ZF, a leading global technology company, has announced the next generation of its range extender technology, set to enter volume production in 2026. Designed to address persistent range anxiety among electric vehicle (EV) buyers, these new systems offer a flexible, efficient solution for extending battery range without the need for oversized battery packs or complex hybrid architectures.
Although modern EVs typically offer around 500 km of range, many potential buyers still hesitate. 'This is where range extenders present a real alternative to larger, more expensive batteries or traditional plug-in hybrids,' said Dr Otmar Scharrer, Senior Vice President R&D, Electrified Powertrain Technology at ZF.
The next-generation solutions, named electric Range Extender (eRE) and electric Range Extender Plus (eRE+), are highly integrated systems adaptable to various power levels, E/E architectures, and voltage platforms (400V or 800V). The eRE combines an electric motor with an integrated inverter, software, and planetary gearset, while the eRE+ adds an intelligent clutch and a differential, allowing it to serve both as a current generator and a secondary drive. Outputs range from 70 to 110 kW for the eRE and up to 150 kW for the eRE+.
Unlike plug-in hybrids, range extenders are optimised to run in the most efficient operating range, ensuring lower fuel consumption and reduced CO2 emissions. They also offer manufacturers lower additional costs, shorter development cycles, reduced platform complexity, and simpler supply chain management—key advantages especially for new entrants in the EV market.
ZF’s expertise in this space is well established, with its electric machines already deployed in the iconic London taxi fleet. Now, with growing global interest, particularly from China where range-extended EVs (REEVs) are gaining momentum, ZF’s new solutions are well-timed. Chinese development teams played a central role in shaping this new technology to meet market demands for vehicles capable of exceeding 700 km in range.
Interest is also rising in the US and Europe, where market projections for pure battery-electric vehicles have fallen short. 'For this intermediate phase, range extenders can offer the perfect solution,' said Scharrer. By enabling smaller, more economical batteries while maintaining long-range capability, range extenders help traditional and emerging automakers alike meet customer expectations and regulatory emission targets.
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