient drive mode to improve performance and boost high-speed efficiency. [3] [17] [18]

According to General Motors' real time tally of the distance driven by Volt owners in North America, by mid June 2014 they had accumulated more than 800 million all-electric km (500 million miles). GM also reported that Volt owners driving is more than 63% in all-electric mode. Volt owners who charge regularly typically drive more than 1,560 km (970 miles) between fill-ups and visit the gasoline station less than once a month. [19] A similar report, issued by GM in August 2016, reported that Volt owners have accumulated almost 2.4 billion km (1.5 billion miles) driven in EV mode, representing 60% of their total distance traveled. [20]

BMW i3

An optional range-extender is available for the BMW i3, which allows the car to qualify as a range-extended battery-electric vehicle (BEVx) according to the California Air Resources Board regulations. BMW i3 (19939421151).jpg
An optional range-extender is available for the BMW i3, which allows the car to qualify as a range-extended battery-electric vehicle (BEVx) according to the California Air Resources Board regulations.

The BMW i3 all-electric car with at least 22 kWh battery capacity offers an optional gasoline-powered range extender APU. [21] The range extender is the same 647 cc two-cylinder gasoline engine used in the BMW C650 GT scooter with a 9 L (2.0 imp gal; 2.4 US gal) fuel tank. The US model originally had its tank electronically limited to a smaller 7 L capacity. [22] The range extender engages when the battery level drops to 6%. It generates electricity to extend the range from 130–160 km (80–100 miles) to 240–300 km (150–190 miles) [23] [24] Performance in range-extending mode may be more limited than when it is running on battery power, as BMW designed the range extender as a backup to enable reaching a recharging location. [25]

According to BMW, at the beginning of the i3 release, the use of range-extender was much more than the carmaker expected, more than 60%. Over time it has decreased significantly, with some people almost never using it, and by 2016 it is being regularly used in fewer than 5% of i3s. [26]

The range-extender option costs an additional US$3,850 in the United States, [27] an additional €4,710 (~ US$6,300) in France, [28] and €4,490 (~ US$6,000) in the Netherlands. [29]

The range-extender option of the BMW i3 was designed to meet the CARB regulation for an auxiliary power unit (APU) called REx. According to rules CARB adopted in March 2012, the 2014 BMW i3 with a REx unit fitted will be the first car to qualify as a range-extended battery-electric vehicle or "BEVx." CARB describes this type of electric vehicle as "a relatively high-electric range battery-electric vehicle (BEV) to which an APU is added." The APU, which maintains battery charge at about 6% after the pack has been depleted in normal use, is strictly limited in the additional range it can provide. [2] [30]

Other examples

The discontinued Fisker Karma is an extended-range electric vehicle. Fisker at speed in the fog trimmed.jpg
The discontinued Fisker Karma is an extended-range electric vehicle.

Other range-extended electric vehicles include the discontinued Cadillac ELR and the discontinued Fisker Karma. [31] [32] [33] In June 2016, Nissan announced it will introduce a compact range extender car in Japan before March 2017. The series plug-in hybrid will use a new hybrid system, dubbed e-Power, which debuted with the Nissan Gripz concept crossover showcased at the 2015 Frankfurt Auto Show. [34] The technology, without the plug-in ability, had been deployed to the Nissan Note e-Power and Nissan Kicks e-Power.

The LEVC TX London taxi was launched in 2017 and features a 33 kWh battery that is charged by a 1.5-litre gasoline engine. [35]

The Li Auto One is a large SUV which combines a 41-kWh battery with a small 1.2-litre gasoline engine. [36] [37]

This approach has also been used for heavy vehicles, such as Wrightbus's Gemini 2 [38] and New Routemaster [39] buses.

Hydrogen fuel cells have also been used as a range extender for battery electric buses, allowing them to have greater range. [40] For example, the Mercedes-Benz eCitaro has a range of 280 kilometres (170 mi) as a battery electric model, with the eCitaro fuel cell bus having a range of 400 kilometres (250 mi) thanks to a 60kW Toyota fuel cell that recharges the battery. [41]

Ford has patents for a bed mounted gasoline-powered generator for their fully electric pickups. [42] Rivian has patents for bed mounted additional batteries for increased range. [43] Rivian electric trucks can charge each other for extended range. [44]

Unmanned aerial vehicles

The 2010 Wolverine 3 program included an ICE range extender for its unmanned aerial vehicle. [45]

Powertrain

Schematic classification of alternative powertrains Schema-Antriebe.jpg
Schematic classification of alternative powertrains

A range-extended electric vehicle uses a series hybrid drivetrain.

