A new device from German auto supplier Mahle aims to make electric trucking easier for fleets that aren’t ready to rely solely on battery power. The company unveiled an all-in-one range extender that can be easily integrated into existing electric trucks. The unit includes a compact diesel engine, a generator, a fuel tank, an AdBlue tank, and all the necessary thermal and fluid management systems. Mahle says the solution can replace about a third of the battery capacity in an electric truck.
Compact Power for Heavy Loads
The all-in-one enclosure contains a compact diesel engine, a generator that powers the high-voltage battery, and everything else required to keep the vehicle moving. This includes a fuel tank, an AdBlue tank, an exhaust gas treatment system, and a cooling system. Mahle says this complexity is necessary to support the additional hardware. The generator does not have a direct physical connection to the driven wheels. Instead, it sends between 110 kilowatts and 130 kilowatts to the electric drive system.
The system reduces the rear axle load by roughly 881 pounds and the total vehicle weight by about 1,322 lbs. This reduction in weight allows the truck to carry heavier loads. Total range can exceed 500 miles, with the battery providing about 250 miles and the range extender powering the remaining 250 miles. The generator does not use any rare earth elements, which makes it environmentally friendly. Mahle states that the diesel engine can be powered by biofuels like HVO100 biodiesel, resulting in virtually zero carbon dioxide emissions according to the company.
Related: Battery Factory Powers Electric Vehicle Boom
Under real-world conditions using conventional fuel, Mahle claims a truck with the range extender emits about 80% less CO2 compared to a conventional diesel truck. This creates a bridge technology for the industry. By removing the need for massive battery packs, the physical weight of the vehicle decreases, which directly impacts payload capacity. While electric trucks have advanced, the sheer size of the batteries required for long-haul travel can eat into the cargo space. This system attempts to solve that specific engineering trade-off by offloading part of the energy storage burden to an onboard power plant.
Operational Availability
Production is scheduled to begin in 2025. The system is designed to be compatible with many existing electric trucks, which helps fleets upgrade without buying entirely new vehicles. The solution addresses the current limitations of battery technology, such as charging time and energy density. This approach offers a practical path for logistics companies to reduce their carbon footprint while maintaining the operational flexibility of traditional diesel power. It bridges the gap between current electric capabilities and the demands of long-distance freight.
Logistics operators face challenges with battery weight and charging infrastructure. The Mahle range extender reduces these hurdles. It allows for longer trips without the need for frequent stops to recharge. The onboard generator can run continuously, ensuring the truck stays on the road. This technology provides a viable alternative for routes where charging stations are scarce. Companies can now consider electric trucks for a wider range of applications, including cross-country hauls.
