| RANGE EXTENDER MODULE TRANSMISSION TOPOLOGY STUDY |
| Konrad Herold, Marius B, Rene Savelsberg, Alexander M, Jan Schr, Jan Karthaus, Un-Jae Seo, Georg Jacbos, Kay Hameyer, Jakob Andert |
| RWTH Aachen University |
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| ABSTRACT |
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Range extender modules are one option to compensate for short drive ranges of electric vehicles. The close interaction of combustion engine and generator poses new challenges in development. A key requirement for range extender systems is to be light and virtually imperceptible in operation. High-speed electrical machines aim at increasing power density. However, their introduction in a range extender requires a gearbox. The combustion engine torque fluctuations can lead to rattle in the gearbox. The rattle can be overcome by a dual mass flywheel. An interdisciplinary model is developed and used to analyse three different range extender systems: one with a low speed generator without gearbox, one with a high-speed generator, and one with a high-speed generator and a dual mass flywheel. The efficiency was found to be higher for the system with a low speed generator, whereas the power density and the costs are beneficial for the high-speed concept. A dual mass flywheel eliminates the changes of torque direction in the gearbox. It reduces the speed fluctuations of the gearbox and generator by over 90 % compared to the low speed setup. But it increases rolling moment and subsequently chassis excitation compared to a setup with only a gearbox. |
| Key Words:
Range extender, Electric generator, Combustion engine, Gearbox, Dual mass flywheel, Speed fluctuations, Efficiency, NVH |
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