ZF pushes range extender technology to the next level: A boost for the electric range
Images are for editorial use only. ZF further develops electric range extender systems –production begins at the start of 2026 Longer range, lower emissions: range extenders make electrified mobility attractive to more buyers Advantages for automotive manufacturers: shorter development cycles, less effort than BEV platform approach Friedrichshafen, Germany. Many potential buyers of electric vehicles still feel the so-called range anxiety that accompanies all-electric driving. In these cases, range extenders can be one solution: A combustion-powered generator that is coupled to an electric motor and thus generates energy for the vehicle battery. ZF is now introducing its new generation of this technology, which will go into volume production in 2026. Designed to meet increasing global demand, this further development is ideally suited to meet dynamic market and customer requirements as well as flexible drive concepts. It is an unnerving scenario for many electric drivers: the battery’s state of charge dropping to near zero with no charging station in sight. “Although the all-electric range of passenger cars is around 500 km on average, range anxiety still influences a wide range of buyers when choosing their next vehicle,” explains Dr. Otmar Scharrer, Senior Vice President R&D, Electrified Powertrain Technology. This is especially true in regions where a charging infrastructure is not yet universally available. ZF is currently developing the next generation of range extenders for these situations. “These represent a real alternative to larger – and thus more expensive – batteries or plug-in hybrids,” says Dr. Scharrer. With range extenders, a combustion-powered engine is coupled to an electric motor that generates power for the vehicle battery as soon as its state of charge drops below a certain threshold. As the name implies, this increases the range that can be driven electrically. A further advantage over PHEVs or conventional combustion engines is that the range extender unit always operates in the ideal performance range for fuel consumption and lower CO2 emissions. ZF’s range extender technology: A lot of experience, new developmentsZF already has range extender technology in volume production and amongst other vehicles, it was installed in the iconic London taxi. ZF is currently working on the next generation, with the electric Range Extender (eRE) and the electric Range Extender plus (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 for both models. The output ranges from 70 to 110 kW (eRE) or 70 to 150 kW (eRE+). “The new interest and the increased demand for range extenders shows that the potential of this technology is far from exhausted – in particular for model platforms that are already designed for battery-electric drivelines,” says Scharrer while adding: “Behind our solutions is a system and platform concept. This means that we are optimally equipped to be able to respond to all customer and market requirements with shorter development cycles.” The advantages of range extenders for manufacturers and customersCompared to parallel-hybrid drive solutions, for example a PHEV, range extenders are compelling due to their lower additional costs, shorter development cycles, reduced platform integration 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 with so-called “Range Extended Electric Vehicles” (REEV), which, thanks to the technology, can cover distances of more than 700 kilometres. “This is where we find it convenient that there is a wide range of BEV platforms that can be supplemented by range extenders,” explains Scharrer. This was one reason why ZF locations in China headed up development. However, the interest of manufacturers is also increasing in the USA and Europe. “The market for all-electric vehicles has not developed as much as predicted a few years ago,” says Scharrer. “For this intermediate phase, range extenders can be the ideal solution.” REEV drivers can enjoy the advantages of electromobility without having to sacrifice the flexibility of PHEVs or combustion engine passenger cars. Range extenders are also of interest for traditional manufacturers. They allow smaller (and therefore more economical) vehicle batteries to be installed and help to comply with emission limit values for fleets. Captions: With a range extender, drivers can enjoy the advantages of electromobility without having to sacrifice the flexibility of a classic combustion engine or plug-in hybrid vehicle. With its latest electric Range Extender (eRE) system, ZF is currently developing a range extender for the next generation. The modular platform approach allows the technology to respond to dynamic customer and market requirements. ZF utilises its expertise in transmission technology to develop the “electric Range Extender plus” (eRE+) system. The technology can be used either as a current generator or as an additional secondary drive. Images: ZF Press contact:Media Contact UK:Elan PR LtdKay RobinsonMob: +44 (0)7482 560217Email: kay@elan-pr.com Nick BaileyMob: +44 (0)7813 956664Email: nick@elan-pr.com About ZFZF is a global technology company. The company supplies highly developed products and systems for the mobility of passenger cars, commercial vehicles and industrial technology. With its comprehensive product range, ZF primarily supplies automotive manufacturers, mobility providers and start-up companies in the field of transport and mobility. ZF electrifies a wide range of vehicle categories. With its products, the company contributes to reducing emissions, protecting the climate and enhancing safe mobility. In addition to the passenger car and commercial vehicle automotive sectors, ZF also serves market segments such as construction and agricultural machinery, wind power, marine propulsion, rail drives and test systems. In 2024, ZF achieved sales of €41.4 billion with approximately 161,600 employees worldwide. The company is represented at 161 production locations in 30 countries. For further press information and photos please visit: www.zf.com
