Worldwide, there is a strong trend towards highly efficient, low (preferably zero) emission vehicles, i.e. electrical vehicles. In order to facilitate the transition from conventional fuel-driven vehicles towards electrically driven vehicles, there is a short(er) term need for advanced electrical vehicles with range extenders and/or advanced plug-in hybrids. For this purpose, highly efficient, compact, clean and low cost engines are required. Such engines are to provide battery charging over longer trips and/or in areas where electric recharge infrastructure is not (yet) available. Moreover, these engines should be able to significantly improve over future Euro 6 standards for noxious emissions.
The OptiMoRE project will take on the challenge to develop and optimise the concept of the fully integrated, range-extended, electrified light duty vehicle.
- Cost, weight and volume optimisation of REX unit in light commercial Vehicle. Target weight reduction for REX is 20% together with a reduction of Range Extender length by 25% respect to FUerex configuration.
- RE fuel consumption and emission optimisation acting both on ICE and electric machine efficiency and RE utilisation strategies. Emission target is to match half of EuroVI standard with a correspondent best BSFC of 230gr/kWh.
- Standardisation and modularisation.
Three different Range Extender (RE) concepts will be developed and demonstrated to serve the niches from city vehicles, medium sized passenger cars up to light commercial vehicles.
Each concept is based upon:
- Definition of real world driving conditions (driving cycles and comfort requirements) as a baseline for further optimisation and EV assessment.
- Optimisation of components and the whole RE system regarding emission, fuel consumption, cost, weight and exhaust gas after-treatment.
- Modular setup of an EV concept to fulfil a wide range of customer expectations.
- Advanced control strategies as a key for cost reduction and system optimisation.
- Functional and Electrical safety analysis and concept development to define necessary measures to fulfil and implement ISO 26262.
- Build-up and optimisation of three technology demonstrator vehicles covering EV aspects for delivery trucks, all-purpose vehicles and city cars
- City compact Electric Vehicle, with a rotary engine (2020+)
- A family Electric Vehicle either as FEV or EV-RE with a 3 cyl engine (modular) (2020+)
- Light commercial Electric vehicle 2 cyl engine (2015+)...
The three vehicle concepts will be assessed based on real world driving cycles, regarding achievable all electric range total energy consumption and NVH. The vehicles will be tested and assessed on both the NEDC and ARTEMIS test cycles and under real driving conditions, developed in WP6.
The main project results/deliverables of OptiMoRE are:
- Typical driving cycles for robust optimisation of EVs RE-EVs.
- Three integrated and optimised range extenders with improved performance.
- Range Extender unit with a gasoline 2 cylinder Natural Aspired engine where the integration of internal combustion engine and electric components allows a strong weight, cost and volume reduction and efficiency and packaging optimisation.
- Modular vehicle concept covering BEV, RE-EV and PHEV.
- Bench test demonstrating emissions, efficiency and performance for total RE.
- Vehicle test demonstrating integration/NVH and vehicle performance.
- Functional Safety concept for EVs with safety requirements including High Voltage safety according ISO 26262.
- Study on volume production optimisation (low cost solutions).
- A method to optimise range extenders for different vehicle niches and different usage profiles.