EV Range Extenders for Commercial Applications
We supply EV range extenders for a broad range of commercial applications, including light commercial vehicles, medium- and heavy-duty commercial vehicles, off-road equipment, and marine applications. Our solutions support vehicle platforms such as urban delivery vehicles, trucks, buses, mining vehicles, port equipment, construction machinery, and hybrid marine systems.
Designed for diverse duty cycles and operating environments, our range extenders enable commercial EVs to achieve extended driving range, enhanced operational flexibility, and improved total cost of ownership (TCO), while reducing dependence on charging infrastructure.
Extended Range for Diverse Operations
Our EV range extenders provide additional onboard power generation to address range limitations and charging availability challenges, enabling commercial electric vehicles to operate reliably across longer routes and more demanding duty cycles.
High-Efficiency Power Generation
Through optimized engine-generator integration and independent power generation control, our EV range extenders allow the combustion engine to operate within its high-efficiency operating zone, improving fuel economy and reducing lifecycle operating costs.
Scalable Solutions Across Multiple Platforms
From LCVs and medium-duty trucks to heavy-duty vehicles, off-road equipment, and marine systems, our modular EV range extender solutions support various vehicle platforms and operating environments.
EV Range Extenders by Commercial Applications
Our EV range extenders portfolio covers rated power outputs from 10 kW to 300 kW, providing scalable solutions for different commercial vehicle platforms and operating requirements. The product range includes compact systems for light commercial vehicles, high-power solutions for medium and heavy-duty vehicles, as well as dedicated configurations for off-road equipment and marine applications.
Each solution is optimized for specific vehicle architectures, duty cycles, and integration requirements, enabling OEM customers to select the appropriate power level and system configuration for their electrification projects.
01
EV Range Extenders for Light Commercial Vehicles
EV range extenders provide an effective electrification solution for light commercial vehicles operating in scenarios where battery-only operation may be limited by range requirements, charging availability, or harsh operating conditions. By combining battery-electric driving with an onboard power generation system, EV range extenders enable LCVs to maintain the efficiency and driving characteristics of electric vehicles while improving operational flexibility.
For LCV applications where daily operating mileage typically reaches 150–300 km, OEMs can adopt a battery-electric platform combined with a compact EV range extender to achieve an optimized balance between battery size, vehicle cost, and operational flexibility. The vehicle operates primarily in pure electric mode for regular routes, while the range extender provides additional energy support when longer trips or challenging operating conditions exceed battery capability.
EV Range Extender Solution Advantages for LCVs
Extended Range Without Oversized Battery Packs
Enable longer-distance operation while reducing battery capacity, vehicle weight, and initial system cost.
Reliable Operation Beyond Charging Infrastructure Limitations
Provide an additional onboard energy source to maintain fleet operation when charging availability is limited.
Pure Electric Driving Experience
Maintain zero mechanical connection between the range extender and drivetrain, preserving smooth and responsive EV driving characteristics.
Optimized Total Cost of Ownership
Combine the low operating cost of electric driving with the flexibility of fuel-based energy generation for commercial applications.
Stable Performance Under Different Operating Conditions
Support variable payloads, seasonal temperature changes, and demanding delivery schedules.
