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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Abbreviations
- c :
-
spring constant, Nm/rad
- d :
-
damping constant, Nm/rad/s
- i :
-
current, A
- J :
-
mass inertia, kg/m2
- L :
-
inductance, H
- n :
-
rotational speed, 1/min
- P :
-
power, W
- p :
-
number of pole pairs, 1
- r :
-
radius, m
- R :
-
resistance, Ω
- T :
-
torque, Nm
- u :
-
voltage, V
- v :
-
velocity, m/s
- θ :
-
phase angle, rad
- ρ :
-
density, kg/m3
- σ :
-
stress, N/m2
- τ :
-
time constant, s
- Ψ :
-
magnetic flux linkage, Vs
- ψ :
-
angle, rad
- ω :
-
angular velocity, rad/s
- I, II:
-
primary/secondary side
- a, b, c:
-
phase quantities in the three phase system
- B:
-
combustion
- CD:
-
combustion duration
- CS:
-
combustion start
- d:
-
direct axis
- DMF:
-
dual mass flywheel
- el:
-
electrical
- F:
-
permanent magnet excitation
- GB:
-
gear box
- i:
-
current control loop
- ICE:
-
Internal combustion engine
- max:
-
maximum value
- n:
-
nominal value
- R:
-
radial
- s:
-
stator domain
- ST:
-
connecting rod
- T:
-
tangential
- tot:
-
total
- PMSM:
-
permanent magnet synchronous machine
- q:
-
quadrature axis
- red:
-
reduced
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Herold, K., Böhmer, M., Savelsberg, R. et al. Range Extender Module Transmission Topology Study. Int.J Automot. Technol. 19, 869–878 (2018). https://doi.org/10.1007/s12239-018-0084-2
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DOI: https://doi.org/10.1007/s12239-018-0084-2