Frank Beste

Range extender module

The use of AVLs Pure Range Extender module as a serial hybrid solution is described. The AVL concept is optimised for electric power generation in single-point operation and allows a compactly integrated, cost- and weight-efficient module design. In addition to its use in simplified four-stroke designs the Pure Range Extender can be applied to emission-optimised and fuel consumption-optimised two-stroke and rotary piston engines. Details are given of the reductions in weight and running costs and the increases in range that can be achieved. The development process is discussed and the key specifications of the Pure Range Extender provided in a table. The design of the internal combustion engine and generator-starter are considered in more detail. A feature of the system is its flexible design which will allow its use in a wide variety of vehicles.

Lightweight engine structures: Mechanical, acoustic and production aspects

Significant weight reduction on the powertrain can only be achieved by the combined use of lightweight materials with specific design approaches. The component with the highest contribution to the engine weight is the crankcase. As the central component with many integrated functions, new crankcase concepts require comprehensive development in view of the mechanical and acoustic behavior. After basic concept development and FE-analysis a test engine was built to evaluate the forward-looking light-weight concepts under realistic conditions. Especially the comparison of modern cylinder running surfaces was a topic of extensive material investigation and engine durability tests. Both Aluminum and Magnesium were investigated as material for the crankcase of the test engine. Beside the functional aspects the production cost of lightweight concepts is the decisive issue for their implementation in volume production. The lightweight development program was conducted in close cooperation with volume production suppliers.

Range-Extender-Modul. Wegbereiter fuer elektrische Mobilitaet

Fur eine breite Akzeptanz von Elektrofahrzeugen erscheint ein Range-Extender als serielles Hilfsaggregat fur einzelne langere Fahrstrecken von entscheidender Bedeutung. Der Ansatz von AVL ist auf Batterienachladung im Einpunktbetrieb ausgelegt und ermoglicht ein kompakt integriertes, gewichts- und kostenoptimiertes Modul. Der Verbrennungsmotor des sogenannten Pure-Range-Extenders von AVL kann neben vereinfachten Viertakt-Konzepten auch als, fur die Anwendung optimierter, Zweitakt- beziehungsweise Rotationskolbenmotor ausgefuhrt werden

Lightweight engine structures — Crankcase concepts for high-performance diesel engines

Weight reduction is one of the major targets for passenger cars with special attention to powertrain systems.