Our LCV EV Range Extenders Portfolio
|
Model
|
Fuel Type
|
Rated / Peak Power / Voltage
|
Voltage Range
|
Generation Efficiency
|
Dimensions
|
Weight
|
Emission
|
|---|---|---|---|---|---|---|---|
|
JRE12-G-V-01
|
Gasoline
|
12 kW, 324 VDC
|
144-750 VDC
|
2.38 kWh/L
|
L556*W421*H565 mm
|
105 kg
|
China Stage V
|
|
JRE15-D-V-01
|
Diesel
|
15 kW, 576 VDC
|
144-750 VDC
|
3.23 kWh/L
|
L680*W442*H592 mm
|
189 kg
|
China Stage IV
|
|
JRE20-G-V-01
|
Gasoline
|
20 kW, 480 VDC
|
300-750 VDC
|
2.50 kWh/L
|
L678*W465*H575 mm
|
130 kg
|
China Stage V
|
|
JRE20-D-V-01
|
Diesel
|
20 kW / 25 kW, 525 VDC
|
300-750 VDC
|
3.33 kWh/L
|
L696*W440*H610 mm
|
210 kg
|
China Stage IV
|
|
JRE30-G-V-01
|
Gasoline
|
30 kW / 35 kW, 540 VDC
|
300-750 VDC
|
2.78 kWh/L
|
L720*W629*H485 mm
|
154 kg
|
China Stage VI
|
|
JRE35-G-V-01
|
Gasoline
|
35 kW / 40 kW, 540 VDC
|
350-750 VDC
|
2.78 kWh/L
|
L732*W579*H599 mm
|
167 kg
|
China Stage VI
|
|
JRE40-G-V-01
|
Gasoline
|
40 kW / 45 kW, 540 VDC
|
350-750 VDC
|
2.78 kWh/L
|
L732*W579*H599 mm
|
170 kg
|
China Stage VI
|
* For additional configurations and customized solutions, please contact us at: contact@jenwyntech.com
Why Choose Our EV Range Extenders for LCVs
Integrated 5-in-1 Modular Power Generation System
Integrates engine, engine ECU, generator, GCU, and range extender control unit (RCU) for simplified vehicle integration.
Fast Vehicle Integration & Remote Calibration Capability
Supports dynamic/static system calibration, remote diagnostics, and rapid performance optimization during vehicle development and after-sales service.
Advanced Thermal & NVH Management
Features mature engine-generator thermal management and three-level noise and vibration control strategies for enhanced driving comfort.
Flexible Power Generation Strategies
Supports constant voltage, constant power, and load-following power generation modes to adapt to different vehicle energy requirements.
Scalable System Architecture
Supports multiple range extender units operating in parallel with master-slave control strategies for higher power applications.
02
EV Range Extenders for Medium & Heavy Commercial Vehicles
Medium and heavy commercial vehicles operate under demanding duty cycles characterized by high payloads, extended operating hours, and limited charging flexibility. For applications where battery-only solutions may face challenges in range, charging availability, or operating efficiency, range extender technology provides a practical pathway to enhance vehicle versatility while maintaining the advantages of electric propulsion.
Jenwyn Tech offers EV range extenders with rated power outputs from 65 kW to 200 kW, designed for a wide range of medium and heavy commercial vehicle applications, including 4–12 ton trucks, 6–12 meter buses, concrete mixer trucks, sanitation vehicles, dump trucks, and tractor units. By combining electric drive efficiency with onboard power generation, our solutions enable longer operating ranges, improved energy flexibility, and optimized total cost of ownership for commercial fleets.
EV Range Extender Solution Advantages for Medium and Heavy Commercial Vehicles
Extended Operating Range for Demanding Duty Cycles
Enables commercial vehicles to maintain operational continuity on long-distance routes and high-utilization applications where charging infrastructure availability may be limited.
Reduced Dependence on Charging Infrastructure
Provides additional onboard energy generation capability, reducing downtime caused by charging duration, charging station availability, and route constraints.
Enhanced Low-Temperature Performance
Provides additional energy support in cold climates, helping mitigate battery performance degradation and maintain stable vehicle operation.
Optimized Battery Capacity and Vehicle Payload
Allows OEMs to select an application-specific battery size, reducing unnecessary battery weight and initial vehicle cost while maintaining required operating capability.
