Mahle, a major automotive supplier, plans to introduce a new range extender system designed specifically for heavy-duty electric trucks at the IAA Transportation trade show in Hannover, Germany in September. The company developed the technology to address what it identifies as the primary obstacles preventing wider adoption of battery electric trucks: limited driving range and insufficient charging infrastructure in many regions.
The range extender system consists of a compact internal combustion engine paired with an efficient high-voltage generator capable of continuous output of 110 kilowatts and peak output up to 130 kW. According to Mahle, the unit can be integrated into existing battery electric vehicle platforms by occupying the space typically reserved for batteries. A truck equipped with this system would achieve a total range exceeding 800 kilometers, with batteries providing approximately 400 kilometers of range and the range extender supplying the remainder.
A key advantage of the Mahle design is its weight efficiency. The system replaces about one-third of typical battery capacity, allowing trucks to carry smaller, less expensive batteries. This configuration reduces rear axle load by approximately 400 kilograms and total vehicle weight by around 600 kilograms. The system features advanced thermal management with high-temperature and low-temperature cooling capacity to maintain stable operation under demanding conditions.
Regarding environmental performance, Mahle states that trucks equipped with the range extender emit approximately 80 percent less carbon dioxide during range extender operation compared to conventional diesel-powered vehicles. The company notes that if renewable fuels such as HVO100 bio-diesel power the system, carbon dioxide emissions would be negligible. Mahle representatives emphasized that the range extender addresses operational concerns for fleet operators by maintaining service availability when charging stations are unavailable or when route changes become necessary due to traffic, weather, or infrastructure limitations.
Mahle is also unveiling other technological improvements for electric heavy commercial vehicles, including a new electric motor designed for drive axles that does not require permanent magnets or rare earth elements.
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