Design and Optimization of Extended-Range Electric Vehicles: A Simulation-Based Approach

Abstract

Electric Vehicles face challenges such as limited driving range, long charging times, and high costs. In this regard, this study proposes converting a fully Electric Vehicle (EV) into an Extended-Range Electric Vehicle (EREV) by integrating an Internal Combustion Engine (ICE) to power an alternator for battery charging. A simulation-based Sequential Quadratic Programming (SQP) framework is employed to optimize battery capacity and alternator current. The optimization results showed a reduction in battery capacity by $68.6 \%$ and $71.9 \%$ from the fully electric configuration for highway and urban routes, respectively, and by $21.4 \%$ and $29.8 \%$ from the initial EREV configuration. Furthermore, the optimization ensured that the State-Of-Charge (SOC) consistently remained above $40 \%$ throughout the operation, guaranteeing stable and reliable performance across varying driving scenarios while achieving reduced weight and improved energy efficiency.