Tag Archives: Range Extender

BMW May Bring Back the Range Extender—And China Might Be the Reason Why

BMW, a company that once swore off the range extender after the quirky i3 REx, might be preparing for a comeback tour. Early reports hinted that the next-generation X5 could get a gasoline-powered generator, and now Bloomberg is echoing the same message—BMW is actively evaluating range-extender variants for upper-tier models like the X5 and 7 Series, according to insiders familiar with the brand’s long-term planning.

If you’re wondering why BMW would dust off a technology it abandoned years ago, the answer comes down to a single word: China.

China’s EREV Surge Is Too Big to Ignore

BMW’s grip on the Chinese market isn’t what it once was, but the region is still the automaker’s most important. In 2024, nearly one-third of all BMW Group sales—29.2%—went to China, outpacing the U.S. and Germany combined. And unlike Europe and North America, China has developed a serious taste for extended-range EVs (EREVs).

According to data from the China Passenger Car Association, EREV sales jumped almost 50% in the first five months of 2025 alone. Homegrown brands like BYD (with the Yangwang U8), Aito’s M9, and Li Auto’s runaway-success L9 are dominating the segment. Their formula is simple: electric driving for everyday use, plus a compact, fuel-sipping generator for when the battery runs dry.

Sound familiar? That’s essentially the same recipe BMW cooked up with the i3 REx—just scaled up for massive luxury SUVs.

Why BMW Might Be Revisiting the Idea

The pitch makes sense: a next-gen X5 or 7 Series that delivers pure EV performance most of the time, but with a compact engine humming along at a constant rpm to juice the battery on long highway runs. No wheel-driving from the engine, no hybrid complexity—just a generator smoothing out the road-trip anxiety that comes with big EVs and big distances.

And it’s not just China showing interest. In the U.S., range-extender thinking is quietly gaining traction in the heavy-duty segment. Ram will use a generator-supported electric powertrain in its upcoming Ramcharger, and the reborn Volkswagen Scout lineup is expected to offer something similar. It’s a way to keep towing capability and road-trip freedom without going back to a full gas-powered drivetrain.

Europe throws another wrinkle into the mix. Regulators are still tweaking what the 2035 combustion-engine ban will and won’t allow. Depending on how “emission-neutral” rules evolve, future EREVs might skate through as compliant, creating yet another reason for BMW to keep its options open.

Inside the Engineering Playbook

Should BMW pull the trigger, the likely blueprint remains close to the i3’s:

  • The engine never drives the wheels.
  • It runs at an optimal, fixed rpm to maximize efficiency.
  • It acts purely as a generator, feeding electricity back into the pack.

BMW already has a suite of compact, highly efficient gasoline engines ready to adapt for generator duty. Combined with the company’s EV-first platforms and existing battery know-how, development time wouldn’t be as long as it was a decade ago.

But Don’t Get Too Excited Yet

Officially, BMW isn’t confirming anything. When Bloomberg reached out, a company spokesperson stuck to the corporate script: BMW is “continuously analyzing usage patterns, customer needs, and market developments” and “reviewing the market potential of various technologies.”

Behind the scenes, the story is even murkier. Sources tell us no range-extender programs have been formally approved. Nothing is locked in. Not yet.

But the signals are getting harder to miss. China’s appetite for EREVs is exploding. U.S. buyers are warming to generator-backed electric trucks and SUVs. Europe may soon carve out regulatory breathing room for the format. And BMW has two large, spacious platforms—the X5 and 7 Series—that could take the hardware without compromise.

If the range extender is coming back from the dead, BMW might be the brand bold enough to resurrect it.

Source: Automotive News

ZF Revives Range Extender Tech with New eRE and eRE+ Systems

Sometimes, a great idea just needs time to find the right moment. Take the range extender — a technology that’s quietly lingered on the fringe of electrified mobility for decades. Now, thanks to ZF Friedrichshafen’s ambitious eRE and eRE+ systems, it might be poised for a dramatic return, bringing with it a smarter, more versatile approach to electric driving.

