Mahle begins first range-extender projects with truck manufacturers
Mahle is taking the next step with its range extender for electric trucks: Following the announcement in August, the supplier has now begun initial concrete projects with commercial vehicle manufacturers. These aim to develop prototypes that will hit the roads soon.
Mahle’s range extender consists of a compact unit that includes a generator, internal combustion engine, and thermal management systems.
Image: Mahle
The range extender system was announced in August ahead of the IAA Transportation. Now, this technology makes its debut at the exhibition in Hannover and appears to be on its way to being installed in early models of vehicles. According to the supplier, concrete projects are underway with commercial vehicle manufacturers to develop prototypes and subsequently test them in real road conditions. However, Mahle has not yet provided details regarding partners, production volumes, or a potential launch date.
The system combines a high-voltage generator with 110 kW continuous power and 130 kW peak power alongside a compact internal combustion engine. The generator, engine, thermal management system, fuel and AdBlue tanks, as well as exhaust aftertreatment are integrated into one unit that replaces part of the battery in an electric truck. The wheels remain powered exclusively by electricity.
According to Mahle, about one-third of the original battery capacity may be lost. This is intended to make the vehicle roughly 600 kilograms lighter despite the additional range extender. For a truck designed accordingly, the supplier promises a total range of over 800 kilometers—about 400 kilometers from the battery and another 400 kilometers using the range extender.
Mahle positions this technology primarily as a solution to gaps in charging infrastructure for heavy commercial vehicles. However, it remains to be seen whether the promised advantages in range, weight, and operating costs will hold true in actual fleet use, as demonstrated by the prototypes now announced.
Mahle presents an electric motor without rare earths
Another IAA premiere is the previously announced Contactless Transmitter (MCT) for electric drive shafts in heavy commercial vehicles. The electric motor eliminates the need for permanent magnets, thereby avoiding rare earth elements. Its peak power is 370 kW, with a torque of over 900 Nm. Mahle claims an efficiency of 95 percent in the VECTO cycle.
The supplier has also revised the estimates for material and weight savings: compared to a similar permanent-magnet synchronous machine, up to three kilograms of rare earth magnets can be eliminated per vehicle, resulting in a drive system that is up to ten kilograms lighter.
Meanwhile, Mahle uses its IAA presence to advocate once again for technology-friendly regulatory frameworks. In addition to battery-electric drives, the company believes range extenders, hydrogen, and renewable fuels can also help decarbonize road freight transport. To achieve this, Mahle calls for a revision of European CO₂ regulations for heavy commercial vehicles.