Mahle launches first range-extender projects with truck manufacturers
Mahle is moving forward with its range extender for electric trucks: Following an announcement in August, the supplier has now launched its first concrete projects with commercial vehicle manufacturers. Prototypes are now in development and set to hit the road soon after.
Mahle's range extender for electric trucks consists of a compact unit including a generator, combustion engine, and thermal management.
Image: Mahle
It was during the run-up to the IAA Transportation in August that Mahle announced its range-extender system. Now, the technology is not only making its trade fair debut in Hanover – it’s also finding its way into vehicles. According to the supplier, concrete projects are underway with commercial vehicle manufacturers to build prototypes and subsequently test them in real-world road operations. However, Mahle has not yet disclosed any details about partners, unit numbers, or a possible start of series production.
The system combines a high-voltage generator with 110 kW continuous and 130 kW peak power with a compact internal combustion engine. The generator, combustion engine, thermal management, fuel and AdBlue tanks, as well as exhaust aftertreatment, are all integrated into a single unit that replaces part of the battery of an electric truck. The wheels continue to be driven exclusively electrically.
According to Mahle, approximately one-third of the original battery capacity can be omitted. As a result, the vehicle is expected to be around 600 kg lighter despite the additional range extender. For a correspondingly designed truck, the supplier promises a total range of more than 800 km – around 400 km from the battery and a further 400 km with the help of the range extender.
Mahle positions the technology primarily as a response to gaps in the charging infrastructure for heavy commercial vehicles. However, the prototypes will now need to demonstrate whether the promised advantages in range, weight, and operating costs hold up in real-world fleet operations.
An electric motor – without rare earth elements
Another IAA premiere is the previously announced Contactless Transmitter (MCT) for electric drive axles in heavy commercial vehicles. This electric motor does without permanent magnets and thus without rare earth elements. Its peak power is 370 kW, with torque exceeding 900 Nm. Mahle states that its efficiency in the VECTO cycle is 95 per cent.
The supplier has also quantified the material and weight advantages: compared to a comparable permanently excited synchronous machine, up to three kilograms of rare earth magnets per vehicle can be omitted, and the drive system can be up to ten kilograms lighter.
In parallel, Mahle is using its IAA appearance to advocate once again for technology-open regulatory frameworks. From the company’s perspective, in addition to battery-electric drives, range extenders, hydrogen, and renewable fuels should also contribute to decarbonising road freight transport. Mahle is calling for a revision of the European CO₂ regulation for heavy commercial vehicles.