Mahle has introduced a range extender system for battery-electric heavy trucks, presenting the technology at IAA Transportation in Hanover as part of its latest commercial vehicle portfolio.
The company said the system is designed to extend the driving range of battery-electric trucks to more than 800 kilometers by integrating onboard power generation with thermal and fluid management in a compact package.
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Integrated Range Extender
According to Mahle, the system combines a 110-kilowatt high-voltage generator, an internal combustion engine, AdBlue and fuel tanks, exhaust aftertreatment, and cooling systems within a single self-contained unit.
The company said the package is designed to occupy space equivalent to approximately one-third of a truck’s battery capacity, allowing operators to reduce battery size while extending vehicle range.
Mahle estimates the configuration reduces vehicle weight by around 600 kilograms and delivers a power density of more than 7 kilowatts per kilogram.
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The system also incorporates a 63-kilowatt thermal management unit to maintain operating temperatures during heavy-duty use.
Lower Emissions
Mahle said the range extender can reduce carbon dioxide emissions by approximately 80% compared with a conventional diesel truck under real-world operating conditions.
The company added that emissions can be reduced further when the internal combustion engine operates on HVO100 renewable biodiesel.
Rare-Earth-Free Electric Motor
Alongside the range extender, Mahle introduced its Mahle Contactless Transmitter (MCT) electric motor for heavy commercial vehicle axles.
The permanent-magnet-free motor eliminates the use of rare earth materials while delivering peak output of 370 kilowatts.
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According to Mahle, the motor achieves approximately 95% VECTO efficiency and reduces vehicle weight by eliminating up to 3 kilograms of rare earth materials per vehicle.
Commercial Vehicle Focus
Mahle said it currently supplies approximately 8 million electric drive systems annually and provides components used in battery-electric and fuel cell trucks operating in Europe.
Commercial vehicle products account for around 20% of the company’s overall business, reflecting continued investment in electrification technologies for heavy-duty transport.
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