- ZF eRE Plus 4-in-1 Range Extender Drive System enters production.
- Integrated architecture cuts hardware costs by over 30%.
ZF Friedrichshafen AG has started mass production of its eRE Plus 4-in-1 range extender drive system, with the technology selected for the flagship D19 model from Leapmotor. The solution was engineered specifically for the rapidly expanding new energy vehicle market in China and is intended for range-extended electric vehicles (REEVs). By combining multiple functions into a compact architecture, the company aims to improve drivetrain efficiency while lowering overall system complexity and manufacturing costs.
Integrated Design Reduces Hardware Complexity
According to ZF, the eRE Plus combines power generation, on-demand front-axle drive assistance and efficient front-axle disengagement by reusing a single electric motor, motor controller and transmission. Unlike conventional all-wheel-drive range-extender systems that require a separate front-drive motor and dedicated motor controller, this configuration removes the need for a second electric drive system. As a result, hardware redundancy is significantly reduced, enabling related system costs to decrease by more than 30% while maintaining the required vehicle functionality.
Single Motor Architecture Enables Fast Mode Switching
The eRE Plus system incorporates a single electric motor paired with a smart gearbox, allowing rapid transitions between power generation, vehicle drive and front-axle disengagement modes in under 200 milliseconds. Its technical configuration includes a hairpin-wound motor, a side-mounted inverter and a planetary gear reducer. The system also supports both silicon-based and silicon carbide power devices while remaining compatible with both 400 V and 800 V electrical architectures, providing flexibility for a wide range of future REEV platforms.
Frequently Asked Questions
What is the ZF eRE Plus 4-in-1 range extender drive system?
The ZF eRE Plus 4-in-1 range extender drive system is an integrated propulsion solution developed for range-extended electric vehicles. It combines power generation, front-axle drive assistance and front-axle disengagement using a single motor, motor controller and transmission. This design eliminates the need for a separate front electric drive system, reducing hardware redundancy and lowering system costs by more than 30%. It also supports both 400 V and 800 V electrical architectures and multiple power semiconductor technologies.
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