Built for Scale, Episode 1
2026 / 01 / 29
Dr.-Ing. Alexander Rosen

Range extenders face a simple but brutal challenge: continuous power in low-speed operation.
This isn’t about peak numbers. It’s about keeping torque high when it matters most – during highway drives, mountain climbs, towing situations, or prolonged high-load operation. And the limiting factor is almost always thermal management.

That’s why we made oil cooling a core part of our generator platform.

THE PROBLEM WITH TRADITIONAL COOLING
Most e-motors today rely on water jackets or external cooling loops. These systems work – up to a point. But they struggle when continuous torque is required for longer durations:

▪ Heat builds up at the conductor level
▪ Temperature gradients reduce efficiency
▪ Performance is throttled to avoid thermal limits

This creates real-world compromises that reduce the value of range extenders – exactly where they should shine.

OUR SOLUTION: DIRECT OIL COOLING
Our architecture enables direct conductor oil cooling. That means:

▪ Heat is absorbed directly at the source (the copper windings)
▪ Thermal resistance is dramatically reduced
▪ The system stays within safe operating range even under long load durations

This isn’t theoretical. In our current configuration:

▪ We enable infinite operation with high torque output without overheating
▪ We maintain efficiency across the full operating range
▪ We reduce the size and complexity of the overall cooling system

FLEXIBLE BY DESIGN
We’re not saying oil cooling is always the answer. That’s why we offer both water and oil cooling variants, depending on the use case:

▪ Passenger cars: cost- efficient water cooling for compact architectures
▪ Commercial/heavy-duty: oil cooling where prolonged torque is expected

This flexibility allows OEMs to match their cooling strategy to vehicle type – without compromising on performance.

WHY IT MATTERS
This approach unlocks new possibilities:

▪ True long-distance and towing capability for EVs
▪ Smaller thermal safety margins = more usable power
▪ Less derating = consistent driver experience

Oil cooling isn’t just a thermal feature. It’s a performance enabler. And it’s one of the key reasons our generator is different by design.

Stay tuned for next week, where we show how we fit all this into a package that’s smaller and lighter than anything else in its class.