Mahle unveils range extender for electric trucks

German automotive supplier Mahle has unveiled a range extender system designed for electric trucks to address challenges regarding limited range and insufficient charging infrastructure. The technology functions as a series hybrid, where a compact internal combustion engine does not drive the wheels directly but instead powers a high-voltage generator.

The generator provides a continuous output of 110 kW, with peaks up to 130 kW, to supply electricity to the vehicle's propulsion system and battery. The entire unit—including the engine, generator, fuel tank, AdBlue tank, and exhaust treatment—is integrated into a single compact module designed to fit into the space typically occupied by batteries in fully electric trucks.

By replacing approximately one-third of a standard battery's capacity with this module, Mahle aims to reduce the vehicle's total weight by roughly 600 kilograms and decrease the load on the rear axle by 400 kilograms. The system is intended to provide a total range exceeding 800 kilometers, with the battery covering approximately 400 kilometers and the range extender providing the remaining distance.