BMW Working on a REx Upgrade to Increase Performance

The 650cc twin cylinder engine used in the i3 is borrowed from BMW's Motorrad division and modified for the REx

From the first word that the North American version of the i3 REx would have restrictions not found on its European counterpart, i3 enthusiasts and customers in the US and Canada have wondered how well it would work under strenuous driving conditions.

In fact, it is by far the topic I now get the most correspondence over. I have probably received over 100 emails through this blog from followers that want to know how well the range extender works and how capable it is. People want to know things like what speed the car can maintain in charge sustaining mode and for how many miles can the car maintain highway speeds on a certain percentage upgrade, and so on. I even have had people ask me if I could conduct specific tests with my car to confirm it can do what they need it to. The reason being is the 34hp REx engine can only deliver about 25kWs (although some reports say BMW upped it to 28kWs) of power. That is plenty of power for nearly all normal driving needs, but not enough for continued high speed or long upgrade driving. The problem then arises if you continue to consume more energy than the REx can deliver.

My i3 when the REx turns on. Notice the tiny little bar of electric reserve to the left of the triangle. That indicates the 6.5% SOC position where the REx initiates and tries to maintain. There isn't a lot of buffer there for strenuous driving conditions.

The root of the problem reverts back to BMW's desire to have the i3 REx certified a BEVx vehicle by the California Air Resource Board. This allows BMW to get the most ZEV credits per vehicle, and also allows the i3 REx to qualify for other perks, like sales tax exemption in New Jersey and Washington State. It also allows the owner to get the full $2,500 California CVRP rebate, unlike all other PHEVs which only get $1,500. However this came with a cost, one that everybody with an i3 REx from every state has to endure. BMW had to restrict the REx use to comply with CARB's BEVx classification. The European i3 REx can be manually turned on any time the state of charge is lower than 75%. This is called a Hold Mode and allows the driver to hold a higher state of charge and keep a higher battery buffer which they may need for continued strenuous driving conditions later in the journey. The North American version has no Hold Mode, and the range extender only comes on when the battery is reduced to a critically low 6.5%. For normal driving that is fine, but when really pressed for continued periods, the car cannot maintain full power.

The European i3 REx has a Hold Mode which allows the driver to manually turn on the range extender if they need to. This feature is disabled for North America and is that is the root of the problem.

This creates a problem when the driver needs to drive for an extended period which demands an energy draw of more than 25kWs. The meager 6.5% battery reserve can quickly deplete in these conditions. When this happens, the car goes into a reduced power mode and can only maintain a speed of about 40mph. To make matters even worse, the driver gets no warning and the car just slows down. This is not what you want happening to you when you are on a highway and cars are whizzing by you at 70mph. This is a real issue, and compounded by the problem that most BMW client advisers didn't know how to communicate this to the customers and sold them the cars without informing them how to properly operate the vehicle in REx mode. I've had people contact me that were completely unaware of how the range extender worked and said they were told by their client adviser that "the car can do anything in range extender mode as it can in all electric mode, it just doesn't have quite as much power." That isn't true, and many early i3 REx customers were disappointed when they found out they couldn't drive up that mountain to their summer home, for example. In fact, one the Born Electric guest bloggers here mentioned an instance where he went into reduced power mode with a car full of friends.  

Don Parsons of Denver, Colorado recently took his i3 REx to the summit of Mt Evans which is the highest elevation with paved road in the US. He did experience the REx reduced power mode, but it didn't stop him from completing the14,000 ft ascent to the summit. This, of course is about as taxing on the range extender as it gets!

All that said, I now have over 10,000 miles on my i3 REx and not once have I ever gone into reduced power mode, and I've actually tried to make it happen! The "problem" I'm having is the highways are relatively flat here in New Jersey and the REx can basically handle anything I give it. The times I have tried to make it happen the flow of traffic wasn't fast enough for me to maintain a speed of over 75mph for a long enough period. 75 mph on relatively flat ground seems to be the upper limit the REx can handle for continued driving. There is plenty of energy to go up and down the hills I routinely drive over, and also to have short bursts of power well past 80 mph for passing if needed in REx mode, so for me the car works perfectly and I really don't need a modification. However my friends in California and other areas of the country that have long, steep inclines to negotiate disagree, and want to see some kind of modification to allow the range extender to turn on at a higher state of charge so the vehicle has a larger electric buffer. In fact, there will soon be a two-part post here by an i3 Rex owner in California that has been obsessing a bit over this very topic. (well, I call it obsessing, he calls it studying - I'll let you be the judge when you read his post next week!)

The Chevy Volt has a much more robust range extender engine and can operate under just about any condition without an issue. However it has about half the electric range as the i3 REx, meaning you will need to use it much more, so it has to be more capable. With a 70-80 mile all electric range, most i3 owners will not need to use the REx frequently.

So now that we understand the problem, what is the solution. Should BMW simply give up the value of the BEVx designation and allow the driver to initiate Hold Mode as the European i3 REx owners can? That isn't happening as far as I can tell. What I do believe is going to happen? Well for starters there will be software updates that include better indicators that the car may be headed to reduced power mode if you don't take action to alleviate it. Perhaps by slowing down 5-10 mph you can completely avoid having a problem at all. I also expect there will be a better state of charge display so the driver has more accurate display of how much power they have left. I would also love if BMW could add a display that would show the actual power draw you are using, so the driver can see if they are drawing more energy than the REx is producing. That would be an awesome tool for the driver to use in these situations and I do hope the BMW engineers consider adding it.. However I'm saving the best for last. It is my belief that BMW is working on an update that will indeed allow the range extender to turn on much earlier than the 6.5% threshold if the car determines you will need the extra power. This will work with the navigation system which accounts for topography. Once a destination is entered, the car will determine how early the REx will need to be turned on so it avoids reduced power while climbing an upgrade at the end of the journey. 