Our Medium and Heavy Commercial Vehicle Range Extenders Portfolio
|
Model
|
Fuel Type
|
Application
|
Rated / Peak Power / Voltage
|
Voltage Range
|
Generation Efficiency
|
Dimensions
|
Weight
|
Emission
|
|---|---|---|---|---|---|---|---|---|
|
JRE75-D-V-01
|
Diesel
|
8-12 t truck; 8-10 m bus
|
75 kW / 85 kW, 618 VDC
|
500-750 VDC
|
4.00 kWh/L
|
L931*W685*H785 mm
|
380 kg
|
China Stage VI-B
|
|
JRE65-D-V-01
|
Diesel
|
4.5-8 t truck; 6-8 m bus
|
65 kW / 80 kW, 576 VDC
|
400-720 VDC
|
4.06 kWh/L
|
L813*W670*H791 mm
|
270 kg
|
China Stage VI
|
|
JRE75-N-V-01
|
Natural Gas
|
8-12 t truck; 8-10 m bus
|
75 kW / 100 kW, 576 VDC
|
400-720 VDC
|
4.71 kWh/kg
|
L947*W649*H910 mm
|
475 kg
|
China Stage VI
|
|
JRE100-D-V-01
|
Diesel
|
12-36 t truck; 8-12 m bus
|
100 kW / 125 kW, 576 VDC
|
400-720 VDC
|
4.09 kWh/L
|
L952*W678*H907 mm
|
470 kg
|
China Stage VI
|
|
JRE150-D-V-01
|
Diesel
|
Concrete mixer truck; sanitation truck; dump truck, etc.
|
150 kW / 170 kW, 600 VDC
|
400-720 VDC
|
4.21 kWh/L
|
L1140*W820*H1063 mm
|
667 kg
|
China Stage VI
|
|
JRE150-N-V-01
|
Natural Gas
|
Concrete mixer truck; sanitation truck; dump truck, etc.
|
150 kW / 171 kW, 600 VDC
|
400-720 VDC
|
4.84 kWh/kg
|
L1436*W919*H995 mm
|
795 kg
|
China Stage VI
|
|
JRE200-D-V-01
|
Diesel
|
Dump truck; tractor unit and other HCV
|
200 kW / 240 kW, 600 VDC
|
400-720 VDC
|
4.23 kWh/L
|
L1419*W845*H1084 mm
|
805 kg
|
China Stage VI
|
* For additional configurations and customized solutions, please contact us at: contact@jenwyntech.com
Why Choose Our EV Range Extenders for Medium & Heavy Commercial Vehicles
Compact and Highly Efficient Generator Architecture
Featuring a flywheel generator directly coupled to the engine crankshaft, eliminating intermediate transmission components, reducing mechanical losses.
Proven System Development and Validation Capability
Developed through integrated CAE simulation and engineering validation covering EMC design, structural analysis, thermal management, and durability testing.
Intelligent Energy Management & Power Generation Control
Supports multiple operating strategies, including constant power generation, multi-point efficiency optimization, and load-following control, enabling optimized energy conversion.
Improved Fuel-to-Electric Conversion Efficiency
Advanced engine-generator matching and control algorithms improve fuel utilization efficiency by up to 20%.
03
EV Range Extenders for Off-Road Equipment
We provide EV range extender solutions with rated power outputs from 65 kW to 300 kW for off-road equipment, supporting a wide range of applications including forklifts, port tractors, reach stackers, loaders, mining vehicles, and other heavy-duty industrial equipment.
Designed for heavy-duty off-road operations where equipment availability and productivity are critical, our range extenders provide reliable onboard power generation for applications such as mining, ports, construction sites, and industrial operations.
By supporting long-duration operation under high-load and low-speed working conditions, our solutions reduce charging downtime, improve equipment utilization, and enable practical electrification in environments where conventional battery-electric solutions remain challenging to deploy.
EV Range Extender Solution Advantages for Off-Road Equipment
Extended Operating Hours for Continuous Operations
Enable longer working hours without frequent charging interruptions, supporting demanding applications such as mining, ports, and construction sites where equipment availability directly impacts productivity.
Reliable Power Supply in Remote and Challenging Environments
Provide onboard power generation capability for locations with limited charging infrastructure, reducing dependence on large-scale charging deployment in remote industrial areas.
Optimized Energy Efficiency for Heavy-duty Applications
The range extender operates within optimized efficiency zones, working together with electric drive systems to reduce fuel consumption while maintaining high torque output and operational performance.
