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Title: Development of a range-extended electric vehicle powertrain for an integrated energy systems research printed utility vehicle

Rapid vehicle and powertrain development has become essential to for the design and implementation of vehicles that meet and exceed the fuel efficiency, cost, and performance targets expected by today’s consumer while keeping pace with reduced development cycle and more frequent product releases. Advances in large-scale additive manufacturing have provided the means to bridge hardware-in-the-loop (HIL) experimentation and preproduction mule chassis evaluation, recently. Our paper details the accelerated development of a printed range-extended electric vehicle (REEV) by Oak Ridge National Laboratory, by paralleling hardware-in-the-loop development of the powertrain with rapid chassis prototyping using big area additive manufacturing (BAAM). BAAM’s ability to accelerate the mule vehicle development from computer-aided design to vehicle build is explored. The use of a hardware-in-the-loop laboratory is described as it is applied to the design of a range-extended electric powertrain to be installed in a printed prototype vehicle. Furthermore, the integration of the powertrain and the opportunities and challenges it presents are described in this work. A comparison of offline simulation, HIL and chassis rolls results is presented to validate the development process. Chassis dynamometer results for battery electric and range extender operation are analyzed to show the benefits of the architecture.
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  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Publication Date:
Report Number(s):
Journal ID: ISSN 0306-2619
Grant/Contract Number:
AC05-00OR22725; AC36-08GO28308
Published Article
Journal Name:
Applied Energy
Additional Journal Information:
Journal Volume: 191; Journal Issue: C; Journal ID: ISSN 0306-2619
Research Org:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Fuels, Engines and Emissions Research Center (FEERC); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). National Transportation Research Center (NTRC); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF); National Renewable Energy Lab. (NREL), Golden, CO (United States)
Sponsoring Org:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (EE-5A)
Country of Publication:
United States
33 ADVANCED PROPULSION SYSTEMS; printed vehicle; range extender; additive manufacturing; rapid prototyping; hybrid vehicles; natural gas
OSTI Identifier:
Alternate Identifier(s):
OSTI ID: 1342672; OSTI ID: 1352993