German automotive supplier ZF has unveiled a new electric range extender system at the Auto Shanghai motor show, designed to enhance the capabilities of extended range electric vehicles (EREVs). The system is capable of functioning both as a generator and a secondary drive unit using a single electric motor, and is scheduled to enter production in the first half of 2026.
ZF said the new solution offers three primary advantages: compatibility with all-wheel-drive vehicles without requiring an additional drive unit, a compact design for easier integration into engine compartments, and efficient operation of both electric and combustion components. “These represent a real alternative to larger – and thus more expensive – batteries or plug-in hybrids,” said Otmar Scharrer, Senior Vice President R&D, Electrified Powertrain Technology at ZF.
See also: ZF Secures Order to Supply Electric Axle Drives for India’s Emission-Free Bus Fleet
Two versions of the system will be offered. The base variant, called eRE, includes an electric motor, integrated inverter, software, and a planetary gearbox, with power outputs ranging from 70 to 110 kW. A more advanced version, eRE+, adds an intelligent clutch and differential, expanding output to between 70 and 150 kW. Both versions support 400- and 800-volt system architectures and are adaptable to different types of semiconductors.
The company noted that its market share among Chinese vehicle manufacturers has increased, benefiting from strong demand for EREVs, particularly in rural areas where access to charging infrastructure remains limited. “Although the all-electric range of passenger cars is around 500 km on average, range anxiety still influences a wide range of buyers when choosing their next vehicle,” Scharrer added.
See also: ZF Unveils High-Power Electric Drive for Larger Construction Equipment at Bauma
Alongside the new range extender, ZF also showcased additional electric drive technologies at its Auto Shanghai stand, including the AxTrax 2 integrated axle system for commercial vehicles and its Chassis 2.0 platform for autonomous driving. CEO Holger Klein highlighted the company’s commitment to the local market: “ZF has continuously invested in innovative technologies for the Chinese market in recent years… We have also consistently optimised our production and development processes to the requirements of our Chinese customers and thus literally fulfil ‘China Speed’.”