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Gasoline engine downsizing is already established as a technology for reducing vehicle CO2 emissions. Further benefits are possible through more aggressive downsizing, however, the tradeoff between the CO2 reduction achieved and vehicle drivability limits the level of engine downsizing currently adopted by vehicle manufacturers. This paper will present the latest results achieved from a very heavily downsized engine, and resulting demonstrator vehicle, featuring eSupercharging in combination with a conventional turbocharger. The original 1.2 litre, 3-cylinder, MAHLE downsizing engine has been re-configured to enable a specific power output in excess of 160 kW/litre. Of key importance is a cost effective, efficient and flexible boosting system.

This paper, which is the fourth of a series, presents the REEV demonstrator vehicle developed by MAHLE Powertrain, which features a specifically designed range extender unit. The previous papers describe the specification setting, detailed design and the development of the range extender engine. A current production gasoline fuelled compact-class car was used as a donor vehicle and converted into a range-extended electric vehicle (REEV). The all-electric driveline specification has been developed to meet the performance criteria set for the demonstrator, matching the acceleration and maximum speed capabilities of the conventional donor vehicle. Also, a target electric only range has enabled the battery pack capacity to be specified. The resulting vehicle is intended to reflect likely, near to market, steps to further the wider adoption of electric vehicles in the compact-class passenger car segment.