MAHLE says its new range extender system and advanced electric motors will bridge the gap to climate-neutral commercial fleets

MAHLE is accelerating the electrification of road transport. With its new range extender system for heavy electric (BEV) trucks, the Stuttgart automotive component supplier is now paving the way for a faster changeover from diesel trucks, which currently dominate the road transport sector, to battery-electric trucks.
Range extender electric trucks combine the sustainability of electric drive systems with the flexibility and range of the internal combustion engine.
MAHLE says they assist the cost-intensive road transport sector to lower total cost of ownership over the vehicle life cycle and facilitate climate-friendly investments, while contributing to achieving European carbon dioxide fleet targets.
With its electrification products for commercial vehicles, MAHLE says it is among the market leaders in Europe and is also expanding its presence with Chinese commercial vehicle manufacturers, who are increasingly entering the European market with battery-electric trucks.
“With high-performance technologies and production-ready products for electrification we are aiming for further growth,” MAHLE Chairman of the Group Management Board and Chief Executive Officer, Arnd Franz, said at a tech event held by the company in Stuttgart.
At this year’s IAA Transportation, which is to be held in Hannover from September 15 to 20, MAHLE is exhibiting under the motto of “Electrified. Efficient. Economical.”
At this event, the company will be presenting its new range extender system as a world premiere as well as other high-efficiency products for greater sustainability and improved economics in the transport sector.
In addition to products for battery-electric trucks and hybrids, the technology group is showcasing technologies for the use of renewable fuels for the defossilisation of the road transport sector.
Forwarders and fleet operators face the challenge of making their business more climate-friendly despite steadily growing pressure on costs, without jeopardising their economic viability or competitiveness.
In this sector, the main obstacles to the growth of e-mobility are still the inadequate charging infrastructure for commercial vehicles in many regions and the limited ranges of battery-electric trucks.
Flexibility and reliability are the key factors for business success in this sector.
“Time and energy are limited, valuable resources, especially in road transport business; only operators who work economically can survive,” Arnd said.
“With electrification products, MAHLE can help make heavy trucks more efficient and flexible at the same time as reducing operating expenses.
“This is what we will be demonstrating to our customers, international vehicle manufacturers, and fleet operators at this year’s IAA Transportation.”

Range extender system – a range and flexibility booster for fleets
MAHLE says its range extender system provides a flexible range without any compromises and efficiency without restrictions.
With this MAHLE innovation on board, the company says a battery-electric truck can cover all the daily ranges required.
“Our range extender is a smart ‘emergency power unit’ that is activated at precisely the right moment and significantly increases the range available,” Vice President MAHLE Corporate Research and Advanced Engineering, Dr Marco Warth, said.
The key component of the new system is an efficient high-voltage generator with a continuous output of 110 kilowatts (kW) and a peak output of up to 130 kW, driven by a compact internal combustion engine.
The high-voltage generator supplies reliable power to the electric drive system even on difficult trips with a full load. Its architecture can be adapted easily to the performance requirements of a variety of applications and regional markets.
Thanks to its newly developed advanced oil cooling system, the generator has a power density of more than 7 kW per kilogram, allowing a high-power output with reduced weight and simplified interfaces.
MAHLE has developed its range extender system as an autonomous unit combining generator, internal combustion engine, thermal and fluid management systems, fuel tank, AdBlue tank and exhaust gas treatment in a compact “box.”
This unit will fit into the normal battery installation space of a battery-electric truck and can therefore be integrated into existing battery-electric vehicle platforms without any problems.
The system replaces about one-third of the present battery capacity of a battery-electric truck, allowing the truck to be equipped with a smaller battery.
As a result, the rear axle load is reduced by about 400 kg and the total vehicle weight by about 600 kg. All in all, a range extender BEV truck 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.
Under real-life operating conditions, the truck emits about 80 percent less CO2 in range extender operation than a truck with a conventional drive system.
If the internal combustion engine, which is biofuel-ready thanks to MAHLE components, is operated with renewable fuels such as the advanced HVO100 bio-diesel, the truck has virtually zero CO2 emissions, says MAHLE.
A comprehensive thermal management system with 48 kW of high-temperature and 15 kW of low-temperature cooling capacity ensures stable operation of the range extender system under heavy-duty operating conditions.
For the internal combustion engine, MAHLE has continued the development of components to reduce fuel consumption and operating costs.
For example, the new Power Cell Unit (PCU) features higher performance, a longer service life and greater efficiency.
The new oil management system combining the oil filter, oil cooling system and bypass valve as well as other optional functions, also features improved efficiency and economics.
Depending on the material used for the housing, MAHLE says the material cost can be reduced by up to 20 percent, the CO2 footprint of the product by up to 50 percent and the weight by as much as 25 percent.
In addition, this product has a longer service life, further reducing overall operating expenses. The PCU and the oil management module can also be used with other types of drive system and are being showcased for the first time at IAA Transportation.
“Our range extender is the key to disconnecting the market ramp-up of battery-electric trucks from the inadequate pace of infrastructure development,” Dr Warth said.
“If the charging station is busy, or alternative routes are called for as a result of weather conditions or congestion and infrastructure reaches its limits, other fleets can be stranded; an e-truck with range extender just carries on. Operational availability is maintained, even under peak conditions.”

