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Facts and figures

  • Full name: Optimised Modular Range Extender for every day customer usage
  • Acronym: OptiMoRE
  • Start date: 1/10/2012
  • End date: 30/9/2014
  • Funding EU: 2.7 M€
  • Total budget: 5.1 M€

About Optimore

The OptiMoRE project did take on the challenge to develop and optimise the concept of the fully integrated, range-extended, electrified light duty vehicle. Three different RE concepts have been developed and demonstrated to serve the niches from city vehicles, medium sized passenger cars up to light commercial vehicles.

Find the direct links to the three different concepts right here:


Objectives

  1. 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.
     
  2. RE fuel consumption and emission optimisation acting both on ICE and electric machine efficiency and RE utilization strategies. Emission target is to match half of EuroVI standard with a correspondent best BSFC of 230gr/kWh.
     
  3. Standardisation and modularization.

Main results

The three vehicle concepts are assessed based on real world driving cycles, regarding achievable all electric range total energy consumption and NVH. The vehicles have been tested and assessed on both the NEDC and ARTEMIS test cycles and under real driving conditions, developed in WP6.

Read more about the Functional Safety
Read more about the Optimisation of the range extender

In conclusion, 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 optimize range extenders for different vehicle niches and different usage profiles.

Project structure

WP 1 – Project management
Project coordination activities are included in WP1. A detailed description of management
structure and activities is provided in section 2.1.

WP 2 – Commercial Vehicle moving to efficiency in real driving cycles
To approach industrial sustainability, RE components will be improved and optimized to reduce costs, weight and volume and to improve efficiency. To increase system overall efficiency during vehicle lifetime also a optimized hybrid capability will be implemented in an optimized range extender control SW.


WP 3 – Modular electric range extender vehicle

A modular approach towards an electric vehicle, which can be equipped with either an extra battery, a Range Extender for extra urban use or an ICE turbo charged with gearbox Range Extender for longer trips. By this approach the electric vehicle can satisfy the needs of many potential customers.

WP 4 – City electric vehicle
Here, the approach is to develop an electric city vehicle equipped with a Rotary engine range extender. The operating system for the electric city vehicle will be adapted to real world operating conditions with special attention to user comfort needs and emission requirements. Reliability, performance and cost of needed hardware will be optimized and identified to reflect production intent material, cost and safety level.

WP 5 – Functional Safety Development
A functional safety concept will be worked out to assure safety in electric and hybrid vehicles containing a high voltage battery. Herein potential hazards due to torque handling of the appropriate control units as well as the high voltage contact safety will be considered. Potential risks will be minimized by both hardware and software measures.

WP 6 – Optimisation of range extender, battery size and control for different niches
The optimisation method and the analysis of optimal sizing for different vehicles are aimed to support the commercialization of the REX technologies, rather than to optimize the
demonstrator vehicles within OPTIMORE. The demonstrator vehicle will show that the
technologies meet the expectations, while the ability to define attractive and cost effective REX systems for a wide set of vehicles will be demonstrated through a theoretical simulation study.

WP 7 – Dissemination
Main objective of this work package is to establish an appropriate and effective communication of the project results to relevant stakeholders and the automotive community in general.

 

 

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This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 314252

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