German supplier Mahle has announced the premiere of a new range extender system with a rated continuous output of 85 kW for the IAA in September. The unit is set to impress with its high efficiency and power density – and keep Mahle’s combustion engine business alive for longer.
The system consists of a “especially efficient high-voltage generator powered by a compact internal combustion engine,” Mahle states. The generator is a permanently excited electric machine with a fully integrated cooling concept. According to Mahle, the 800-volt unit combines “high peak efficiency in excess of 97 per cent” and achieves a power density of over 50 kW per litre, “minimising material and space requirements as well as costs.” These figures refer to the electric part of the range extender system; the combustion engine naturally does not reach an efficiency of up to 97 per cent.
However, Mahle says its high-tech petrol engine still achieves 42 per cent efficiency while incorporating several Mahle components. With this range extender system, the supplier aims to “market acceptance of battery-electric vehicles” – vehicles using this drivetrain could reach up to 1,350 kilometres of WLTP range, depending on model and battery size.
“It is small, lightweight, easy to integrate and conserves resources – Mahle’s range extender is a convincingly compact, efficient power pack for drive systems,” said Marco Warth, Head of Corporate Research and Advanced Engineering.
At Mahle’s Tech Day ahead of the IAA, CEO Arnd Franz called for technological neutrality and openness towards hybrids and range extenders – and urged a rapid revision of CO2 regulation in Europe to include sustainable combustion engines and climate-neutral fuels. “As a supplier, we need technology neutrality in legislation. So that we can make rapid progress with climate protection. So that the expertise and innovative strength of the European automotive industry can continue to flourish in Europe. So that jobs remain in Europe and Europe’s economy can recover its old strength,” said Franz. “We have a clear commitment to climate protection. And to e-mobility. We are ready.”
The transformation of drivetrains poses major challenges for suppliers like Mahle. For years, the company earned significant revenue from its conventional drivetrain solutions, such as pistons and injection systems, and must now invest in further development of these high-tech components to meet customer and regulatory demands. At the same time, carmakers are pushing down prices for their suppliers, who nonetheless also have to invest in electric drives – Mahle sees great potential here thanks to its thermal management expertise.
Mahle’s IAA presence will therefore be under the motto “Efficiency3”, showcasing innovations from all three strategic fields. Alongside the range extender and engine components for methanol-capable combustion engines, Mahle will also present a compact thermal management module with an integrated heat pump to significantly extend EV range.
This module is designed to act as the central interface for the entire cooling and refrigerant circuit of an EV, ensuring that “each component of the drive and energy storage system is maintained at the right temperature at all times under all climate conditions at the same time as ensuring a comfortable climate in the passenger compartment,” as Mahle explains. The thermal management module is designed for the current refrigerant R1234yf but can also operate with the alternative future refrigerant R290 (propane) with minimal adjustments.
“This provides automakers with security for the future when integrating the system in current vehicle platforms as extensive design modifications will not be needed to change the system over to the new refrigerant,” Warth explained. Thanks to the modular, compact system layout, only three instead of the previous four coolant pumps are needed in the vehicle. The system is currently in development and will go into series production within the next two years.
mahle.com
