Operational Review/Report

The objective of this task is to publish a report on operational performance and use the report to support exploitation.

Key results:

Video showing the CREEV Expander unit is bested to capture the performance data

At 5500rpm, SFC improved by 21% from previous Gen1 expander

288.83g/kWhr to 238.7 g/kWhr.

SFC Vs rpm; Gen1 & Gen2 Expander Comparison
SFC Vs rpm; Gen1 & Gen2 Expander Comparison

At 5500rpm, power improvement by 14% from previous Gen1 expander

18.32kW to 21.39kW.

SFC Vs rpm; Gen1 & Gen2 Expander Comparison
SFC Vs rpm; Gen1 & Gen2 Expander Comparison
Further work is required to develop the oil strategy to improve hydrocarbon emission for Euro6. 65db noise level is achievable, again further development required in post project activities.
Weight Analysis – 225CS/Expander QTY Weight (g) Total (g)
Core Engine 1 10780 10780
Induction System 622
Throttle Body w/TPS sensor 1 275 275
Ram pipe 1 259 259
Filter 1 60 60
Miscellaneous 1 28 28
Mounting System 870
Top Bracket 1 187.5 188
Bottom Bracket 1 67.5 68
AV Mounts 4 41.25 165
Miscellaneous 2 225 450
Sensor System 1 140 140
Ignition System 315
Coil 1 175 175
HT Leads 2 40 80
Spark Plugs 2 30 60
Lubrication System 2990
Oil Tank 2 895 1790
Oil Pump 4 140 560
Oil lines 2 138 276
Oil tank Clamps 2 125 250
Miscellaneous 1 114 114
Cooling System 2530
Radiator 1 655 655
Pump 1 645 645
Header Tank w/cap 1 380 380
Miscellaneous 1 850 850
Fuel System* 1359
Fuel Filter 1 1 228 228
Fuel Filter 2 1 50 50
Regulator 1 263 263
Pump 1 468 468
Miscellaneous 1 350 350
Electrical System 1060
ECU 1 395 395
Harness 1 665 665
Batteries 4 2.1 8
Exhaust System 118
Open Stub Pipe 1 118 118
Expander 1 10000 10000
Frame 1 48000 48000
Power Electronics 1 10300 10300
Motor Controller 1 4700 4700
Inverter 1 5600 5600
Generato 1 7500 7500
Total 96584
Weights table for demonstrator
With the demonstrator unit operational, AIE plans to present the unit at 2019 CENEX LCV show (https://www.cenex-lcv.co.uk/). In the past the electric van was incapable of reaching the LCV show (~100mile single journey) from AIE’s location without finding a suitable charging point on-route. This unit will allow AIE to achieve this and charge at any point.