German auto supplier ZF is paving the way for the future of electric vehicles with its plans to introduce a new electric range-extender system in 2026. This innovative technology combines the benefits of electric and gas-powered engines, providing a solution for range anxiety and enhancing overall efficiency.
The concept of an electric range extender is simple yet effective. It consists of an electric motor powered by a large battery, similar to a traditional electric vehicle (EV). However, what sets it apart is the inclusion of a small gas-powered engine that acts as a generator to recharge the battery when needed, eliminating the need for frequent charging stops.
While range extenders are not a new concept, ZF sees potential in revitalizing this technology. Dr. Otmar Scharrer, Senior Vice President of R&D at ZF, highlights that despite the increasing range of electric vehicles, range anxiety still influences many buyers’ decisions. This is where range extenders come into play, offering a practical solution for those concerned about running out of battery power.
ZF’s new range extender system comes in two variants: eRE and eRE+. The eRE model features an electric motor connected to an integrated converter and planetary gearset, while the eRE+ adds an intelligent clutch and differential for added flexibility. Both models offer adjustable power output ranging from 93 to 147 horsepower for the eRE and 93 to 201 hp for the eRE+, catering to different customer needs.
Scharrer emphasizes that range extenders are a cost-effective alternative to larger batteries or plug-in hybrids. They are easier to produce, have shorter development cycles, and utilize simpler supply chains. Additionally, since the gas engine is not directly connected to the wheels, it can operate at its most efficient rpm, reducing fuel consumption and emissions.
ZF’s commitment to innovation is reflected in its system and platform concept, which allows for customization to meet specific customer requirements quickly. This approach positions ZF as a leader in the evolving automotive industry, where flexibility and adaptability are key to success.
The demand for range extender systems is on the rise, with other manufacturers like Dodge and VW-backed Scout Motors also exploring similar technologies. With ZF’s new electric range-extender system set to debut in 2026, the future of electric vehicles looks brighter than ever, offering a compelling solution for consumers seeking enhanced range and efficiency.
