MAHLE Unveils Range Extender and Magnet-Free Motor for Heavy Commercial Vehicles

MAHLE has announced two commercial vehicle powertrain technologies ahead of IAA Transportation in Hanover, including a compact range extender box for heavy-duty electric trucks and a magnet-free electric motor designed without rare earth elements. 

The newly developed range extender unit pairs a high-voltage generator with a compact internal combustion engine, delivering a continuous electrical output of 110 KW and a peak output of up to 130 KW. Engineered as an autonomous module containing integrated thermal management, fuel storage, and exhaust treatment, the assembly fits into standard battery installation spaces on existing battery-electric truck chassis. MAHLE says that the vehicle weight drops by about 600 kilograms, while reducing rear axle loads by 400 kilograms and enabling an operational range of over 800 kilometers.

Alongside the range extender, MAHLE also introduced a Contactless Transmitter electric motor for heavy vehicle drive axles. Operating without permanent magnets, the unit saves up to a claimed 3 kilograms of rare earth magnets per vehicle relative to conventional permanent magnet synchronous motors. The motor delivers a peak output of 370 KW and over 900 Nm of torque, achieving approximately 95 percent efficiency across standard operating cycles while reducing motor weight by 10 percent.