Flexible Electric Operation with Reduced Downtime
Support pure electric operation for low-emission working zones and range extender operation for extended duty cycles, enabling flexible adaptation to different operating requirements.
Our Off-Road Equipment EV Range Extenders Portfolio
|
Model
|
Fuel Type
|
Application
|
Rated / Peak Power / Voltage
|
Voltage Range
|
Generation Efficiency
|
Dimensions
|
Weight
|
Emission
|
|---|---|---|---|---|---|---|---|---|
|
JRE65-D-O-01
|
Diesel
|
Forklifts, terminal tractors, and other off-road equipment
|
65 kW / 75 kW, 576 VDC
|
400-720 VDC
|
3.81 kWh/L
|
L902*W656*H839 mm
|
290 kg
|
T4
|
|
JRE75-D-O-02
|
Diesel
|
Forklifts, loaders, terminal tractors, and other off-road equipment
|
75 kW / 95 kW, 576 VDC
|
400-720 VDC
|
4.12 kWh/L
|
L1110*W640*H910 mm
|
410 kg
|
T4
|
|
JRE100-D-O-01
|
Diesel
|
Mining vehicles, reach stackers, loaders, and other off-road equipment
|
100 kW / 120 kW, 576 VDC
|
400-720 VDC
|
4.11 kWh/kg
|
L1023*W634*H960 mm
|
531 kg
|
T4
|
|
JRE150-D-O-01
|
Diesel
|
Mining vehicles and heavy-duty off-road equipment
|
150 kW / 190 kW, 600 VDC
|
400-720 VDC
|
4.14 kWh/L
|
L1459*W786*H1100 mm
|
849 kg
|
T4
|
|
JRE200-D-O-01
|
Diesel
|
Mining vehicles and high-load off-road equipment
|
200 kW / 240 kW, 600 VDC
|
400-720 VDC
|
4.11 kWh/L
|
L1384*W793*H1023 mm
|
929 kg
|
T4
|
|
JRE250-D-O-01
|
Diesel
|
Mining vehicles and heavy-duty off-road applications
|
250 kW / 290 kW, 600 VDC
|
400-720 VDC
|
4.27 kWh/L
|
L1675*W1032*H1213 mm
|
1100 kg
|
T4
|
|
JRE250-N-O-01
|
Natural Gas
|
Terminal tractors, mining vehicles, and other heavy-duty off-road applications
|
250 kW / 300 kW, 600 VDC
|
400-720 VDC
|
5.20 kWh/kg
|
L1709*W928*H1127 mm
|
1145 kg
|
T4
|
|
JRE300-D-O-01
|
Diesel
|
Terminal tractors, mining vehicles, and other heavy-duty off-road applications
|
300 kW / 320 kW, 620 VDC
|
480-720 VDC
|
4.41 kWh/L
|
L1571*W968*H1277 mm
|
1154 kg
|
T4
|
* For additional configurations and customized solutions, please contact us at: contact@jenwyntech.com
Why Choose Our EV Range Extenders for Off-Road Equipment
Integrated High-efficiency Power Generation System
Compact design with a direct-connected flywheel motor and engine crankshaft eliminates intermediate transmission components.
Proven Durability for Industrial Applications
Validated through comprehensive CAE simulation, component-level testing, range extender system testing, and demanding vehicle operating condition verification.
Intelligent Power Management Strategy
Supports multiple operating strategies, including constant power generation, multi-point efficiency optimization, and load-following control, enabling optimized energy conversion.
Advanced Thermal and Noise Management
Optimized engine-generator thermal management and multi-level vibration/noise control ensure stable operation and improved operator experience.
BEV vs. REEV: Choosing the Right Electrification Solution for Commercial Applications
Commercial vehicle electrification requires a solution that matches real-world operating conditions. While Battery Electric Vehicles (BEVs) provide zero-emission operation and high energy efficiency, their suitability can be limited in applications requiring long operating hours, extended driving range, harsh environments, or limited charging infrastructure.
