Marco Warth

Analysis of Real World Data from a Range Extended Electric Vehicle Demonstrator

MAHLE Powertrain has built a range-extended electric vehicle demonstrator, with a series hybrid configuration. The vehicle is intended to operate predominantly purely electrically. Once the battery state of charge is depleted a gasoline engine (range extender) is activated to provide the energy required to propel the vehicle. As part of the continuing development of this vehicle, MAHLE Powertrain has recorded data during real world driving, with the aim of further investigating the actual usage a range-extended electric vehicle under nonlaboratory test conditions. The vehicle is instrumented with a data acquisition system which records physical parameters, for example coolant temperatures, as well as CAN-based data from the engine and vehicle management systems. This recorded data has been analysed, using tools developed in-house, to establish the effect of environmental factors such as ambient temperature, human behavioral characteristics and variation in usage patterns on the efficiency and operational behaviour of the range-extended electric vehicle system as a whole. Of particular interest are factors such as the frequency, and duration, of operation of the range extender engine under normal daily usage. The resulting data will guide the design direction and specification, at both component and system level, in future range-extended electric vehicle design and development programmes. This paper presents an overview of the recorded data and analysis of the key trends identified. The hardware and software systems are briefly discussed and the control strategy is described within the context of the results presented. This paper also demonstrates that both the range extender unit and the traction circuit components have been sized correctly and that a reduction in traction battery pack size, relative to a pure electric vehicle, is both feasible and appropriate.

MAHLE Advanced EGR Systems for Commercial Diesel Engines to Meet Future Emission Demands

Given the ever more stringent emission regulations modern diesel engines undergo these days, the need for advanced EGR systems becomes crucial in all major applications, in particular on- & off-road commercial diesel engines. One of the key aspects of these so-called advanced EGR systems thereby is to reliably provide the engine with the appropriate, high amounts of EGR over the entire range of operating conditions. Whereas common systems are either optimized for low-torque/low-speed operating conditions, or a narrow range around one specific engine speed, the advanced systems aim to both cover the entire operating range and significantly increase the current level of EGR. The advanced EGR systems developed at MAHLE make use of two types of fast acting devices in a modular approach. Depending on the engine size/layout and the amount of EGR needed, the devices are either placed directly in the EGR line or the intake manifold. Using the latest technical advances in mechatronics, the oscillating valves can be opened or closed within less than 3ms, which makes it not only possible to accurately control the amount of EGR fed back into the engine, it also allows to boost the amount of EGR using the exhaust pressure oscillations. In addition to these oscillating valves, rotational flaps have been developed to significantly reduce the complexity of the systems, while still offering similar benefits in terms of EGR rates and variability. Shown hereafter are the results from thorough investigations conducted on both European and US heavy-duty diesel engines. Focusing on some of the most common engine characteristics, such as EGR rates, emissions of nitrogen oxide and fuel consumption, significant benefits can be seen using the newly developed technologies. Compared to conventional measures, such as increased exhaust backpressure and/or constant charge-air throttling, the advanced systems prove to be both more efficient and flexible in terms of EGR rates, as well as beneficial regarding some of the most important engine characteristics.Copyright

MAHLE Efficient Electric Transport – an efficient system solution for the electrified urban mobility

Driven by numerous trends and challenges the automotive industry faces a tough transformation. This affects car manufactures as well as the whole supplier industry. The main challenge thereby is the further reduction of CO2 emissions.