ZF Launches Next-Gen Electric Range Extender Systems Set for 2026 Production
In an innovative move to address evolving consumer demands for electric vehicles, ZF has announced the launch of its next-generation electric range extender (eRE) systems, set to enter production in early 2026. This includes two variants: the standard eRE and the enhanced eRE+, both designed for performance flexibility in electric vehicle (EV) applications.
A range extender functions as a combustion engine paired with an electric motor, generating power for the vehicle’s battery when it falls below a specified charge level. ZF’s designs feature high levels of integration and adaptability, accommodating both 400V and 800V architectures, as well as various semiconductor types. The eRE integrates an electric motor, inverter, software, and planetary gearset, while the eRE+ includes an intelligent clutch and differential, enabling operations as a current generator or as a supplementary drive.
With power outputs ranging from 70 kW to 150 kW, these range extenders provide a viable alternative for regions lacking reliable charging infrastructure. Dr. Otmar Scharrer, ZF’s Senior VP for R&D in electrified powertrain technology, emphasized the growing relevance of range extenders, especially as concerns about range anxiety persist among consumers despite the average all-electric range of around 500 km.
ZF argues that range extenders offer several advantages over plug-in hybrid electric vehicles (PHEVs) and traditional combustion engines, such as improved fuel efficiency and lower CO2 emissions, alongside reduced costs and development times. This positions ZF’s solutions as attractive for manufacturers new to the market.
Highlighting the untapped potential for range extenders in battery-electric platforms, Scharrer noted the company’s readiness to adapt to market demands swiftly. For further insights, check out Hyundai’s recent announcement regarding its next-gen hybrid powertrain, featuring a versatile transmission and dual motors.
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