MAHLE Steps In to Support Fleet Electrification
MAHLE has introduced a range extender system engineered specifically for heavy-duty battery-electric (BEV) trucks. Designed as an autonomous, drop-in box unit, the system mounts directly into standard battery frame spaces across existing electric vehicle platforms.
The core component features a high-voltage, oil-cooled generator delivering 110 kW of continuous output and a peak output of 130 kW, driven by a compact internal combustion engine. The self-contained power pack consolidates the engine, generator, fluid and thermal management systems, fuel tank, DEF tank, and exhaust aftertreatment. By replacing roughly one-third of a standard heavy electric truck's battery pack, the unit reduces rear axle loads by 400 kg and lowers total vehicle weight by approximately 600 kg.
In real-world duty cycles, a range extender BEV truck achieves a combined operating range exceeding 800 km—split equally between battery power and generator output—while reducing CO2 emissions by up to 80% compared to conventional diesel powerplants. Dr. Marco Warth, Vice President of Corporate Research and Advanced Engineering at MAHLE, noted that the system acts as an operational insurance policy for commercial fleets facing limited megawatt charging availability or route diversions.
Alongside the range extender, MAHLE highlighted its Contactless Transmitter (MCT) electric motor engineered for heavy commercial e-axles. The motor eliminates permanent magnets entirely, saving up to 3 kg of rare earth materials per vehicle while generating 370 kW of peak power and 900 Nm of torque at 3,900 rpm.
MAHLE’s hybrid-electric power architectures provide a transitional pathway to meet fleet emissions compliance while protecting vehicle payload capacity and operational uptime.
