New ZF Range Extender Helps EVs Go Further Using Petrol

Electric vehicles are great, but for many drivers, the worry about running out of charge – known as "range anxiety" – is a real barrier. 

German automotive supplier ZF believes it has a rather clever solution that could help ease these fears and bridge the gap towards a fully electric future: a new range extending system.

Range extender tech isn't a brand-new innovation. Early examples of mainstream cars featuring this kind of system included the Chevrolet Volt and later the BMW i3. 

However, such systems are less frequently seen these days because the driving range of many current electric vehicles is now comparable to that of cars with internal combustion engines. 

Despite this, ZF believes there remains an opportunity in the market for an improved range extender system.

Petrol Power for Electric Kilometres

ZF's technology essentially adds a small generator to an electric car. The vehicle primarily runs on battery power, using an electric motor. 

However, when the battery charge dips too low, the onboard generator – which is typically a compact petrol engine – quietly starts up. Its sole job is to generate electricity to top up the battery, allowing you to keep driving without needing to find a charging point immediately.

Two Variants: eRE and eRE+

The basic eRE system links an electric motor to a converter. 

The more advanced eRE+, however, adds an "intelligent clutch" and a differential. This means the eRE+ isn't just a generator; it can also act as a secondary power source to help drive the wheels directly if needed.

Keeping ICE Relevant (For Now)

ZF sees these range extenders as a more straightforward and cost-effective solution compared to complex plug-in hybrids. 

By using a combustion engine purely as a generator, they can operate more efficiently, potentially offering better fuel economy than traditional cars where the engine is always mechanically linked to the wheels. 

This technology could help keep internal combustion engines relevant for a while longer, providing a stepping stone for drivers not yet ready to commit to pure electric vehicles.

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