MCT electric motor for heavy commercial vehicles – free from rare earth elements, lighter, and more efficient
As another world premiere at IAA Transportation, the company will be showcasing a MAHLE Contactless Transmitter (MCT) electric motor developed for use on the electric drive axles of heavy commercial vehicles.
This motor is not equipped with permanent magnets and therefore does not require any rare earth elements.
Compared with a benchmark permanent magnet synchronous motor (PMSM), the MCT electric motor saves up to three kilograms of rare earth magnets per vehicle.
The avoidance of rare earth magnets further reduces the environmental footprint of the electric drive system.
The new motor from MAHLE is said to be 10 percent lighter and more efficient than permanently excited electric motors with magnets under real-life driving conditions.
MAHLE says the advantage compared with the permanently excited variant is higher efficiency within a significantly larger operating envelope covering a variety of different driving situations.
The MCT electric motor has a peak output of 370 kW and torque of over 900 Nm at 3,900 rpm. The motor efficiency in the VECTO cycle, an EU simulation tool for determining the fuel efficiency of new vehicles, is about 95 percent.

Renewable fuels need to be expanded, says MAHLE
The internal combustion engine remains the dominant drive system for commercial vehicles throughout the world. The share of internal combustion engines in this sector is expected to fall only slightly from the current figure of about 83 percent to about 73 percent by 2035, while electric drive systems will continue to grow but will still play a secondary role.
Even if the ramp-up of e-mobility were to succeed as planned, the CO2 emissions of the conventional fleet would still remain at the 2010 level, said Arnd, referring to figures published by the International Energy Agency (IEA): “It is therefore clear that, in addition to electrification, supplies of sustainable fuels such as HVO100 and bio-LNG need to be massively expanded.”
In this situation, MAHLE says it remains a reliable supplier of components for high-efficiency internal combustion engines which can make a considerable contribution to reducing carbon dioxide emissions in road transport with renewable fuels.
In the market for medium and heavy commercial vehicles, MAHLE says it is among the top five suppliers of components for internal combustion engines for nearly each product group. In the case of piston assemblies, cooling modules, Visco fans and air conditioning systems, the group states it is among the top three suppliers or even the market leader.
Large quantities of biofuels are already available, and these can help in effectively reducing carbon dioxide emissions immediately, also and especially with respect to existing vehicles.
The MAHLE Global Biomobility Center in Brazil has been in operation for two years for the further development of biofuels, bio-materials, and related applications. Currently, the research and development facility is working on a wide variety of projects, for example for optimising the efficiency of biofuel engines and multi-fuel engines as well as new, sustainable materials and their applications.
MAHLE also sees hydrogen and hydrogen derivatives as a key factor for the de-fossilization of the road transport sector and says it is therefore working on all the major hydrogen engine projects that are currently in progress.
MAHLE is currently participating in a large number of major development projects in Europe and Asia.
“The transformation to climate-neutral road transport is technically feasible and can also be accomplished economically,” Arnd said.
However, he added that this would only be possible if industry, government and customers acted together in a coordinated way.
“At MAHLE, we contribute technological diversity and comprehensive systems competence to actively forge ahead with the transformation. The truck of the future will operate with MAHLE!” he said.

For more from MAHLE, visit www.mahle.com