Range extender for a 48V-electric vehicle

Prototype of the range extender for a light commercial 48V electric vehicle (Melex 945 DS). Stable working (not final) version. Design consist of 4-stroke single cylinder spark ignition engine (163 ccm) + ribbed belt transmission + 3-phase AC generator (formerly 28V) + 6-diode rectifier + control system. Red LCD - battery voltage, Green - charging current, blue - engine rotational speed.
Engine has electric starter and a motorcycle muffler with three-way catalytic converter. AFR control implemented, so exhaust is relatively clean.
Result of the works of Science club "Internal combustion engines" at Cracow University of Technology.

[@pcpatel01]

Wonderful project

[@zumunta1]

The Honda GX160 engine is not very efficient it produces far more pollutants and carbon emissions than a 2 liter Toyota engine however you could improve efficiency greatly by modifying the inadequate ignition system, I ran a project on one of these engine a few years ago, I fabricated a plasma ignition system with a 4.5mm spark plug gap and ran a Propane carburetor but instead of using propane I ran it on Gasoline vapor. The vapor was generated by by a vacume pump I was able to run super lean fuel air mixtures with this set up. Full load fuel consumption went from 7 hours per gallon to 10.5 hours per gallon, CO, CO2 and NOX emissions where all drastically reduced too.

[@nuki1980]

Of, course this engine is initially not efficient and has huge emissions. We have added simple AFR control (additional air downstream from the carburetor) and muffler with three-way catalytic converter. Now engine is fed with a stoichiometric mixture, so efficiency is improved and it allowed decrease of emissions by TWC. If future an applicaction of a full-variable engine management system (EMS) with fuel injection is planed. We think also of feeding with hydrogen to not have CO2-emissions, but it would be much more difficult than adding of EMS.

[@zumunta1]

@@nuki1980 This is an interesting project I would fit a system like this in a Tesla Model 3 if I could afford one lol. However one of the biggest problem with this engine is the carburetor, it suffers from bad atomization fuel droplets are too large to burn completely so additional air will just worsen this as it will drop air speed at the Venturi, additionally as I said before the ignition system is woefully inadequate its impossible to burn all the fuel in the combustion chamber with the standard ignition system but with plasma ignition you can run lean burn ratios without overheating problems, hope this advice helps.

[@nuki1980]

@@zumunta1 What is so funny for you? Have you read the description? This is developed not for Tesla Model 3, but for teaching purposes. Many issues are to be resolved in this project in field of mechanical engineering, combustion engines, electrical engineering, electronics, control systems, programming, etc. Development of this range extender is a good opportunity for students to learn many things in practise. It is better to fix GX160 engine, or golf cart than even the cheapest electric car.

[@zumunta1]

@@nuki1980 You dont understand I am in support of this project that is why I am giving you more clues, I am not criticizing to be honest I am not really a fan of electric cars they are good for short trips in the city but they are very boring. I believe petrol engines make more sense if they are well designed they can be more environmentally friendly than electric motors when you consider the impact of producing batteries. If students can learn how to make better petrol engines through your project that is really great

[@nuki1980]

@@zumunta1 Excuse me. I didn't catch your words correctly. I am not a very big fan of electric cars too, but whether we like it or not electric drives will supersede combustion engines in road vehicles. With this project we would like to be somewhere in the middle (closer to combustion engines). Regards.

[@carlitomadrona6211]

Haha like it. Electric vehicle with ICE👏👏👏

[@gorlier5388]

The first BMW i3 prototype 🤣

[@mavrigs2964]

Vegan who eats beef behind curtains

[@cueQu]

if you scaled this up, you could do this with a used suv. gas engine runs the gen. think its possible. its called series hybrid

[@MAG8163]

Hi! What type of 48v alternator did you use? fancy project :)

[@nuki1980]

Hello! It was 28V generator from a truck with an external (DIY) controller, so 48V, even over 60V at the end of charging is possible.

[@bmw328igearhead]

This application was achieved by removing the internal rectifier assembly from the stock alternator, and feeding the unrectified 3phase high voltage AC to a different (external as mentioned) charge controller. That controller outputs 48/52vDC instead of 24/28vDC. Most alternators can be modified in this manner, provided the rotor windings are fed native voltage to power the rotors electromagnets. PMA units do away with the electromagnets in favour of high strength neodymium magnets. So you no longer need slip rings, brushes, and source voltage.

[@abdul-kabiralegbe5660]

​@@bmw328igearhead Thank you! Very important explanation.

[@bmw328igearhead]

@@abdul-kabiralegbe5660 Happy to oblige! If you learned anything from my jibbering, it only makes me smile. Thank you for the kind words. May peace and safety be upon you, in every facet of life.

[@andreacecchetto5748]

Hello any chance to have more information? Thanks

[@nuki1980]

Hello, Some more detailed information about this project you can find here: www.combustion-engines.eu/entityfiles/files/articles_published/2019-220.pdf

[@martinmartin5904]

@@nuki1980 your link doesn't work : ''The requested page doesn't exist''

[@nuki1980]

@@martinmartin5904 try this one: www.combustion-engines.eu/Development-of-the-range-extender-for-a-48-V-electric-vehicle,116371,0,2.html

[@abdul-kabiralegbe5660]

​@@nuki1980 Thanks!

[@akbarmas__far1211]

Hello.pls show me electrical diagram and equipment s

[@akbarmas__far1211]

29v change to 60v and batries charging?

[@nuki1980]

@@akbarmas__far1211 The generator has new voltage regulator and rectifier in order to charge 48V batteries (~60V needed at the end of charging).

[@ChandanKumar-xn4uz]

इसके बारे मे विस्तार में जानकारी देने का कस्ट करें

[@nuki1980]

Just copy and paste the following titles in google: 1. The Effects of Use of the Range Extender in a Small Commercial Electric Vehicle 2. Development of the range extender for a 48 V electric vehicle PDFs of these papers are in open-access. Hope this helps you.

[@Jcruce7122]

You do realize, your running a MOTOR why not just buy a NON electric, you simply reversed the processed of getting from a to b 😂

[@bashithabashitha4535]

Electric is fell