Range Extended Electric Vehicles (REEVs) combine the advantages of electric drive with onboard power generation. By allowing vehicles to operate primarily in electric mode while providing additional energy support when required, REEV solutions improve operational flexibility for commercial applications where pure battery electric operation may not fully meet user requirements.
|
Application Scenario
|
BEV
|
REEV
|
|---|---|---|
|
Short-range urban operations
|
Ideal for predictable routes with sufficient charging availability. Provides the lowest energy cost and simplest vehicle architecture.
|
Suitable when occasional extended range or additional operational flexibility is required.
|
|
Extended-range logistics & commercial transportation
|
Requires larger battery capacity to achieve longer operating distances, which may increase vehicle weight and cost.
|
Provides extended driving range with optimized battery sizing, reducing range limitations and charging dependency.
|
|
Heavy-duty & high-utilization applications
|
Suitable when dedicated charging infrastructure and predictable operating schedules are available.
|
Better suited for long working hours, high-load operation, and applications where minimizing downtime is critical.
|
|
Off-road, mining & industrial equipment
|
Effective for controlled environments with dedicated charging solutions.
|
Enables electrification in remote areas with limited charging infrastructure and continuous operation requirements.
|
|
Cold climate & challenging environments
|
Range may be affected by low temperatures and increased energy consumption for thermal management.
|
Provides additional energy support to improve operational reliability under harsh conditions.
|
When BEV is the Better Choice
- Operating routes are fixed and predictable
- Daily mileage is within battery capability
- Charging infrastructure is readily available
- Zero-emission operation is required throughout the duty cycle
- Lowest energy cost and simplest architecture are primary objectives
Typical Applications
- Urban delivery vehicles
- Short-range logistics vehicles
- Fixed-route buses
- Depot-based commercial fleets
When REEV Provides Additional Value
- Vehicle utilization requires extended operating hours
- Daily mileage varies significantly
- Charging infrastructure is limited or unavailable
- Vehicles operate in remote or harsh environments
- Heavy-load applications requiring continuous power availability
Typical Applications
- Medium and heavy-duty trucks
- Mining vehicles
- Port equipment
- Construction machinery
Proven Applications & Vehicle Integration
Our EV range extender systems have been deployed in real-world commercial applications, covering urban buses, logistics vehicles, heavy-duty trucks, and off-road equipment. Validated across ports, mining operations, and industrial environments, our solutions deliver reliable electric power support, improved fuel efficiency, and extended operational capability.
From 100 kW systems integrated into 10.5 m city buses to 300 kW solutions for 100-ton-class mining trucks, our range extenders have demonstrated significant efficiency improvements, including up to 53.6% fuel savings in bus applications, over 55% fuel savings in port tractors, and more than 30% fuel savings in heavy-duty mining vehicles.
Technical Support for EV System Integration
Successful EV projects require effective technical communication between vehicle developers and system suppliers. We provide technical support for our EV systems, including product documentation, interface information, communication protocols, and engineering assistance during system integration.
Our support helps customers better understand system requirements, address technical issues during development and testing, and improve integration efficiency throughout the project lifecycle.
Our support includes:
- Review EV system configurations and identify potential risks
- Discuss vehicle requirements, interfaces, and application conditions
- Provide 3D and STEP files for layout and mechanical fit assessment
- Support sample installation, commissioning, and validation
- Support fault diagnosis and system troubleshooting
- Provide continuous technical communication throughout the project
Quality Assurance & Manufacturing Capability
Our EV range extenders are developed through a comprehensive engineering, validation, and manufacturing system aligned with IATF 16949 quality management standards. By integrating advanced simulation capabilities, full-system testing, and intelligent manufacturing processes across our supply chain, we ensure reliable performance, consistent quality, and production readiness for commercial vehicle applications.
Engineering & Simulation Capability
Advanced simulation capabilities cover component-level design, powertrain optimization, and complete vehicle system analysis. CAE-based development methods support structural, electromagnetic, thermal, and system-level optimization to accelerate product development and application adaptation.
