Range Extender Module Transmission Topology Study |
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Authors: | Konrad Herold Marius Böhmer Rene Savelsberg Alexander Müller Jan Schröter Jan Karthaus Un-Jae Seo Georg Jacbos Kay Hameyer Jakob Andert |
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Institution: | 1.Institute for Combustion Engines (VKA),RWTH Aachen University,Aachen,Germany;2.Institute for Machine Elements and Machine Design (IME),RWTH Aachen University,Aachen,Germany;3.Institute of Electrical Machines (IEM),RWTH Aachen University,Aachen,Germany;4.Mechatronic Systems for Combustion Engines (MSCE),RWTH Aachen University,Aachen,Germany |
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Abstract: | 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. |
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