Strong interest in MAHLE range extender for e-trucks

Electric truck with the everyday capabilities of a diesel
The demands faced by the road transport industry are high. Haulage companies need to reduce carbon dioxide emissions at the same time as ensuring reliable, economical operation of their fleets. Especially in long-distance transport, the charging infrastructure, which is still inadequate in many areas, long charging times and high charging prices continue to pose challenges for the ramp-up of battery-electric trucks.

The MAHLE Group’s response to these challenges is its new range extender system for electric trucks. This is a smart power unit that starts up at precisely the right time and significantly extends the range of a battery-electric truck as the need arises. “Range extenders may represent a breakthrough for the electrification of road transport at the same time as safeguarding fleet economics,” said Arnd Franz.

The range extender is a compact unit combining generator, internal combustion engine, thermal management, fuel tank, AdBlue tank and exhaust gas treatment. The unit can easily be integrated in existing battery-electric vehicle platforms. The main component is a high-voltage generator with a continuous output of 110 kW and a peak output of up to 130 kW. Thanks to its newly developed advanced oil cooling system, the generator has a power density of more than 7 kW per kilogram. The integrated thermal management system with 48 kW of high-temperature and 15 kW of low-temperature cooling capacity also ensures efficient, reliable operation.

The range extender replaces about one-third of the present battery capacity of a battery-electric truck. As a result, the rear axle load can be reduced by about 400 kilograms and the total vehicle weight by about 600 kilograms. All in all, a BEV truck equipped with this system can reach a total range of more than 800 km, with the battery providing about 400 km and the range extender the remaining 400 km.

Compared with a conventional drive system, the CO₂ emissions in real-life operation can be reduced by more than 80 percent. If HVO100 renewable fuel is used, the truck can be operated with virtually zero CO₂ emissions.

Another world premiere at the IAA: MCT electric motor without rare earth elements
The new MCT (MAHLE Contactless Transmitter) electric motor for electric drive axles of heavy commercial vehicles is not equipped with permanent magnets and therefore does not require any rare earth elements. Compared with a conventional permanent magnet synchronous motor, the MCT electric motor saves up to 3 kilograms of rare earth magnets per vehicle, thus reducing dependence on critical raw materials.

With a peak output of 370 kW and torque of over 900 Nm, the MCT electric motor offers the high power density needed for demanding applications in heavy truck operation. It makes the drive system also up to 10 kg lighter than comparable solutions, further improving vehicle efficiency. In the VECTO driving cycle, the motor has an efficiency of 95 percent. In real-life driving cycles covering a wide variety of applications, the drive system reaches higher efficiency levels than comparable permanent-magnet electric motors. The technology therefore combines resource conservation, high performance and energy efficiency in a future-oriented drive system concept for electric commercial vehicles.

Renewable fuels play a key role in defossilization
Even though the use of internal combustion engines is declining throughout the world, especially in China and Europe, they remain relevant and account for significant volumes in all regions. This is especially the case because the demand in the commercial vehicle sector remains high. This is why MAHLE is consistently developing these drive systems for use with renewable fuels such as hydrogen, bio-ethanol, HVO100 or bio-LNG. Especially with respect to existing vehicle fleets, these fuels offer considerable potential for the rapid, large-scale reduction of CO₂ emissions.

“Technology diversity does not present a conflict for defossilization; on the contrary, it is a prerequisite,” said Arnd Franz. Battery-electric drive systems, hydrogen technologies, renewable fuels and range extender systems should supplement each other with a view to achieving climate targets as rapidly and economically as possible. This will only be possible with reliable regulatory conditions. This is why MAHLE calls for a review of European CO₂ regulations for heavy commercial vehicles in the near future which gives greater consideration to the realities of the marketplace.

MAHLE grows with commercial vehicle technologies
MAHLE is and remains a reliable partner to its 120 commercial vehicle customers. Components from the technology group are used in Europe in almost all battery-electric and fuel cell trucks and MAHLE is participating in virtually all the hydrogen engine projects currently in progress.
With many products for the commercial vehicle segment, MAHLE is either the world market leader or among the top three. “For customers who need technological expertise and system competence, MAHLE is the right address. Over the next five years, we intend to grow faster than the market with our commercial vehicle business,” said the MAHLE CEO.