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Air Intake Systems

MAHLE air intake systems include the entire scope of the system, from raw air intake with preliminary removal of dust and water to the air filter module with the main filter element and safety insert to the turbocharger inlet interface. As a result, MAHLE is able to fully respond to system inquiries and to develop and produce modules completely in house.
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DC Motors

These would particularly include material handling and transport industries, as well as other applications, such as winches, industrial cleaning machines, and marine applications. Some of the DC motors are also designed to be used as traction motors. They are available in standard versions and also designed according to special customer requirements. The advanced design results in low noise operation and low EMC emissions. Within this type of drive systems, we offer the ECU with soft-start and speed regulation functions for all 24 V series and compound DC motors with nominal power up to 3, 5 kW.
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Fuel Filters

Fuel filter modules for commercial vehicles efficiently prepare diesel fuels for the combustion process. For this purpose, they use high-separation filter media and feature an advanced functionality scope. For diesel engines, the functional range of the MAHLE fuel filter modules can be rather complex. The fuel can be cooled or heated, for example, or the water content of the fuel can be separated.
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Heaters Air And Blow

  • power range 200–600 W
MAHLE heaters use PTC technology and are available in modular variants, such as bar heaters, plug-in heaters (stand-alone), and solutions that can be integrated into the filter housing. The power range is 200600 W, and the maximum flow rate is 200 Lh. Various control concepts such as thermoswitches, electronic switches, and independent controls using pressure and temperature are all possible. The advantages of MAHLE heaters are the optimized heating function and the potential for a high level of integration in the engine periphery.
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Electric Heaters

  • high power output 600 W
When designing the heaters, MAHLE drew upon the companys broad knowledge base in the area of fuel systems, thus achieving a high level of integration in the fuel filter module. Other salient features of the heaters include low pressure loss during high heat transfer to the medium, a robust design with separate chambers for the electronics and heating element, a low energy requirement, and a high power output (600 W). The heater is controlled by the integrated electronics or the engine management system. The heating element is based on modern resistance technology with a positive temperature coefficient (PTC), and the integrated overheating protection ensures maximum safety. With its modular design, MAHLEs electric heaters can be flexibly adapted to the specific requirements of passenger car and commercial vehicle manufacturers.
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Air Filter Modules

Critical package constraint situations present a formidable challenge to the development of air filters for commercial vehicles. MAHLE air filter modules are individually customized according to customer requests with regard to package constraint, weight, and interfaces to other systems. Another development focus of MAHLE is on achieving long maintenance intervals. Mechanical and electrical sensors reliably display the maintenance status of the filter system. The filter is freely accessible and tool-free maintenance is possible.
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Electric Pumps

Pumps for water (or other liquids) are driven by electric motors. These can be used in wet or dry rotor environments. More controlled flow of coolant, reduction of fuel consumption and pollution (CO2), longer pump life, and quieter operation are some of the advantages found in new, modern, hybrid and electric passenger cars with electrically driven water pumps. Highly innovative rotor protection for operation in liquid is used in the motor design to ensure reliable, long-life operation.
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Recirculation Exhaust Gas

The reduction of pollutant emissionsparticularly of nitrogen oxide emissions in diesel enginesis an important task within the development process. Engine-internal methods such as exhaust gas recirculation seek to reduce raw emissions during combustion itself.
One approach to meeting the new NOx (nitrogen oxide) emissions limits is to incorporate cooled exhaust gas recirculation (EGR). This involves extracting a portion of the main exhaust flow between the engine outlet and the turbine, cooling it in a special heat exchanger, and feeding it back to the intake air downstream of the charge air cooler. The combustion temperature in the engine is thereby lowered, thus reducing the formation of NOx. Our EGR coolers offer exceptional thermomechanical strength, reduced tendency to sooting, and outstanding specific performance. Thanks to the use of high-performance winglet tubes, extremely stable EGR temperaturesand thus improved EGR controlcan be achieved.
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Commercial Vehicles Fuel Management

Fuel management in commercial vehicles is mainly governed by fuel preparation, i.e., filtration and water disposal. The trend toward a so-called world engine, or engine platform for use in every region of the world, gives rise to considerable technical challenges. On the one hand, the engine must meet the partly strict exhaust gas legislation, which leads to a high level of technological advancement. On the other hand, it is this sophisticated level of technology that is confronted with different biofuel shares and fuel quality levels. It is therefore necessary to enable optimal separation of contaminants and water even under these conditions.
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Oil Filter Modules

The development and production of complex oil filter modules has long been one of MAHLEs core competences. When the overall system of engine lubrication and cooling is considered, many other functions can be integrated along with the filtration and cooling of the lubricating oil. These include oil mist separation, sensors for pressure and temperature control, oil pressure and crankcase pressure regulation, and the optional incorporation of a fuel cooler. Thanks to the integration and use of state-of-the-art materialsespecially of high-performance plastics, significant cost and weight savings can be achieved. Completely incinerable ecological filter elements that are easy to replace and dispose of are seeing increased use. Long-term filter elements using modern filter media and manufacturing processes provide an essential contribution to the extension of service intervals.
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Cooling Modules

Cooling modules comprise multiple engine cooling components as well as the condenser, which forms part of the air conditioning circuit. The cooling module primarily consists of a radiator and the charge air cooler. In indirect (coolant-cooled) charge air cooling systems, the charge air cooler is replaced by a low-temperature radiator which is located between the condenser and the radiator. For maximum efficiency, all components are optimally matched. The modules are assembled according to the vehicle design concept, thus reducing development, production, and logistics costs.
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Egr Coolers

