ZF's eRE Plus Quad-in-One Range-Extending Drive System Enters Mass Production, Debuts on Leapmotor D19

ZF's eRE Plus integrated four-in-one range-extender drive system, specifically developed for China's new energy vehicle market, has officially entered mass production and made its debut on Leapmotor’s flagship model D19. Addressing key challenges of current range-extended electric vehicles—such as low utilization of the secondary electric drive system, high costs, excessive front-compartment space occupation, and limited fuel efficiency due to fixed engine-generator pairing—the eRE Plus adopts a single-motor reuse design. Combined with a bidirectional claw-type clutch switching mechanism and an optimized combination of generator-side pre-gear ratio and drive-side reduction ratio, the system integrates three functions into one: power generation, on-demand front-wheel assist, and efficient disengagement. Compared to conventional architectures featuring a separate “range extender + independent front-drive motor and inverter,” the eRE Plus reduces system costs by over 30%. It employs a highly integrated structure combining a hairpin-wound motor, side-mounted inverter, and planetary gear reducer, supporting both silicon-based and silicon carbide (SiC) power devices and compatible with both 400V and 800V electrical platforms. The system features intelligent variable-ratio control, enabling independent adjustment of the generator speed ratio and drive reduction ratio. This allows the engine to operate more frequently within its optimal efficiency range while meeting requirements for wheel torque output and vehicle speed coverage. Additionally, the eRE Plus integrates torsional vibration damping and active vibration suppression functions, effectively mitigating torque shocks during engine start-stop cycles and load transitions to enhance ride comfort. It can seamlessly switch among power generation, driving, and disengagement modes within 200 milliseconds and intelligently allocates regenerative energy recovery based on the vehicle’s control strategy. The system is tailored for typical Chinese driving scenarios—primarily urban with occasional highway use—and also offers limited off-road traction capability.