MAHLE’s new range extender debuts as a compact “box” integrating generator, biofuel-ready ICE, and thermal/fluid systems for the battery installation space.
MAHLE is accelerating the electrification of road transport. With its new range extender system for heavy electric (BEV) trucks, the Stuttgart automotive component supplier is paving the way for a faster changeover from diesel trucks, which currently dominate the road transport sector, to battery-electric trucks.
Range extender electric trucks combine the sustainability of electric drive systems with the flexibility and range of the internal combustion engine. MAHLE noted that they help the cost-intensive road transport sector lower total cost of ownership over the vehicle life cycle and facilitate climate-friendly investments. In addition, range extender BEVs contribute to achieving European carbon dioxide fleet targets.
“With high-performance technologies and production-ready products for electrification we are aiming for further growth,” said Arnd Franz, chairman of the group management board and CEO of MAHLE, at a tech event held by the company in Stuttgart. With its electrification products for commercial vehicles, MAHLE said that it is among the market leaders in Europe. The company is also expanding its presence with Chinese commercial vehicle manufacturers. Manufacturers who are increasingly entering the European market with battery-electric trucks.
Range Extender System Details
The range extender system provides flexible range without compromises and efficiency without restrictions. With this MAHLE innovation on board, a battery-electric truck can cover all the daily ranges required.
“Our range extender is a smart “emergency power unit” that is activated at precisely the right moment and significantly increases the range available,” said Dr. Marco Warth, vice president, MAHLE Corporate Research and Advanced Engineering. The key component of the new system is an efficient high-voltage generator. It offers a continuous output of 110 kilowatts (kW) and a peak output of up to 130 kW, driven by a compact internal combustion engine. The high-voltage generator supplies reliable power to the electric drive system even on difficult trips with a full load.
The manufacturer noted that its architecture adapts easily to the performance requirements of various applications and regional markets. Thanks to its newly developed advanced oil cooling system, the generator has a power density of more than 7 kW per kilogram. This allows for a high power output with reduced weight and simplified interfaces. MAHLE has developed its range extender system as an autonomous unit combining generator, internal combustion engine, thermal and fluid management systems, fuel tank, AdBlue tank and exhaust gas treatment in a compact “box.”
This unit fits into the normal battery installation space of a battery-electric truck. It also integrates into existing battery-electric vehicle platforms. The system replaces about one-third of the present battery capacity of a battery-electric truck. This could allow the truck to use a smaller battery. As a result, the system reduces the rear axle load by about 400 kg. This reduces the total vehicle weight by about 600 kg.
How Much Range Does it Provide?
All in all, a range extender BEV truck can reach a total range of more than 800 km. The battery provides about 400 km and the range extender provides the remaining 400 km. Under real-life operating conditions, the truck emits about 80% less CO2 in range extender operation than a truck with a conventional drive system. A comprehensive thermal management system with 48 kW of high-temperature and 15 kW of low-temperature cooling capacity ensures stable operation of the range extender system under heavy-duty operating conditions. For the internal combustion engine, MAHLE has continued the development of components to reduce fuel consumption and operating costs. For example, the new Power Cell Unit (PCU) features higher performance, a longer service life and greater efficiency.
The new oil management system, combining the oil filter, oil cooling system and bypass valve as well as other optional functions, also features improved efficiency and economics. The choice of housing material can reduce material costs by up to 20%. The product’s CO₂ footprint is reduced by up to 50%, and its weight by as much as 25%. In addition, this product has a longer service life, further reducing overall operating expenses.
The PCU and oil management module also work with other types of drive systems and debut at IAA Transportation. “Our range extender is the key to disconnecting the market ramp-up of battery-electric trucks from the inadequate pace of infrastructure development,” said Marco Warth. “If the charging station is busy, or alternative routes are called for as a result of weather conditions or congestion and infrastructure reaches its limits, other fleets can be stranded; an e-truck with range extender just carries on. Operational availability is maintained, even under peak conditions.”
MCT Electric Motor for Heavy Commercial Vehicles
The company is also showcasing a MAHLE Contactless Transmitter (MCT) electric motor. This was developed for use on the electric drive axles of heavy commercial vehicles. This motor uses no permanent magnets and therefore requires no rare earth elements. Compared with a benchmark permanent magnet synchronous motor (PMSM), the MCT electric motor saves up to 3 kilograms of rare earth magnets per vehicle.
The avoidance of rare earth magnets further reduces the environmental footprint of the electric drive system. The new motor from MAHLE is 10% lighter and more efficient than permanently excited electric motors with magnets under real-life driving conditions. The advantage compared with the permanently excited variant is higher efficiency within a significantly larger operating envelope.
The MCT electric motor has a peak output of 370 kW and torque of over 900 Nm at 3,900 rpm. The motor efficiency in the VECTO cycle, an EU simulation tool for determining the fuel efficiency of new vehicles, is about 95%.
Electrification Growth and Customer Position
Every year, MAHLE sells about 8 million electric drive systems and electric ancillaries to customers. From 2026 to 2029, more than 35 electrified vehicle platforms of leading passenger car and truck manufacturers will be launched based on MAHLE technology and products. In Europe, MAHLE is present in every battery-electric and fuel cell truck.
The company is a market leader for electric climate compressors. MAHLE is among the top three in the marketplace for electric pumps and fans. In China, MAHLE is working together with all truck manufacturers to expand its presence in electrified vehicles. The group intends to grow in the commercial vehicle sector, especially with thermal management modules, electric fans, charging connection boxes, battery cooling plates and traction motors.
Medium and heavy commercial vehicles account for about 20% of the group’s business with the automotive industry. The group benefits from its development and production network in all major markets and from its broadly diversified customer portfolio. MAHLE cooperates with more than 120 customers in the commercial vehicle and off-road sector and maintains an especially strong presence in Europe and the Americas.
Post time: Jul-24-2026
