High-Efficiency methanol-powered Range Extender System for Electric Vehicles – Advanced Performance, Ultra-Low Emissions, and Exceptional Reliability
This cutting-edge range extender engine delivers unmatched efficiency, lightweight engineering, and environmental sustainability—making it ideal for modern electric mobility solutions. Designed with a focus on performance optimization and Clean energy utilization, this system integrates advanced combustion technologies, modular architecture, and rigorous durability testing to exceed global standards in Fuel economy, noise control, and emissions reduction.
Key Features:
- Industry-Leading Thermal Efficiency (45.96%): The engine achieves a peak thermal efficiency of 45.96%, while the motor operates at up to 97.44% efficiency, ensuring minimal energy loss during power conversion. This makes it one of the most efficient internal combustion units available for hybrid-electric applications.
- Ultra-Lightweight Construction: Engineered using aluminum components—including the cylinder head cover, Oil pan, turbocharger intake manifold, and flywheel housing—the system reduces overall mass without compromising structural integrity or heat dissipation capabilities.
- Modular Design for Easy Integration: With a dedicated machine cooling module and air intake system aligned with crankshaft dynamics, installation and maintenance are streamlined across various vehicle platforms, from light-duty EVs to commercial fleets.
- Exceptional NVH Performance: At steady-state operating points of 20 kW and 150 kW, sound pressure levels remain below 70.5 dBA and 90.2 dBA respectively—significantly quieter than comparable competitors in the market.
- Ultra-Low Operating Costs: Utilizing theoretical air-fuel ratio closed-loop control and multi-point fuel injection strategies, this unit optimizes combustion efficiency, reducing fuel consumption by up to 40.2% compared to traditional Diesel Engines—a major cost-saving advantage for fleet operators and long-range transport systems.
- Proven Longevity (B10 Life ≥1.5 Million Kilometers): Through comprehensive CAE simulations and real-world validation, the engine is built for endurance under demanding conditions, offering reliability that exceeds industry benchmarks for extended service life.
- Near-Zero Emissions Technology: Powered primarily by M100 Methanol—a renewable, cleaner-burning alternative to gasoline and diesel—this engine cuts CO, HC, and NOx emissions by over 95%, positioning it as a sustainable solution for zero-emission transportation goals.
Detailed Technical Specifications:
The range extender features a four-cylinder inline configuration with a displacement of 5.91 liters (112 mm bore × 150 mm stroke), delivering a rated output of 180 kW at 2000 rpm and maximum torque of 950 Nm between 1200–1500 rpm. It supports a no-load speed of 2200 ± 50 rpm and idles at 700 ± 50 rpm, enabling smooth transitions between charge and discharge cycles. The total engine weight (without fluids) is just 525 kg, contributing to improved vehicle efficiency. Fuel flexibility includes primary use of pure methanol (M100) with optional gasoline assistance for cold starts, though advanced coolant heating systems allow reliable operation without auxiliary fuels. Exhaust temperatures stay below 620°C, enhancing longevity and safety. The system supports a 600 V electrical platform with a continuous current rating of 220 A and a maximum generation capacity of 150 kW, making it compatible with high-voltage battery packs used in next-generation electric vehicles.
Optimal Use Cases:
This range extender is engineered for integration into plug-in hybrid electric vehicles (PHEVs), extended-range electric vehicles (EREVs), and specialized utility vehicles requiring sustained power delivery without frequent refueling. Ideal for urban transit buses, delivery vans, and off-grid power generation units, its combination of low emissions, high efficiency, and quiet operation ensures compliance with strict environmental regulations in Europe, North America, Australia, and other regions. Its modular design allows seamless adaptation to different chassis configurations, from compact city cars to heavy-duty logistics vehicles.
User Feedback Highlights:
Operators across European and North American markets have praised the system’s consistent performance in diverse climates—from Arctic winter conditions to desert summer environments. Users report reduced downtime due to fewer mechanical failures, lower maintenance expenses, and improved driver satisfaction thanks to the quiet cabin experience. Fleet managers particularly appreciate the significant savings in fuel costs and the ability to meet stringent emission targets set by regulatory bodies such as the EPA and EU Commission.
Frequently Asked Questions:
Is methanol safe to handle? Yes, when stored and handled according to standard safety protocols, methanol is stable and non-toxic in controlled environments. Modern storage tanks and handling systems ensure safe usage in both industrial and consumer settings.
How does this compare to diesel engines in terms of running costs? On average, users see a 40.2% improvement in fuel economy versus diesel counterparts, translating into substantial savings over time, especially for high-mileage operations like public transit or freight services.
Can it be integrated into existing EV platforms? Absolutely. The modular architecture, standardized mounting points, and compatibility with 600 V electrical systems make retrofitting or new development straightforward for manufacturers aiming to enhance vehicle range without redesigning core drivetrain components.
What kind of maintenance is required? Routine checks include monitoring coolant levels, inspecting fuel lines, and verifying proper functioning of the electronic control unit (ECU). Due to its robust design and high-quality materials, maintenance intervals are longer than those of conventional internal combustion engines, further reducing lifecycle costs.
