Electric mobilityFYP-1 completeFlagship FYP

Design and Integration of Chassis and Power-train for a Range Extended Electric Vehicle

Developing a REEV prototype for areas with limited charging infrastructure, combining electric propulsion with an engine-driven generator. FYP-1 established the architecture and integration methodology.

Concept illustration of a range-extended electric architecture; not a photograph of the completed project vehicle. View full resolution : Cutaway vehicle illustration showing an electric axle drive, battery, generator and auxiliary engine.

Engineering case study

The engineering brief

How can a REEV prototype retain electric propulsion while reducing dependence on charging access in areas with limited charging infrastructure?

Developing a range-extended electric vehicle (REEV) prototype for areas with limited charging infrastructure at Air University, Islamabad. The selected series architecture keeps the wheels electrically driven: the battery supplies a controller and traction motor, while a petrol engine runs a generator to support or recharge the electrical system when required. The engine has no direct mechanical connection to the wheels. A longer-term ambition is to build a startup that converts existing vehicles into REEVs; that conversion service is future work, not an available product.

Series architecture & integration

Compared battery-electric, hybrid and range-extended concepts through a literature review, then selected a series architecture for the proposed REEV prototype.
Defined the traction path as battery/DC bus → motor controller → electric motor → final drive and wheels. The engine-generator branch supplies electrical energy to the DC bus or battery; there is no mechanical engine-to-wheel path.
Identified the battery, traction motor, controller, petrol engine, generator, fuel tank and DC/DC converter, relating selection to voltage, current, torque and auxiliary-load requirements.
Set out a sizing method using vehicle mass, speed, acceleration and wheel radius for traction requirements, followed by battery voltage, current and energy-capacity considerations. Final compatible values remain later-phase work.
Defined integration and evaluation methodology around motor operation, battery support and generator charging response, with a conceptual state-of-charge flowchart for electric and generator-supported modes.

Design constraints

Battery, motor, controller and generator choices must form a compatible electrical system; the current deliverable establishes the selection method rather than a final hardware specification.
The project concerns component selection and integration. Manufacturing an engine, generator or traction motor is outside its stated scope.
The engine-generator range extender uses petrol, so the architecture is not a zero-emission vehicle claim.

What FYP-1 established

FYP-1 completed the literature review, architecture selection, component identification and sizing/integration methodology.
The block diagram and state-of-charge flowchart explain the proposed energy and control paths. The vehicle rendering communicates the concept, not completed construction.
No achieved driving range, finalized component ratings or completed vehicle demonstration is claimed.

Engineering takeaways

A series architecture separates mechanical propulsion from the range extender: both energy sources support one electric traction path.
Component sizing and integration must be considered together, rather than selecting a motor, battery and generator independently.

The remaining academic phases

FYP-2: carry out the design calculations and component sizing for the selected REEV prototype architecture.
FYP-3: develop the planned prototype, integrating the chassis and power-train and documenting its operation.
Longer-term vision: explore a startup that converts existing vehicles into REEVs. The startup has not launched, and commercial availability, road legality, range, efficiency and certification are not established.