Lotus to Unveil Range-Extending Engine-Generator for Hybrids at Frankfurt Show

Lotus Engineering announced today that it will unveil a range-extending engine-generator for series hybrid vehicles at the Frankfurt Motor Show, held later this month.

Attached to the hybrid's electric motor via the crankshaft, the Lotus Range Extender sustains vehicle operation beyond the range provided by the vehicle's batteries.

Lotus said in a statement that the 1.2-liter, three-cylinder engine-generator can use gasoline or alcohol-based fuels, was designed for maximum fuel efficiency and can recharge the batteries of a series hybrid as well as provide direct power to the electric motor that propels the vehicle.

The Range Extender features an innovative architecture comprising aluminium monoblock construction, integrating the cylinder block, cylinder head and exhaust manifold in one casting. Lotus said this results in reduced engine mass, assembly costs, package size and improved emissions and engine durability.

The engine-generator is optimized between two power generation points, giving 15 kilowatts of electrical power at 1,500 revolutions per minute and 35 kilowatts at 3,500 rpm via the integrated electrical generator.

Lotus said the Range Extender's low weight (123 pounds) makes it ideal for the series hybrid drivetrain configurations for which it is designed. The engine uses an optimized two-valve port-fuel injection combustion system to reduce cost and mass.

Lotus said that for successful market reaction to series hybrid vehicles with an acceptable driving range, automakers must overcome the challenges of high vehicle cost.

The Range Extender engine-generator not only offers the advantage of a cost-effective design, Lotus said, but also its high efficiency and low mass will enable the downsizing of expensive batteries whilst maintaining vehicle efficiency and range.

Lotus also said that the engine-generator was designed using production methodologies and parts procured from low-volume potential production suppliers to offer  a fast route to market for original equipment manufacturers wanting to source a dedicated range extender for series hybrid vehicles.

Clearly, the British automaker intends to sell the Range Extender to other manufacturers. There's no word yet on the price of the unit. Some technical details follow:

General - 1.2 liter 3-cylinder with 2 valves per cylinder, SOHC Belt driven;

Construction - Monoblock with integrated all-aluminum exhaust manifold;

Maximum power - 35 kilowatts (47 base horsepower) at 3500 rpm via integrated electrical generator;

Peak torque - 79 pound-feet at 2500 rpm;

Maximum Engine Speed - 3500 rpm.

Posted by

Scott Doggett September 8, 2009, 12:25 PM

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