See also

Related Research Articles

<span class="mw-page-title-main">Hybrid vehicle</span> Vehicle using two or more power sources

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<span class="mw-page-title-main">General Motors EV1</span> Short-lived lease-only late 1990s U.S. electric car

The General Motors EV1 is an electric car produced and leased by General Motors from 1996 to 1999. It was the first purpose-designed electric vehicle of the modern era from a major automaker and the first GM car designed to be an electric vehicle from the outset.

Hybrid Synergy Drive (HSD), also known as Toyota Hybrid System II, is the brand name of Toyota Motor Corporation for the hybrid car drive train technology used in vehicles with the Toyota and Lexus marques. First introduced on the Prius, the technology is an option on several other Toyota and Lexus vehicles and has been adapted for the electric drive system of the hydrogen-powered Mirai, and for a plug-in hybrid version of the Prius. Previously, Toyota also licensed its HSD technology to Nissan for use in its Nissan Altima Hybrid. Its parts supplier Aisin offers similar hybrid transmissions to other car companies.

<span class="mw-page-title-main">Plug-in hybrid</span> Hybrid vehicle whose battery may be externally charged

A plug-in hybrid electric vehicle (PHEV) is a type of hybrid electric vehicle equipped with a rechargeable battery pack that can be replenished by connecting a charging cable into an external electric power source, in addition to internally by its on-board internal combustion engine-powered generator. While PHEVs are predominantly passenger cars, there are also plug-in hybrid variants of sports cars, commercial vehicles, vans, utility trucks, buses, trains, motorcycles, mopeds, military vehicles and boats.

Hybrid vehicle drivetrains transmit power to the driving wheels for hybrid vehicles. A hybrid vehicle has multiple forms of motive power.

<span class="mw-page-title-main">Alternative fuel vehicle</span> Type of vehicle

An alternative fuel vehicle is a motor vehicle that runs on alternative fuel rather than traditional petroleum fuels. The term also refers to any technology powering an engine that does not solely involve petroleum. Because of a combination of factors, such as environmental and health concerns including climate change and air pollution, high oil-prices and the potential for peak oil, development of cleaner alternative fuels and advanced power systems for vehicles has become a high priority for many governments and vehicle manufacturers around the world.

<span class="mw-page-title-main">Chevrolet Volt</span> Range extended electric automobile

The Chevrolet Volt is a plug-in hybrid car manufactured by General Motors, also marketed in rebadged variants as the Holden Volt in Australia and New Zealand and the Buick Velite 5 in China, and with a different fascia as the Vauxhall Ampera in the United Kingdom and as the Opel Ampera in the remainder of Europe. Volt production ended in February 2019.

All-electric range (AER) is the maximum driving range of an electric vehicle using only power from its on-board battery pack to traverse a given driving cycle. In the case of a Battery electric vehicle (BEV), it means the maximum range per recharge, typically between 150 and 400 miles. For a plug-in hybrid electric vehicle (PHEV), it means the maximum range in charge-depleting mode, typically between 20 and 40 miles. PHEVs can travel considerably further in charge-sustaining mode which utilizes both fuel combustion and the on-board battery pack like a conventional hybrid electric vehicle (HEV).

<span class="mw-page-title-main">History of plug-in hybrids</span>

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<span class="mw-page-title-main">BMW i8</span> Plug-in hybrid sports car developed by BMW

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<span class="mw-page-title-main">Range anxiety</span> Fear of insufficient vehicle range, especially in electric vehicles

Range anxiety is the driver's fear that a vehicle has insufficient energy storage to cover the road distance needed to reach its intended destination, and would thus strand the vehicle's occupants mid-way. The term, which is now primarily used in reference to the practical driving range of battery electric vehicles (BEVs), is considered to be one of the major psychological barriers to large-scale public adoption of electric cars.

<span class="mw-page-title-main">BMW i3</span> Battery electric subcompact car

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<span class="mw-page-title-main">BMW i</span> Sub-brand of BMW

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<span class="mw-page-title-main">Chevrolet Volt (second generation)</span> Motor vehicle

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There are numerous versions of vehicle propulsion systems. Many of those came into fruition due to need for cleaner vehicles. Each of them might have many abbreviations and some might be misleading. This article explains shortly what defines them.

References

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