In the rapidly evolving world of electromobility, IAV stands as a leading partner for innovation and progress. With a deep understanding of both the modern world of battery electric vehicles (BEV) and the traditional powertrain roots, IAV offers a unique perspective on the development of Range Extended Electric Vehicles (REEVs). Dr. Alexander Fandakov, Team Lead Battery & E-Traction at IAV, describes the challenge: "The electric drivetrain along with the energy storage system has advanced significantly, but range anxiety remains. Also, the supposedly poorer infrastructure and longer 'charging times' deter potential buyers. This is where we come in." 

The challenge of range anxiety

The challenge of the - mostly subjective - feeling of being restricted remains a central issue for many potential electric vehicle owners. While internal combustion engine vehicles offer seemingly endless range, BEVs have to cope with the limited capacity of their batteries. They also take longer to recharge due to technology constraints. IAV pursues an approach with the Range Extender to overcome this bias. "We want to enable customers to have a BEV with 'quasi infinite perceived' range, without it being more expensive than a conventional BEV. Ideally, the REEV is only slightly more expensive than the entry-level BEV and definitely cheaper than the top variant in the vehicle configurator," explains Dr. Fandakov. "And the customer wants such a vehicle here and now." IAV's approach is based on scalability of existing platforms, with a combustion engine being integrated into an electric vehicle. 

Integration of Range Extenders: A technical masterpiece

Integrating an existing engine as a Range Extender into a BEV is a technical challenge. A tailored new development is expensive and time-consuming. And a BEV is fundamentally different from a combustion vehicle - from aerodynamics to the platform itself  with the battery in the underbody. So how do you design the package? How about the peripherals? Also, a state-of-the-art combustion engine is not designed to act as a Range Extender. 

Variety of concepts: IAV's tailored solutions

IAV shows a range of possible paths towards a REEV concept and does not develop just one concept. No matter which path is taken, IAV can help develop it. Whether it's a specially designed engine, the integration of an existing one, an adapted battery, a highly intelligent operating strategy, or optimal thermal management - IAV has the expertise. And this is true from the perspective of both OEMs and suppliers. The top priority: The BEV feeling must remain. "It's about designing the vehicle so that it still feels like an electric car - quiet, with lots of torque, low maintenance, and without vibrations or noise," emphasizes Dr. Fandakov. "The REEV increases the attractiveness while simultaneously preserving the BEV’s core identity." 

The market demands more: Powerful Range Extenders

Previously, optimized, often small engines were used as Range Extenders. Out of necessity. The battery technology was not yet developed enough at that time, and many compromises had to be made at the end of the day. But these vehicles found little acceptance, the market wanted and wants something else - strong acceleration and no performance penalties. "Customers are demanding, and rightly so, after all, they have paid a considerable amount for their vehicle. They don't want to notice whether they are driving purely electrically or with Range Extender support. Neither in city traffic nor on the highway - customers do not tolerate performance losses," says Dr. Fandakov. IAV plans all solutions with powerful Range Extenders that offer at least 80 kW. 

REEVs: Enabler for increasing BEV sales

The new generation of REEVs represents an excellent opportunity to combine the advantages of BEVs and combustion vehicles. REEVs can reduce the CO2 fleet value and offer a purely electric range that is smaller but still large enough for almost 100% of cases. And should the stored energy run out, the Range Extender comes into play. 

The trend of REEVs is here, and IAV is already shaping it today. If this trend continues, there will be a second generation - possibly in combination with reFuels. At a time when many manufacturers are still developing BEVs and combustion vehicles in parallel, IAV is the partner that enables customers to have a BEV with quasi-infinite range. 

Our expert on the topic

Alexander Fandakov
alexander.fandakov@iav.de 
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