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This paper forms the third of a series and presents results obtained during the testing and development phase of a dedicated range-extender engine designed for use in a compact-class vehicle. The first paper in this series used real-world drive logs to identify usage patterns of such vehicles and a driveline model was used to determine the power output requirements of a range-extender engine for this application. The second paper presented the results of a design study. Key attributes for the engine were identified, these being minimum package volume, low weight, low cost, and good NVH. A description of the selection process for identifying the appropriate engine technology to satisfy these attributes was given and the resulting design highlights were described. The paper concluded with a presentation of the resulting specification and design highlights of the engine. This paper will present the resulting engine performance characteristics.

Vehicle manufacturers are experiencing a shift in legislation and customer attitudes towards powertrain technologies. To support the pathway towards net-zero emissions by 2050, technologies that significantly reduce CO2 emissions will be needed. This will require increasing levels of electrification, and in the areas of compact cars and urban transportation, the adoption of pure battery electric powertrains is expected to become the dominant technology. For large passenger cars and light commercial vehicles (LCVs) meeting all customer requirements, including range, payload, towing capability, and purchase cost with a pure electric vehicle is challenging and requires the use of heavy and expensive battery packs, which have a high embedded CO2 content. The study builds on the work previously presented on the MAHLE modular hybrid powertrain (MMHP) concept and examines the suitability of this powertrain configuration to meet the future needs of large passenger cars and LCVs.