MAHLE unveils range extender and magnet-free motor for electric trucks

German technology company MAHLE has announced a new range extender solution for battery electric vehicles (BEV) designed to address the limitations of current charging infrastructure and long-distance road transport. The system integrates a generator, combustion engine, thermal management, and exhaust treatment into a single unit that converts fuel into electricity to charge the battery.

This range extender can replace approximately one-third of a vehicle's original battery capacity while reducing total vehicle weight by about 600 kilograms. This allows electric trucks to achieve a total driving range of over 800 kilometers, split between battery power and the range extender. When used with renewable HVO100 fuel, the system can reduce carbon dioxide emissions to nearly zero.

Additionally, MAHLE is introducing the MAHLE Contactless Transmitter (MCT), a world-first permanent magnet-free electric motor for heavy-duty truck drive axles. By eliminating the need for rare earth metals, the MCT motor reduces reliance on critical minerals by up to 3 kilograms per vehicle. The motor offers a peak power of 370 kW and an efficiency of up to 95%.