E-Mobility Leapmotor Uses Range Extender from ZF

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ZF has received its first customer order for its advanced range extender technology eRE+: Starting in 2026, Leapmotor will also offer a version with a range extender for its premium SUV D19.

ZF has secured its first customer order for its advanced range extender technology, eRE+: Chinese automaker Leapmotor will offer a version with a range extender for the premium SUV D19 starting in 2026. In the standard operation of the range extender, the generator mode, a combustion engine drives the electric machine, charges the high-voltage battery, and thus extends its range. The eRE+ technology additionally offers switchable all-wheel drive via the front axle and provides a boost of up to 200 kW for overtaking maneuvers.

Flexible Drivetrain Concept for International Markets

"Range extenders are currently increasingly in demand, especially in the automotive markets of China and North America," explains Sebastian Schmitt, Head of the ZF Division Electrified Powertrain Technologies. While REEVs (Range Extended Electric Vehicles) are considered a variant of so-called "New Energy Vehicles" in the Far East, allowing a smaller battery to be charged by a combustion engine during the drive, they are also becoming an increasingly popular way in the USA to remain mobile with a battery-powered vehicle independent of the charging infrastructure. "We have prepared for this demand in time with a flexible range of range extender technology and local production capacities. This strategy has paid off and led to our new order from Leapmotor," adds Timo Maisel, responsible for the Electrified Powertrain Technology Division in Asia.

eRE+: Extended Range Extender With All-Wheel Drive Function

The advanced range extender technology from ZF, named eRE+, is being used for the first time in the Leapmotor D19 SUV. The basis, as with the eRE, is an electric machine with an integrated inverter, suitable software, and a planetary gear set. While the eRE is designed purely as a power generator, the eRE+ additionally features an intelligent clutch and a differential, allowing it to temporarily act as a secondary drive.

With eRE+, automakers can offer switchable all-wheel functionality and a boost without needing to install separate components or undertake additional development efforts. The range extender used in the D19 delivers 90 kW of generator power and a peak drive output of 200 kW. This enables the SUV to achieve a total range of more than 620 miles. The combustion engine used in this system is not included in ZF's scope of supply.

Contribution to CO₂ Reduction And Support for EU Climate Goals

The engine of the range extender always operates in the most fuel-efficient performance range, which ensures low fuel consumption and, consequently, low CO₂ emissions. "Range extender technology builds a bridge between today's customer needs and the fully electric future. It makes a significant contribution to reducing CO₂ emissions and helps models based on pure electric platforms gain greater acceptance and market penetration," says Mathias Miedreich, CEO of ZF.

Range Extender Technology As A Bridge to the All-Electric Future

According to ZF, range extenders are compelling due to their low additional costs, short development times, and minimal platform complexity. This also simplifies supply chains, making the technology attractive to manufacturers who do not want to rely on traditional combustion engine powertrains for their models. "With our range extender, we can overcome range anxiety among end customers while effectively supporting the EU's climate goals. Our technology combines the advantages of electromobility with the flexibility consumers expect. An EU approval of the range extender beyond 2035 would be a pragmatic step, aligning with Brussels' more realistic perspective on the ramp-up of e-mobility," emphasizes Miedreich.

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