BLDC/PMSM Marine Range Extender System

1. Overview

The extended-range mode is currently widely used in new energy vehicles. The system consists of an oil-generating system (for example, Ideal Auto uses BMW’s 1.5T engine as a generator), an energy storage system and a high-efficiency BLDC/PMSM motor as the engine output. The extended-range mode is also suitable for the composition of the ship’s power system, especially for scenic sightseeing boats, passenger ships, etc.

2. How to Configure the Propulsion System According to the Size of the Ship

• For boats under 5 meters, including inflatable boats and small sailboats under 7 meters, an outboard motor with 1 kilowatt of thrust is generally suitable.
• For fishing boats, lure boats, small cleaning boats, and small sightseeing boats between 6 and 9 meters, an outboard motor with 3 to 6 kilowatts of thrust is generally suitable.
• For government vessels, cleaning boats, and large sightseeing boats between 9 and 15 meters, an outboard motor with 10 to 25 kilowatts of thrust is generally suitable.
• For government vessels, yachts, and single or double-hulled sailboats under 18 meters, an inboard engine with 10 to 40 kilowatts of thrust is generally suitable.
• For workboats, fishing boats, ferries, and medium to large sailboats between 18 and 30 meters, an inboard engine with 100 kilowatts of thrust is generally suitable.

3. Our Range-extended Propulsion System for Vessels

We adopt GenYuan’s self-developed photovoltaic range extender system. The input end is connected to photovoltaic panels (rooftop installation permitted), a diesel generator system. And the output is directed to energy storage and electric motors. Our exclusive E-Router technology is used for accurate energy distribution.

(1)When the vessel is stationary or operating at low power, the solar panels charge the battery, replenishing the energy storage.

(2)When the vessel is in operation, the photovoltaic energy is primarily used to directly drive the propulsion engine. Insufficient energy is supplied by the energy storage system. At this point, the system is in a dual-channel hybrid mode, rather than charging the energy storage with photovoltaic energy and then discharging it to the engine. The advantage of the dual-channel mode is that it eliminates the simultaneous charging and discharging process of the energy storage, significantly reducing the discharge current of the energy storage and greatly increasing its lifespan (an average 30% increase compared to the single-channel mode).

(3)When the energy storage is insufficient, the diesel generator system is activated to generate electricity. The diesel engine operates at its optimal coefficient of performance, typically 85% of its rated capacity. When the vessel is stationary, the diesel generator charges the energy storage. During vessel operation, the E-router enables a dual-channel power routing mode, directly driving the engine load. If the engine load is less than the diesel generator’s output, the surplus power is used to charge the energy storage. The diesel generator is shut down once the energy storage reaches 80% charge, and the remaining power is supplied by the energy.

Advantages of the above range-extender system:

• Flexible Energy Complementarity: E-Hybrid technology allows for the prioritization of energy sources for power supplementation.
• Precise Energy Distribution and Dual-Channel Operation: E-router technology enables precise energy distribution and dual-channel operation, simultaneously enhancing output capacity and significantly extending the lifespan of the energy storage system.
• Substantially Improved Vessel Range: The system significantly increases the vessel’s cruising range.
• Elimination of Range Anxiety: The ability to switch to fossil fuels when the battery is depleted ensures uninterrupted operation.
• Optimized Fuel Economy: The generator operates at its best coefficient of performance (COP), improving fuel economy.

4. Examples and Summary

Taking a 6-meter to 9-meter sightseeing boat as an example, we can typically install 1kW to 1.5kW of solar panels. The energy storage capacity is usually configured at 2 hours of rated power; for instance, a 3kW power system would generally be equipped with a 6kWh energy storage system.
Assuming 4 hours of effective sunlight, the solar panels can provide an additional 4-6kWh of energy, nearly doubling the cruising range and significantly reducing charging frequency. Additionally, a 3kW rated diesel generator system is configured to enable range-extended operation, eliminating range anxiety.
Our marine propulsion system, coupled with our unique range-extender solution, offers a superior solution for our customers.