Gasgoo Munich- On July 7, ZF announced that its eRE Plus—a four-in-one range-extender drive system tailored specifically for China's new-energy market—has officially entered mass production. It is making its debut on Leapmotor's flagship D19 model.Image source: ZFAs range-extended models accelerate toward larger batteries and longer range, the traditional setup of pairing a range extender with an independent front motor is exposing significant shortcomings. Carrying a second electric drive system that sees little use drives up costs and eats into front-end space, while the fixed coupling between the engine and generator often makes it difficult to operate within the most fuel-efficient range.To address these pain points, eRE Plus doesn't simply bolt on a second drive. Instead, it reuses a single motor, employs a bidirectional dog clutch, and combines a generation-side gear ratio with a drive-side reduction ratio. This integrates three functions—power generation, on-demand front-wheel drive boost, and efficient disengagement—into a single assembly.According to ZF, the system cuts costs by more than 30% compared to traditional architectures.Technically, eRE Plus features a highly integrated design with a hairpin motor, side-mounted inverter, and planetary gear reducer, resulting in a compact structure. It offers a choice between silicon-based or silicon carbide power devices and is compatible with both 400V and 800V platforms.Image source: ZFIts intelligent variable ratios allow independent adjustment of generation and drive speeds, making it easier for the engine to run in its efficiency sweet spot while balancing wheel-end torque and speed coverage. Integrated torsion damping and active vibration control effectively suppress torque shocks during engine startup and load fluctuations, enhancing ride comfort.The system supports smooth switching between generation, drive, and disengagement modes within 200 milliseconds. It intelligently distributes regenerative power based on overall control strategies, precisely adapting to China's driving mix—dominated by city driving with highway as a secondary focus—while also offering some off-road recovery capability.Wang Runyi, Executive Vice President of ZF Group, noted that the product is the result of collaborative innovation between ZF's China team and local partners. It aims to deliver more competitive value for automakers across cost, space, and efficiency dimensions. With its debut on the Leapmotor D19, this solution is expected to drive the evolution of range-extender drive systems toward greater efficiency and flexibility.
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