MAHLE has introduced a new range extender system for heavy
battery-electric trucks to support the transition from diesel-powered
commercial vehicles to electric mobility. The Stuttgart-based automotive
component supplier said the technology combines the sustainability of electric
drive systems with the flexibility and range of an internal combustion engine.
The system is designed to help fleet operators overcome
challenges such as limited charging infrastructure and range constraints while
reducing total cost of ownership over the vehicle life cycle. MAHLE will
showcase the technology as a world premiere at IAA Transportation 2026 in
Hanover under the theme “Electrified. Efficient. Economical.”
“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 range extender features a high-voltage generator with a
continuous output of 110 kW and peak output of up to 130 kW, powered by a
compact internal combustion engine. The integrated unit combines the generator,
engine, thermal management systems, fuel tank, AdBlue tank and exhaust gas
treatment within a compact structure that can be integrated into existing battery-electric
truck platforms.
By replacing around one-third of the battery capacity, the
system reduces rear axle load by about 400 kg and overall vehicle weight by
about 600 kg. A range extender-equipped electric truck can achieve a total
range of more than 800 km, with approximately 400 km provided by the battery
and the remaining 400 km by the range extender.
Under real-world conditions, MAHLE stated that the truck can
deliver around 80% lower CO? emissions compared with conventional drive
systems. When operated with renewable fuels such as advanced HVO100 biodiesel,
the vehicle can achieve virtually zero CO? emissions.
MAHLE will also showcase its Contactless Transmitter (MCT)
electric motor for heavy commercial vehicles at IAA Transportation. The motor
eliminates the need for permanent magnets and rare earth elements, saving up to
3 kg of rare earth magnets per vehicle.
The MCT motor is 10 per cent lighter and more efficient than
permanently excited electric motors, delivering a peak output of 370 kW and
torque of more than 900 Nm. Its efficiency in the VECTO cycle is around 95 per cent.
MAHLE said it is expanding its electrification portfolio
across commercial vehicles, including thermal management systems, electric
fans, charging connection boxes, battery cooling plates and traction motors.
The company works with more than 120 customers in the commercial vehicle and
off-road sector and expects its commercial vehicle business to grow faster than
the market over the next five years.
The company also highlighted the continued role of renewable
fuels alongside electrification. MAHLE said sustainable fuels such as HVO100
and bio-LNG will remain important for reducing emissions from existing
commercial vehicle fleets.
“Technological diversity will be crucial. Battery-electric
vehicles, hydrogen and renewable fuels for internal combustion engines must be
used together to reduce CO2 emissions,” said Arnd Franz, Chairman of the Group
Management Board and CEO of MAHLE.