Range Extender Electric Vehicle Drivetrain Architecture
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Solution Overview
Problem
Electric vehicles with battery-powered drive trains face limitations in range and efficiency due to the weight and capacity constraints of batteries, and existing solutions often compromise on either electric-only range or fuel efficiency when incorporating range extenders.
Innovation Solution
A utility vehicle design incorporating a battery-dominant, serial hybrid system with an on-board engine generator that maintains battery state-of-charge and provides power to the electric motor, optimizing weight distribution between batteries and a fuel tank to extend the vehicle's range while improving fuel efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If battery capacity is increased to extend electric range, then electric-only range is improved, but vehicle weight increases
Solution Approach 1:
The power source is segmented into two components: a battery system for electric propulsion and a generator system for range extension. This allows the vehicle to achieve extended range without requiring a single large battery, thereby reducing weight while maintaining operational duration.
Solution Approach 2:
A generator system acts as an intermediary between the fuel tank and the battery/motor system. The generator converts chemical energy from fuel into electrical energy, recharging the battery or directly powering the motor, thus extending range without proportionally increasing battery weight.
2Duration of action of moving object
If range extender is incorporated to extend total range, then total range is improved, but fuel efficiency deteriorates
Solution Approach 1:
The vehicle operates dynamically in multiple modes: pure electric mode using battery power, and range extender mode using the generator. The system adapts between these modes based on range needs, allowing efficient short-distance electric travel while providing extended range capability when necessary, rather than operating continuously in an inefficient hybrid mode.
3Use of energy by moving object
If battery weight is reduced to improve vehicle efficiency, then fuel efficiency is improved, but electric-only range deteriorates
Solution Approach 1:
The generator system serves as a mediator that replenishes battery charge during operation. This allows the battery to be sized for efficient electric operation rather than for maximum range, since the generator can extend the effective range without requiring a proportionally larger battery.
4Use of energy by moving object
If engine displacement is reduced to improve fuel efficiency, then fuel efficiency is improved, but power output deteriorates
Solution Approach 1:
The mechanical engine drive system is replaced with an electrical generator system. The generator converts chemical energy from fuel directly into electrical energy, which then powers the electric motor. This substitution allows for a smaller, more efficient energy conversion system that maintains adequate power output through electrical rather than mechanical means.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The vehicle achieves a maximum range of up to 500 miles with a single tank of fuel, maintaining battery charge during operation, and offers improved fuel efficiency by correlating engine displacement with average power needs, reducing internal friction, and using roller bearings for reduced weight and increased efficiency.
Implementation Method 1
an on-board generator system... an engine generator assembly positioned under the side by side seating and electrically coupled to the battery
Implementation Method 2
an electric motor positioned rearward of the side by side seating and drivingly coupled to the rear wheels
Implementation Method 3
a fuel tank for storing fuel for the engine generator
Data Source
AI summary
A utility vehicle is disclosed having an electric drive. The drivetrain is comprised of batteries, a motor, a transaxle driven by the motor, a rear differential driven by the transaxle, and a prop shaft which is driven by the transaxle and drives a front differential. The batteries are provided in two groups and are supported on the frame of the vehicle. An on-board range extender is provided to charge the batteries and/or to provide power to the motor.