Mahle Introduces Range Extender System for Heavy Electric Trucks

Mahle is driving the decarbonization of freight transport with the global launch of a new Range Extender system for heavy electric trucks (BEV), which will be presented at IAA Transportation next September under the motto "Electrified. Efficient. Economical.". The solution seeks to accelerate the transition from diesel, which still dominates road freight transport, towards battery-electric vehicles, providing greater autonomy with total flexibility and without sacrificing efficiency.

The Range Extender functions as an intelligent emergency power unit that activates exactly when needed and significantly increases the available range. Thanks to this innovation from Mahle, a battery-electric truck can cover all distances required in daily operations.

The key component of the new system is an efficient high-voltage generator with a continuous power of 110 kW and a maximum power of up to 130 kW, driven by a compact combustion engine. This generator ensures a reliable power supply to the electric propulsion system even on demanding routes and with a full load.

It is worth noting that, under real operating conditions, the vehicle emits approximately 80% less CO2 when operating with the Range Extender than a truck equipped with a conventional propulsion system. Furthermore, if the combustion engine, prepared for the use of biofuels thanks to Mahle components, runs on renewable fuels such as advanced HVO100 biodiesel, CO2 emissions are reduced to virtually zero.

"Time and energy are limited and valuable resources, especially in road transport; only operators who work efficiently will be able to remain competitive. With our electrification solutions, Mahle can help make heavy vehicles more efficient and flexible, while reducing their operating costs," said Arnd Franz, CEO of Mahle.

As another world premiere at IAA Transportation, Mahle will also present an MCT (Mahle Contactless Transmitter) electric motor for electric drive axles of heavy commercial vehicles. By not using permanent magnets, it avoids the use of rare earths, saving up to 3 kilograms of magnets per vehicle. The motor reaches a maximum power of 370 kW and a torque exceeding 900 Nm, and its efficiency in the Vecto cycle is around 95%.

Mahle has developed electrification and thermal management, a key area for the development of electric mobility. This position extends to all business areas and applications of the group, especially the commercial vehicle segment.

However, the internal combustion engine remains the predominant propulsion system in commercial vehicles worldwide. Its share in this segment is expected to decrease only slightly, from approximately 83% currently to around 73% in 2035, while electric propulsion systems will continue to grow, although they will still play a secondary role.

In this context, Arnd Franz argues that, to effectively reduce CO2 emissions, technological diversity will be fundamental. "Battery-electric vehicles, hydrogen, and renewable fuels for combustion engines must be used complementarily to reduce CO2 emissions. Range Extender systems should also be pragmatically recognized as an enabling technology for electrification and taken into account in regulation," he explained.

He also pointed out that a successful transformation is achieved through effective interaction between regulation, infrastructure, financing, and industrial policy. In his opinion, Europe should commit more decisively to an integrated approach.