Engine Assembly (Base Structure): The load-bearing core of the unit, serving as the mounting base for all moving and stationary components.
Valvetrain (Intake/Exhaust Control): Responsible for opening and closing valves according to timing schedules to regulate the intake of the air-fuel mixture and the exhaust of combustion gases; range extenders typically utilize a Dual Overhead Camshaft (DOHC) configuration.
Intake System: Supplies clean air to the cylinders; range extender systems prioritize high-efficiency intake during low-load operation.
Fuel Supply System: Predominantly Gasoline Direct Injection (GDI), with some port injection applications; designed to meet the ultra-low fuel consumption requirements of hybrid vehicles.
Exhaust System: Discharges combustion gases while managing noise, emissions, and thermal regulation.
Ignition System (Gasoline Engines Only): Equipped only on gasoline-powered range extenders; diesel range extenders utilize compression ignition and do not require an ignition system.
Cooling System: Designed for the range extender's long-duration, steady-state operation and stable thermal load; the system focuses on maintaining a constant operating temperature.
Lubrication System: Provides friction reduction, cooling, cleaning, and sealing for moving parts; the range extender operates within a narrow RPM range, allowing for a simplified lubrication strategy.
Electronic Control System (System "Brain"): The core control unit; unlike traditional internal combustion engines, it operates through full integration with the vehicle's master controller.
Power Generation Coupling Mechanism (Unique to Range Extenders): A critical, exclusive component not found in traditional engines; the engine drives only the generator and is mechanically disconnected from the vehicle's wheels.
The fuel injection control system is responsible for precisely controlling injection timing, quantity, pressure, and frequency; by matching these parameters to varying loads and engine speeds, it achieves fuel savings, reduced emissions, and stable combustion.
The range extender's ignition and fuel injection control system comprises four core components: the engine ECU, actuators, various sensors, and the CAN communication network. Unlike traditional internal combustion vehicles, the range extender does not provide direct drive to the wheels; instead, its load, start/stop operations, and rotational speed are governed entirely by the vehicle control unit (VCU) based on battery state-of-charge and overall power demand. The ECU focuses solely on executing power output control, operating under more consistent conditions and prioritizing steady-state operation within high-efficiency ranges. Mainstream configurations utilize gasoline direct injection (GDI) combined with an independent ignition system.
The fuel injection control system precisely manages injection timing, quantity, pressure, and frequency—adjusting to varying loads and speeds—to optimize fuel economy, reduce emissions, and ensure stable combustion.
The ignition control system generates a high-voltage spark near the top dead center (TDC) of the compression stroke to ignite the air-fuel mixture and drive the piston to perform work. Range extenders predominantly utilize independent ignition (one ignition coil per cylinder) and do not employ a distributor.
Coordinated control of the fuel injection and ignition systems—the core logic of the range extender—ensures the two systems operate in perfect synchronization. They are centrally managed by a single ECU and work in concert with the vehicle VCU, Battery Management System (BMS), and generator controller to ensure integrated system operation.
| Vehicle Brands & Models | Range extender models | Spray type | System working pressure | Injector assembly model | fuel injector assembly model | core suppliers | Supplementary Explanation |
|---|---|---|---|---|---|---|---|
| Ideal L6/L7/L8/L9 | L2E15M 1.5T | GDI direct injection cylinder | 350bar | 0445110951 / 0445110952 | DLLA145P2287 | Bosch | 4/6 wells, compatible with Miller cycle, atomized particle size ≤8μm |
| Wenjie M5/M7 (older models) | H15RT 1.5T | Multi-point fuel injection (MPI) | Approximately 4 bar | 0280156403 | - | Bosch | 6-hole low-pressure fuel injector |
| Wenjie M8/M9 (New Model) | HG15T 1.5T | GDI direct injection cylinder | 350bar | 0445110987 | DLLA150P2301 | Bosch | Seres' self-developed 1.5T range extender |
| Voyah Free / Chasing the Light | DAM15NTEDU 1.5T | GDI direct injection cylinder | 350bar | 0445110899 | DLLA148P2259 | Bosch | Compatible with Dongfeng DFMC15TE3 model |
| Deep Blue SL03/S7 | JL469Q1 1.5L Naturally Aspirated | Multi-point fuel injection (MPI) | Approximately 4 bar | 23250-0P010 | - | Denso | 12-hole low-pressure fuel injector |
| Deep Blue G318 | Blue Whale 1.5T | GDI direct injection cylinder | 500bar | EX631234 | L245PBC | Delphi (Fenia) | High-pressure direct injection models |
| Star Journey Star Era ES/ET | SQRH4J15B 1.5T | GDI direct injection cylinder | 350bar | 0445110923 | DLLA143P2245 | Bosch | High thermal efficiency model, compatible with 92# gasoline |
| Multiple entry-level range extender models | Dong'an M15NTDE 1.5L | Multi-point fuel injection (MPI) (Dual PFI) | Approximately 4 bar | A2C59513558 | - | Siemens VDO | 8-hole layout, suitable for entry-level consumer models. |
| Jetour/Mountain and Sea Series | 1.5T turbocharged range extender | GDI direct injection cylinder | 350bar | 0445110857 | DLLA152P2213 | Bosch | Mainstream economy 1.5T range extender matching |
Check out our recommended fuel injectors, or contact us directly for expert advice.
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