The i3's range extender sits next to the electric motor above the rear axle

While this isn't quite as good as having the ability to manually turn on the range extender, it's pretty close. The bottom line is people just want to be able to get to their destination without worry of a reduced power "slowdown" while driving on the highway. If the modifications that BMW are working on do indeed work, I don't think anyone will complain. In fact, I've privately asked this very question to quite a few current i3 REx owners and every one said as long as it works, and they can use the car to drive up long, sustained inclines at highway speeds, then they'll be very happy. From what I understand the update could be available as early as the first quarter of 2015 and will indeed be available as a software update to existing i3 REx owners.Of course it would have been better if this was available right from the launch, but at least BMW is working quickly (the i3 has only been available for about five months in North America) to correct the problem.

My New Side Job: BMW i Dealer Training

It's -2 degrees F here in Canada and I'm talking BMW i3 at Budd's BMW in Oakville!

I've written a few posts on my blogs about how poorly many dealerships have done when it comes to selling their electric car offerings. I blasted Nissan and GM pretty good a while back and had hoped that BMW would learn from the mistakes the other OEM's made when they rolled their EV's into their dealers' showrooms. However I'm starting to wonder if that will be the case.

Electric cars are different in so many ways. If the sales team isn't prepared for the onslaught of questions that they are going to get hit with as soon as the i3 becomes available to order, then it will not only hurt sales of the i3 but it will certainly tarnish the BMW brand image. BMW dealers will have an even tougher time than the other brands had in my opinion because the i3 isn't just an electric car, it really is a revolutionary vehicle. Besides the typical EV questions about the car's anticipated range, battery life, battery management, the effects of weather on the battery, charging, etc, they also have to explain the unique architecture with the carbon fiber and aluminum construction and the thermoplastic skin. How will it respond in an accident? How expensive will it be to repair? Why are the tires so skinny and will they perform well? And that's before they even begin asking about the range extender. Can it drive up a long hill at highway speeds? Can I simply refill it with gas and keep going? Why can't it be turned on manually? Does the waste heat from the engine warm the cabin? What is the maintenance schedule? And so on...

I've been working with JMK BMW in Springfield to help get them ready for the i3 also.

When I first heard about the new "Genius Everywhere" program that BMW was launching I really thought they had solved the dealer problem. It sounded brilliant and I figured these "Geniuses" would be thoroughly trained about the i3 and be able to assist a BMW client adviser with any issue or question about the i3 that a potential customer would have. However once I learned a little more about the program I started to wonder. The Geniuses are there to assist not only with BMW i questions, but technical questions on all BMW products.  Yikes I thought, that's a lot of information for them to absorb. Yes, they will have fancy iPads in hand to help them pull up info that they don't know off the top of their head but still, BMW has a lot of vehicles in their lineup now, and even a "Genius" has their limit. Then came the real concerning revelation. I started getting emails and private messages from BMW "Geniuses". They reached me though this blog and the BMW i3 forums on the internet where I post regularly and answer questions about the i3. After completing Genius training they felt they didn't know enough about the i3 to be comfortable, so they were reaching out to me to help answer questions they had. The worrisome part, is the questions they have are basic, generic electric vehicle questions. If they weren't taught this stuff then they will likely be no help at all to the dealers. In fact one person said this when describing how he feels about going to his designated dealership if someone asks him anything about the i3: "I feel like I'm being blind folded while walking into a room!" This isn't good to hear and believe me it gives me no pleasure at all to have to report it.

In addition to the Geniuses asking me for help, I have recently been getting emails from BMW dealerships asking me questions about the i3. They say BMW has promised them support for the i brand, but they haven't gotten it yet and people are now starting to call and come in to ask for i3 and i8 information and they don't have anything. I have even been asked to come to a couple of dealerships to help train the staff. One dealer in particular, Budds' BMW in Oakville, Canada really wanted me to come and give them a crash course in the i3. They flew me to Toronto and paid me to spend the whole day there and instruct three training sessions. I didn't do it for the money. I really just wanted to help them out since they clearly want to establish themselves as the area's premier BMW i dealer. They were willing to go the extra mile to fly me out there and pay me to help train them and I respect that so I went. The day went really well, and I'm sure they learned a lot about the i3. The following day I got emails from both the dealership manager and the owner and they both thanked me and were so pleased with how the training went they indicated that they would like me to come back to help them more once they get closer to the i3 launch. I have to say they were all really great people up there and I will certainly continue to help them if they ask.

It's not too late to get everybody up to speed, but the clock is ticking. The i brand launches in a couple of months and there is a LOT of ground to cover. I'll continue to help out when I can and in fact I have another dealership training set up for next week. I won't mention which dealer because I didn't ask them if I could talk about it.  Budds' was fine with me talking about this, and they really should be in my opinion. I commend them for wanting to be prepared. They are obviously a forward-thinking, progressive dealership that wants to have a competitive advantage and I really respect that. The next few months should be very interesting. I guess I'll know how well BMW is doing in preparing their dealer network for the i3 by how many phone calls for help that I get! I really hope they do it well. BMW put so much into the development of the i3 and i8, it would be a shame to have them do poorly because they didn't help their dealers get prepared for these unique and ground-breaking, cars.