High output range extender engine
Extended range electric vehicles (E-REVs) essentially func-
High output range extender engine
tion in the same way as full electric vehicles whenever suf-
4-stroke gasoline engine
ficient energy is available from their on-board batteries (or
900 cc twin cylinder
other rechargeable energy storage system).
30 kW output (standard version)
However, when the battery energy is depleted, they are
40 kW output (high speed version)
also equipped with an auxiliary energy supply, or range ex-
50 kW output (with e-booster)
tender, using a separate fuel source that is only engaged
Horizontal or vertical installation capability
when necessary. For the majority of time, these vehicles will
Unit weight 70 kg (75 kg e-boosted)
operate in a purely electric-only mode and their energy stor-
Compact design
age systems are recharged (by connecting to an external
supply) when they are not in use, e.g. over-night. Thus, the
batteries are sized to cope with the majority of daily usage
that these vehicles will encounter, and they only rely on the
range extender for infrequent, longer journeys.
Your contact
Tel. +44 (0)1604 738 000
[email protected]
MAHLE Powertrain Ltd.
Costin House, St. James Mill Road
Northampton NN5 5TZ - United Kingdom
www.mahle-powertrain.com
MAHLE Product Information 10/2015
© MAHLE Powertrain Ltd, 2015
1
High output range extender engine
MAHLE has developed a dedicated Range Extender (REx)
Technical specifications
unit, focussed on meeting the necessary requirements for
a compact-class E-REV. Key attributes for the REx engine
Engine displacement:
900 cc
were identified as being low cost, small package volume,
Layout:
2 in-line,
good NVH attributes and reasonable fuel efficiency. The
4-stroke, gasoline
resulting design produces 30 kW at 4000 1/min from a 0.9
Bore/stroke:
83.0 / 83.0 mm
litre twin-cylinder, four-stroke gasoline engine, featuring a
Compression ratio:
9.8 : 1
fully integrated, axial flux electrical generator housed within
Fuel injection:
Port fuel injection
the crankcase. Another key feature of the engine is the oil
Installation angle:
Vertical or horizontal
system which enables the engine to be installed vertically
Power outputs:
30 kW [4000 min ]
or horizontally for increased package flexibility.
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40 kW [5500 min ]
To broaden the scope of application of the REx unit, the
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50 kW [5500 min ] (with
specific output of the original unit has now been increased
with minimal modifications to maintain a compact unit. This
has been achieved in two ways - by increasing the maximum
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e-boosting)
Dimensions (L x W x H):
327 x 416 x 481 mm
427 x 416 x 481 mm
operating speed of the engine to 5500 1/min and through e-
(with e-boosting)
boosting. By adopting this dual approach, MAHLE can offer
a family of REx engines, based on a common architecture,
Engine weight (incl. generator): 70 kg (75 kg e-boosted)
to deliver 30, 40 or 50 kW of mechanical power to suit a wide
Fuel consumption:
240 g/kWh minimum
range of vehicle applications.
Emissions level:
Euro 6
MAHLE Product Information 10/2015
© MAHLE Powertrain Ltd, 2015
2