Extended Range Electric Vehicles (EREVs) are picking up in China | What are EREVs, and why are more OEMs gravitating towards them?

According to a recent report by Bloomberg, Extended-range Electric Vehicles (EREVs) have become the fastest-growing propulsion system for cars in China. An Extended Range Electric Vehicle (EREV) is a type of electric vehicle that combines a battery-powered electric motor with a small internal combustion engine. This engine is used solely to generate electricity to recharge the battery when its charge is low, extending the vehicle’s range beyond that of a traditional Battery Electric Vehicle (BEV). There is no direct mechanical linkage between the engine and the motor. EREVs batteries are charged by an external plug-in charger.

EREV Powertrain Structure

Plug-in Hybrid Powertrain Structure

EREVs vs conventional PHEVs

Most conventional plug-in hybrids have a lower electric-only driving range as they use an internal combustion engine as their primary power source and include electric drive in conjunction. The battery packs in EREVs are generally larger than those found in Plug-in Hybrid Electric Vehicles (PHEVs) but smaller than those in BEVs. Despite the presence of the combustion engine, the vehicle is driven exclusively by its electric motor, resulting in a smooth and quiet driving experience. This dual approach helps alleviate range anxiety by reducing reliance on charging infrastructure. 

EREVs are essentially a topology of plug-in hybrid vehicles, says Dr Deb Mukherji, an automotive industry expert. The companies are experimenting with different arrangements of battery and engine to come up with solutions that solve stakeholder concerns of range and pricing, he adds. Given their battery size, EREVs are more expensive than PHEVs but cheaper than BEVs.

EREV sales more than doubled in China over the past year and now account for 30% of the country’s plug-in hybrid sales. Bloomberg New Energy Finance (BNEF) says Chinese manufacturers such as SAIC Motor and Zhejiang Geely Holding are jumping onto the EREV bandwagon. Li Auto leads the market in China for EREVs with a lineup of SUVs. EREVs are anticipated to begin arriving in USA in 2025 when Stellantis NV rolls out the EREV version of its Ram 1500 pickup truck (Ramcharger), with a 690-mile driving range.

The combustion engine provided by most OEMs in an EREV is typically a compact unit between 1.0L and 1.5L in size, while it is also offered in bigger sizes in pickup trucks due to their heavy-duty applications. Mazda uses rotary engines, which are more compact than reciprocating engines of the same power output, thus enabling them to achieve a compact set-up that fits in the engine bay easily and doesn’t require any compromise in cabin space.

According to Nissan and Li-Auto, the gasoline engines used in the EREVs have been achieving thermal efficiencies between 40% and 50% since they are only being used to power the generator to charge batteries. Thus, limiting their operation to specific loads and RPMs contributes to greater efficiency. 

EREVs are not new to the market. For example, the BMW i3 REV was introduced in 2016 with a small two-cylinder engine, but it was later discontinued. The BMW i3 was offered with relatively smaller battery packs and engine options, hence a very low overall range of about 150 km. But EREVs being offered today promise much more range, from 600 km to as high as 1300 km, thanks to the onboard range extenders. 

But what makes EREVs interesting enough now for automakers to reconsider? Some global automakers say they are shifting their focus to Hybrids and EREVs due to the slowdown in global demand for EVs. According to several OEMs, EREVs offer price competitiveness over EVs through battery capacity optimization. They allow both refuelling and stress-free charging while offering a superior driving range when fully charged. 

Leading OEM plans for EREVs

– Leap Motors: In 2023, it announced that it would implement its “BEVs+EREVs” Dual Power Strategy with the launch of 3 EREV models.  

– Mazda: Started mass production of its MX-30 e-skyactive REV in 2023. MX-30 comes with a 17.8 kWh battery and an electric-only range of 85 km. It is equipped with an 830cc rotary engine as a range extender. The combined range offered stands at 630 Km.

– Avatr Technologies: Backed by Changan Automotive and supported by Huawei and CATL, the OEM plans to launch the 7 pure electric and extended-range models in the third quarter of 2024.

– Li Auto: A prominent player in the Chinese market, most of its vehicles are offered as EREVs. The Li6, launched in April this year, has gained popularity, with deliveries extending 20,000 units for the third consecutive month. The Li6 comes with a 36.8kWh battery pack offering a CLTC EV-only range of 212 km. The 1.5L four-cylinder engine enables a combined CLTC range of 1390 km.

– RAM: The Stellantis pickup truck brand introduced its 1500 REV pickup truck.

– Nissan Motors: By FY26, Nissan plans to launch four products on its e-power platform and introduce EVRE models in the US. The automaker says that its E-powered platform, currently in its third generation, will achieve cost parity with ICE vehicles.

– Hyundai Motors: The Korean automaker plans to begin mass production of the new EREV in North America and China by the end of 2026, with sales commencing in earnest in 2027. Hyundai Motor has developed a unique new powertrain and power electronics (PT/PE) system to enable four-wheel drive with the application of two motors. The operation is powered solely by electricity, similar to EVs, with the engine being used only for battery charging. In the North American market, the company will initially launch D-class SUV models of Hyundai and Genesis brands to meet the remaining demand for internal combustion engines, with a target of 80,000-plus units. The company said the new EREV is a key bridge to electrification. It also offers price competitiveness over EVs through battery capacity optimization. It allows both refuelling and stress-free charging while offering a superior driving range of over 900 km when fully charged.

Expert Corner | Sameer Jindal, Director – MG Motor India

Extended Range Electric Vehicles (EREVs) are plug-in hybrid electric vehicles (PHEVs) with an extended range, but these are primarily electric vehicles in which a small internal combustion engine only kicks in to generate electricity and extend the vehicle’s range. These vehicles are particularly gaining traction in China, where the charging infrastructure is rapidly expanding but is not yet ubiquitous, especially outside urban centres. EREV offer electric driving over long distances and a more EV-like experience.

Comparison with Strong Hybrids – On the other hand, strong hybrids, such as the Toyota Camry Hybrid and the Honda Accord Hybrid, operate differently. These vehicles combine an ICE with one or more electric motors, and both can drive the wheels either independently or in tandem. Toyota Camry Hybrid uses a parallel hybrid system where the electric motor provides additional power during acceleration, while the ICE takes over at higher speeds or when more power is needed. The battery is charged through regenerative braking and the engine itself, meaning drivers never need to plug in. EREVs typically come with larger batteries from 18 KW to 29 KW. Strong hybrids, however, usually have smaller batteries, usually 1.5 KW to 2KW, designed for short bursts of electric power in stop-and-go traffic or at low speeds.

Conclusion – Different Roads to Green Mobility

Ultimately, EREV/PHEVs and strong hybrids offer distinct advantages depending on the driver’s needs. EREV are more than just glorified hybrids; they represent a significant step toward full electrification while providing the safety net of gasoline power. In the rapidly evolving mobility ecosystem, multiple technologies will likely continue to coexist, each serving different population segments on the road to sustainable mobility.

None of the automakers have yet introduced or announced EREVs for India.

Cover image: Li6 EREV by Li Auto