The automotive industry is under pressure. It is subject to major, even disruptive, developments. The public perception of the automobile is changing, and it demands environmentally sustainable drive trains. In the context of this development, the electrification of the powertrain has taken the lead in the public discussion. It is also considered the strongest driving force from the perspective of the industry. However, today's sales numbers of electrified vehicles are strongly inhibited by high costs, a weak infrastructure and a short driving range. Even if the installed vehicle battery capacity allows a theoretical electrical driving range of 400- 500 km, the concern of limited range remains for a major part of the consumers. A sensible alternative to increasing the battery capacity further is to choose the opposite direction (smaller battery) and implement a range extender (REX). Analyzing the requirements for such an internal combustion engine, it is clear that it has to fulfil the same emission legislation as any other internal combustion engine. On the other hand it is to be assumed that NVH, weight, package and cost requirements for a REX would be even more stringent. This paper will investigate whether this is really the case. Based on the extremely compact and zero vibration V-REX concept developed by FEV in cooperation with Rheinmetall AG (formerly KSPG), this paper will additionally analyze the implications of using grey cast iron as a block material in the light of the boundary conditions explained above. The penalty of the extra weight will be balanced against possible benefits regarding NVH, compactness, fuel consumption and cost.
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