Mahle develops diesel-powered range extender for electric trucks

German automotive supplier Mahle has developed an Extended Range Electric Vehicle (EREV) technology designed to address range anxiety and charging infrastructure limitations in heavy-duty electric commercial vehicles. The system integrates a compact diesel generator into the space typically reserved for battery modules, effectively doubling the driving range of electric trucks to over 800 kilometers.

Unlike traditional hybrids, the vehicle's movement is driven exclusively by electric motors. When the battery reaches a critical level, an internal combustion engine activates a high-voltage generator to produce electricity rather than providing mechanical power to the wheels. This modular system combines an internal combustion engine, a high-voltage generator, fuel and AdBlue tanks, exhaust treatment, and cooling units into a single unit.

By replacing approximately one-third of the battery space with this generator, the total vehicle weight is reduced by about 600 kilograms, and the rear axle load decreases by roughly 400 kilograms. The generator provides a continuous output of 110 kW and a peak output of 130 kW, supporting the electric powertrain during demanding tasks such as climbing hills or operating under full loads.