The Rebirth of a Forgotten Hero

The basic idea of a range extender is simple yet clever: an electric vehicle (EV) with an onboard generator powered by a small combustion engine. This generator charges the battery while on the move, ensuring that drivers aren’t tethered to charging stations. It’s the kind of solution that made early EV adopters take notice, especially when General Motors launched the Chevrolet Volt in 2011 — a series hybrid that operated primarily on electric power but could call upon a small gasoline engine when needed.

Despite the promise, range extenders never truly caught on. Larger batteries, the rise of plug-in hybrids (PHEVs), and improved charging infrastructure overshadowed the REEV (Range-Extended Electric Vehicle) concept. But now, ZF — one of the world’s leading tier-one automotive suppliers — is betting big on a revival.

Enter the eRE and eRE+: Modular, Scalable, Smart

In November 2023, ZF announced its next-generation range extender systems: the electric Range Extender (eRE) and the eRE+, developed at its Shanghai technical center to address China’s booming appetite for REEVs. These systems are modular, compact, and adaptable, aimed squarely at making integration easy for automakers and adoption seamless for consumers.

The eRE consists of a permanently excited synchronous motor (PSM) acting as a generator, paired with an inverter and a small combustion engine — all optimized for both 400V and 800V vehicle architectures. It uses either traditional silicon or advanced silicon carbide semiconductors, allowing flexibility based on cost or performance goals. Power output ranges from 70 to 110 kW (94 to 148 hp), which is sufficient for keeping batteries topped up during long drives without overburdening the system.

Then there’s the eRE+, a more advanced configuration that adds a planetary gearset, a differential, and an intelligent clutch. This turns the motor-generator into a dual-purpose unit: not only can it charge the battery, but it can also power the front wheels, enabling four-wheel drive. The eRE+ reaches power outputs of up to 150 kW (201 hp), effectively transforming the once humble range extender into a performance-capable, all-wheel-drive contributor.

The Appeal: Simplicity Meets Sustainability

Compared to PHEVs, REEVs have distinct advantages. Since propulsion is always electric, the mechanical complexity is reduced — no need to juggle torque delivery between an ICE and e-motor. The onboard generator simply charges the battery, allowing for a smaller pack, which cuts weight and cost. That makes REEVs especially attractive for developing markets or regions with patchy charging infrastructure.

Kay Schmidt, Product Line Manager at ZF, underscores the environmental appeal: “We recognized the advantages of range extenders early on… Our modular solution significantly reduces the carbon footprint compared to PHEVs.”

Furthermore, using proven components from ZF’s electric and hybrid portfolio keeps development costs low and boosts reliability. It’s a plug-and-play strategy that reduces the engineering burden for automakers — a major factor as they juggle multiple electrification strategies.

Industry Momentum and Market Outlook

While China has been the key growth engine for REEVs, Europe and North America may soon follow. Automakers like Hyundai, Ford, and Stellantis are reportedly evaluating ZF’s technology, with vehicle launches expected within the next two years. With pressure mounting to decarbonize fleets while maintaining affordability and usability, REEVs could offer a practical middle ground.

ZF plans to begin volume production of its eRE and eRE+ systems in 2026. If successful, we could witness a resurgence of the range extender not just as a niche solution, but as a mainstream bridge toward full electrification.

Final Thoughts: From Relic to Relevance

The story of the range extender mirrors the broader EV transition — full of false starts, course corrections, and evolving priorities. But with advancements like ZF’s eRE lineup, the concept is no longer just a relic of early EV experimentation. It’s becoming a serious contender in the electrified powertrain landscape.

As infrastructure races to catch up and battery tech continues to evolve, range extenders may just fill that critical gap — not as a fallback, but as a forward-thinking solution.

Source: ZF Friedrichshafen