Testing & Validation Capability
Comprehensive validation capabilities cover motors, controllers, e-axles, battery electric systems, and EV range extender systems. Supported by advanced test facilities including NVH, cold-start, high-altitude, dust, thermal shock, and durability testing platforms, ensuring reliability under diverse operating conditions.
Manufacturing Capability
The manufacturing is supported by intelligent technologies, including AGV-based logistics and electric torque-controlled assembly processes. Standardized production workflows and quality control systems ensure consistency, traceability, and scalable delivery for commercial vehicle applications.
Frequently Asked Questions
An EV range extender is an onboard power generation system designed to extend the driving range of electric vehicles. It consists of an engine-generator unit that converts fuel energy into electricity to recharge the vehicle’s battery, while the traction motor remains the only source of propulsion.
Unlike hybrid systems, the range extender does not mechanically drive the vehicle. The vehicle maintains the driving characteristics of a battery electric vehicle, including smooth acceleration, instant torque delivery, and regenerative braking capability.
A BEV relies entirely on battery capacity and external charging infrastructure, making it ideal for predictable routes with sufficient charging availability.
A REEV combines electric drive efficiency with onboard power generation. It allows vehicles to operate primarily in electric mode while providing additional energy support for longer routes, high-load applications, extreme climates, or scenarios where charging infrastructure is limited.
The optimal solution depends on vehicle duty cycle, operating environment, and total lifecycle cost.
EV range extenders are particularly suitable for commercial applications where extended operating hours, higher energy demand, or charging limitations are key considerations.
Typical applications include:
- Light commercial vehicles (LCVs) for urban logistics and refrigerated transport
- Medium and heavy commercial vehicles for freight, buses, sanitation vehicles, and construction vehicles
- Off-road equipment including mining vehicles, port machinery, loaders, and industrial equipment
- Marine applications requiring reliable onboard power generation
A REEV solution is typically considered when:
- Daily mileage exceeds the practical range of a reasonably sized battery pack
- Charging availability cannot fully support operational requirements
- Vehicles operate long hours with irregular routes
- Extreme temperatures significantly affect battery performance
- High vehicle utilization requires minimizing charging downtime
For predictable short-distance routes with convenient charging access, BEV remains an efficient and economical choice.
EV range extenders help commercial vehicles achieve greater operational flexibility by combining electric driving efficiency with flexible energy supply.
Key benefits include:
- Reduced dependence on charging infrastructure
- Smaller and more optimized battery sizing
- Extended operating range without increasing excessive battery weight
- Stable performance in cold climates and demanding duty cycles
- Lower total cost of ownership through reduced energy consumption
Modern commercial vehicle range extenders are designed to operate the engine within its high-efficiency operating range, rather than following vehicle speed demand directly.
Jenwyn Tech range extender solutions achieve:
- Diesel generation efficiency up to 4.4 kWh/L
- Gas generation efficiency up to 5.2 kWh/kg
Through optimized engine-generator matching and intelligent energy management strategies, the system improves fuel utilization while maintaining reliable power output for different operating conditions.
Jenwyn Tech provides modular EV range extender solutions covering rated power outputs from 10 kW to 300 kW.
The product portfolio supports a wide range of commercial applications, from compact light commercial vehicles to heavy-duty trucks, buses, off-road equipment, and marine systems.
Jenwyn Tech range extender systems are developed as integrated power generation solutions, combining engine, generator, controllers, and energy management technologies.
Key advantages include:
- Integrated modular design for simplified vehicle integration
- Advanced energy management strategies including constant voltage, constant power, and load-following modes
- Remote calibration and diagnostic capabilities for efficient commissioning and maintenance
- Optimized thermal and vibration management for commercial-duty reliability
- Proven testing capabilities based on automotive-grade development standards
These solutions help OEM customers accelerate electrification across diverse commercial vehicle applications while improving reliability, efficiency, and lifecycle value.