Mahle introduces range extender

Electric vehicles with range extenders could help accelerate the spread of electric vehicles by alleviating consumers' range anxiety. Mahle is now showcasing a range extender system with a rated continuous power output of 85 kW at IAA Mobility.

Mahle's new range extender is designed to create space for cost- and resource-efficient rightsizing of battery size without drivers having to put up with long waiting times at charging stations on longer journeys.

800 V generator with fully integrated cooling concept

The system consists of a particularly efficient high-voltage generator driven by a compact combustion engine. At the heart of the 800 V generator is a permanently excited electric machine with a fully integrated cooling concept. In addition to high efficiency with peak efficiencies of more than 97 percent, this achieves a continuous power density of over 50 kW/litre, which reduces material usage, installation space requirements and costs.

One of the special features of the Mahle concept is the effective direct rotor cooling, which significantly reduces the need for heavy rare earths, among other things.

With jet ignition combustion technology

The Range Extender's turbocharged high-tech combustion engine features Mahle's Jet Ignition combustion technology, direct injection, turbocharging and Miller timing, i.e. the special control of the intake valves in combustion engines, which enables more efficient combustion and lower pollutant emissions. In range extender mode, the engine offers high efficiency of over 42 percent while remaining acoustically unobtrusive. 

»Small, lightweight, easy to integrate, and resource-efficient - the range extender from Mahle is an impressive compact, efficient powerhouse,« emphasises Dr. Marco Warth, head of corporate research and advance engineering at Mahle. The technology kit for range extender engines is supplemented by specially developed engine components such as pistons and valves. Depending on the vehicle and battery size, very long ranges of up to 1,350 km according to WLTP (Worldwide Harmonised Light Vehicles Test Procedure) can be achieved.