ZF is now introducing the new generation of its range extender technology, which will go into volume production in 2026. With range extenders, a combustion engine is coupled to an electric machine that generates power for the vehicle battery as soon as its state of charge drops below a certain threshold.

The range extender machine always runs in the ideal performance range for fuel consumption, which ensures low fuel consumption and therefore also has lower CO₂ emissions.

In recent years, ZF had already launched range extender technology in volume production. Among other things, ZF’s electric machines were installed in a series of iconic London taxis. ZF is currently working on the next generation, the electric Range Extender (eRE) and the electric Range Extender plus (eRE+).

ZF eRE+

Both variants are highly integrated designs that are flexible in terms of performance, E/E architecture, 400V or 800V and semiconductor type. The eRE connects an electric motor with an integrated inverter, suitable software and planetary gearset. The eRE+ also has an intelligent clutch and a differential.

As a result, it can be used either as a current generator or as an additional secondary drive, which saves manufacturers developing a separate component.

Performance can be scaled in both models. The output ranges from 70 to 110 kW (eRE) or 70 to 150 kW (eRE+).

Compared to parallel-hybrid drive solutions, for example with a PHEV, range extenders are compelling due to their lower additional costs, shorter development cycles, lower platform effort, and simplified supply chain management. This makes the technology particularly interesting for manufacturers who are new to the market, and may have little experience with traditional combustion engine drivelines.

China is currently embarking on a model offensive of Range Extended Electric Vehicles (REEV), which, due to the technology, can cover distances of more than 700 kilometers (435 miles). This was another reason why the Chinese ZF locations were in charge of development.

The interest of manufacturers in the US and Europe also is increasing.

The market for all-electric vehicles has not developed as predicted a few years ago. For this intermediate phase, range extenders can be the ideal solution.

— Dr. Otmar Scharrer, Senior Vice President R&D, Electrified Powertrain Technology