This year’s Australian national Dyson Award winner is introducing us to the innovative bolt-on REVR retrofit kit. The purpose of this kit is to convert conventional internal combustion engine (ICE) cars into practical and efficient hybrids. What’s astonishing is that the entire retrofit costs less than US$3,200 and can be installed in under a day. Let’s dive deeper into this groundbreaking technology.
The mastermind behind this retrofit kit is Alexander Burton, a design student at RMIT University. He is currently focused on developing the most mechanically intricate part of the system: the flat, power-dense, liquid-cooled 50-kW motor. This motor is designed to fit snugly between the wheel and brake disc. It’s a unique pancake-style axial flux motor, with a flat stator that bolts to the wheel hub and a rotor plate that delivers torque through the wheel bolts. Although an adapter plate must be customized for each car model, it is expected to be a relatively simple process, and anyone can install the motor within 10 minutes, even without specialized knowledge. The highlight of the REVR kit is its axial-drive electric motor, which can be mounted directly onto the wheel without any modifications.
The battery pack and motor controllers will be housed in the trunk well, taking the place of the spare tire. Inspired by the design of electric vehicles like Tesla, Burton shares that the spare tire will be removed, but the decision is ultimately up to the customer. The spacious trunk well can accommodate approximately a 15-kWh battery pack, providing an all-electric range of over 100 km (62 miles) for stop-start city driving. This range is more than sufficient for the majority of daily commutes. The REVR kit is designed to work in parallel with or without the combustion engine running. By turning the ignition key to the “on” position and pressing a separate switch, you can activate the electric drive. Alternatively, if you wish to start the combustion engine, simply turn the key a little further. The kit includes a large battery pack to keep the regular 12-V battery charged when the ICE engine is not running, ensuring the operation of headlights and other 12-V electrics. Additionally, the kit offers electric alternatives or enhancements for components such as air conditioning, heating, power steering, and brake boosters that typically rely on belts connected to the engine.
The accelerator pedal integration is still being fine-tuned. According to Burton, a potentiometer or similar device will likely be used to read the accelerator input. This data will determine both acceleration and regenerative braking, similar to existing hybrid vehicles. Hydraulic braking will remain untouched and always available to the driver. The system will also need a way to shut off the electric motor or enable reverse operation when the car is put in reverse.
As for a display indicating the battery level, Burton mentions that a basic conversion won’t have one. However, diagnostics can be accessed through a smartphone, maintaining simplicity as a key principle of the kit.
Burton’s vision is to create a retrofit with a zero footprint. Initially, the focus will be on approximately 20% of the most popular car models, starting with the Corolla, Accord, and Civic groups. They are also exploring partnerships and additional directions for REVR. The ultimate goal is to convert one million cars. The anticipated price for a fully installed dual-motor, 15-kWh kit is below AU$5,000 (US$3,200). Burton believes that with widespread adoption and falling materials prices, the cost could be reduced to under AU$10,000 (US$5,400).
Addressing the legality of this modification, Burton acknowledges that certain regulations need to be navigated. However, he believes that updated legislation should allow for it, with the potential for in-house engineering certification to meet any requirements.
Burton plans to be the first to convert his own 2001 Corolla in a few months. The goal is to have the retrofit kit available for purchase in the third quarter of next year. REVR has a pending patent, and there is already significant interest from potential investors and crowd-funding opportunities. Although Burton notes that the primary focus is the Corolla conversion, REVR is open to exploring partnerships and additional avenues for growth. The ambitious stretch goal is to convert one million cars.
Despite the substantial torque increase it offers, Burton does not view the REVR retrofit as a performance-enhancing modification, as there are safety implications involved. Nonetheless, as the project advances, Burton hopes to expand the capabilities of the system, allowing users to remove their engines completely and convert to full electric operation. While a full electric conversion with a larger battery pack would be costlier, REVR’s modular and minimalist structure ensures that it remains more affordable compared to traditional EV conversions.
The core objective of the REVR retrofit is to provide a quick and relatively simple way for car owners to reduce their carbon footprint without having to purchase an expensive new EV or hybrid. It is a noble idea, but there are various challenges that Burton must overcome to ensure that the system is reliable, safe, functional, and compliant with a wide range of existing car models. We eagerly await the progress of this extraordinary project.
Source: [REVR](https://www.revr.com.au/)
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