Range Extender System Integrates Power and Thermal Management to Reduce Battery Dependency
German automotive component supplier MAHLE has announced the development of a range extender system specifically designed for heavy-duty electric trucks. By integrating a diesel engine with a high-voltage generator, the system can replace about one-third of the battery capacity in existing electric trucks. This design reduces the total vehicle weight by approximately 600 kg and lowers the rear axle load by about 400 kg while maintaining the original driving range.
The MAHLE range extender system is a fully integrated module that includes a diesel engine, high-voltage generator, thermal and fluid management systems, fuel tank, AdBlue tank, and exhaust treatment system. The high-voltage generator within the system employs oil cooling technology, delivering a continuous power output of 110 kW and a peak power output of up to 130 kW, with a power density exceeding 7 kW per kilogram. The thermal management system provides 48 kW of high-temperature cooling and 15 kW of low-temperature cooling, ensuring stable operation under various conditions.
MAHLE states that the range extender system effectively reduces the dependency of electric trucks on large-capacity batteries, decreases vehicle weight, and enhances cargo efficiency. This design is particularly suitable for long-haul transportation and markets where charging infrastructure is not yet fully developed, extending the driving range without increasing battery load.
Rare Earth-Free MCT Electric Motor Achieves 95% Efficiency, Reducing Critical Material Usage
MAHLE has simultaneously introduced the Contactless Transmitter (MCT) electric motor, designed specifically for the drive axles of heavy-duty commercial vehicles. This motor does not use permanent magnets, completely eliminating reliance on rare earth elements and reducing rare earth magnet usage by approximately 3 kg per vehicle compared to traditional permanent magnet synchronous motors. The MCT motor is 10% lighter and more efficient than permanently excited designs under real driving conditions.
The MCT motor delivers a peak output of 370 kW, torque exceeding 900 Nm, and a rotational speed of 3,900 rpm, achieving about 95% efficiency in the EU’s VECTO simulation cycle. MAHLE emphasizes that this design not only improves motor efficiency but also lowers production costs and reduces dependence on critical raw materials such as rare earth elements.
Marco Warth, Vice President of Corporate Research and Advanced Engineering at MAHLE, stated, "The range extender system is the key to decoupling the market growth of battery-electric trucks from the inadequate pace of charging infrastructure development. By reducing battery dependency, vehicles can achieve longer driving ranges under existing conditions while lowering overall costs."
MAHLE has not yet disclosed the production timeline or partner manufacturers for the range extender system and MCT motor. However, the company notes that both technologies can be directly integrated into existing electric truck platforms without requiring major structural modifications. As global demand for heavy-duty electric vehicles continues to grow, MAHLE’s solutions are expected to accelerate the electrification process in regions with insufficient infrastructure while reducing reliance on critical raw materials.
