For smart cities using clean energy, optimal energy management has made the development of electric vehicles more popular. However, the fear of range anxiety—that a vehicle has insufficient range to reach its destination—is slowing down the adoption of EVs. The integration of an auxiliary power unit (APU) can extend the range of a vehicle, making them more attractive to consumers. The increased interest in optimizing electric vehicles is generating research around range extenders. These days, many systems and configurations of extended-range electric vehicles (EREVs) have been proposed to recover energy. However, it is necessary to summarize all those efforts made by researchers and industry to find the optimal solution regarding range extenders. This paper analyzes the most relevant technologies that recover energy, the current topologies and configurations of EREVs, and the state-of-the-art in control methods used to manage energy. The analysis presented mainly focuses on finding maximum fuel economy, reducing emissions, minimizing the system’s costs, and providing optimal driving performance. Our summary and evaluation of range extenders for electric vehicles seeks to guide researchers and automakers to generate new topologies and configurations for EVs with optimized range, improved functionality, and low emissions.

Electric vehicles must improve their electric drive system efficiency and effectively use their limited energy to become a viable means of transportation. As such, these technologies have undergone substantial improvements from their initial conception. More efficient powertrains, together with improved storage technologies, have enabled more extended autonomy. However, from an engineering perspective, these systems are still a key area of research and optimization. This work presents a powertrain optimization methodology, developing energy savings and improving the performance of the electric vehicle by focusing on the differential. The proposed methodology includes a study of the dynamics of the electric vehicle and the generation of a mathematical model that represents it. By simulating the vehicle and varying the final ratio of the differential, a significant optimization for energy savings is obtained by developing a standardized driving cycle. In this case, NEDC, WLTC-2, and WLTC-3 test cycles are used. The results show that a short ratio improves performance, even if this implies a larger torque from the prime mover. Depending on the operating cycle used, an energy-saving between 3% and 8% was registered. An extended energy autonomy and an increment in the life-cycle of the batteries are expected in real driving scenarios.