One approach to meeting the new NOx (nitrogen oxide) emissions limits is to incorporate cooled exhaust gas recirculation (EGR). This involves extracting a portion of the main exhaust flow between the engine outlet and the turbine, cooling it in a special heat exchanger, and feeding it back to the intake air downstream of the charge air cooler. The combustion temperature in the engine is thereby lowered, thus reducing the formation of NOx. Our EGR coolers offer exceptional thermomechanical strength, reduced tendency to sooting, and outstanding specific performance. Thanks to the use of high-performance winglet tubes, extremely stable EGR temperaturesand thus improved EGR controlcan be achieved.
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Visco Fans And Visco Fan Drives

Effective dissipation of heat from vehicles requires not only high-performance radiators, but also fans and fan drives to supply the cooling air as efficiently as possible. The aerodynamic matching of cooling module and fan ensures efficient engine cooling at optimum cost.

Electronically controlled Visco fans are used in a wide range of vehiclesfrom heavy trucks to vans and SUVs with powerful engines. They detect all relevant temperature values for cooling and air conditioning purposes and set the exact required fan speed. This ability to deliver precision, on-demand control while ensuring rapid response times and low idling speeds when the drive is deactivated have a positive influence on fuel economy, driving comfort, and noise emissions.

Thanks to the wear-free torque transfer principle, the fan-drives are maintenance-free. Rpm feedback coupled with a fail-safe design ensures reliable vehicle operation. Our permanently refined fan designs guarantee superior efficiency at low noise levels. They also help keep the highly thermally stressed Visco fan drives cool, thus improving their durability.
Since 2011, we also offer electronically controlled Visco coolant pumps. The highly advanced fan drive concept was applied to coolant pumps, hence enabling on-demand control of the coolant flow to permit further improvements in fuel economy.
In addition to Visco fans, MAHLE also develops electric fans. These find application in passenger cars as well as in vans and SUVs with less powerful engines. They are usually supplied as components of fully assembled cooling modules.
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HVAC Modules

HVAC modules are tailor-made to the specifications of vehicle manufacturers. Continuous improvements in efficiency, reductions in weight and pressure loss, as well as the further optimization of acoustics are among our key development objectives. Standardized components and design features help us to economically develop and produce robust and high-performance HVAC modules.
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Vents

Unlike traditional vents, the patented comfort vent has not one, but two air ducts: a helical diffused-flow duct and a centered spot-flow duct. The geometry of the diffuse duct generates a swirl effect, spreading the flow over a wide area and creating a cloud of air within the vehicle cabin. Instead of having an irritating effect on the vehicle occupants, this is experienced as a diffuse, draft-free air flow. In contrast, the spot-flow duct in the center provides a highly focused and precisely directed current of air.
The vehicle occupants can mix and match these two types of air flow according to the conditions and their personal comfort preferences, creating multiple ventilation options:
Draft-free ventilation: air flows through the diffuse duct and is spread over a wide area.
Direct ventilation: air passes through the spot duct, allowing a very direct flow focused on a particular area.
Traditional ventilation setting: a combination of diffuse and focused air flow, corresponding to that of a conventional vent.
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Fragrancing Systems

Automobile buyer demand for greater individualization in vehicle design and enhanced comfort has sparked a strong interest on the market for fragrancing systems. Our fragrance diffuser has a modular structure and can be used in a wide range of vehicle models. Using customized dash bezels, it can be adapted to match the design specifications of automobile manufacturers. The intermittent fragrance discharge prevents fragrance fatigue, thus ensuring long-lasting perception of the fragrance, even on long journeys. If no longer required, it can be switched off completely by the passengers at any time. The diffuser can be fitted with two fragrance cartridges, allowing the vehicle occupants to select the one that best matches their mood and needs. The cartridges can also be replaced with new fragrances at any time.

The system identifies the inserted cartridges automatically and can relay information such as the name and fill level of the fragrance to the dash display.
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Variable Turbine Geometry

  • Weight 250 g
  • temperature range −40°C to +160°C
MAHLE has specifically designed these electric actuators to meet the requirements of modern combustion engines: The models for VTG applications are therefore extremely compact and lightweight, weighing in at less than 250 g. They also allow for maximum flexibility in vehicle applications thanks to a generous adjustment angle of up to 130 and an application temperature range of 40C to +160C as standard.
The actuators are dust-proof and protected against water ingress during high pressure or vapor cleaning of the engine compartment, for example. The actuator is driven by a DC motor with a three-stage transmission. Position feedback is provided via a contactless Hall sensor system with digital or analog output and control via the engine ECU.
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MAHLE Intake Pipe Actuators

MAHLE electric intake pipe actuators provide good mixture formation in four-valve engines with targeted, map-controlled charge motion of the incoming air.

For diesel engines, channel deactivation is used to induce a swirling motion in the combustion chamber. For gasoline engines, the narrowing of the channel and the guiding of the incoming air in the upper half of the channel generates cylindrical tumble flow. Both ensure good swirling of the mixture, thus improving exhaust gas emissions and partial load consumption.
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Connecting Rods

The connecting rod connects the piston to the crankshaft and consists of the small end and big end bores as well as the shank. As the element that transmits forces and motions, it is subjected to alternating stresses and continuously increasing performance. The trend for connecting rods, however, is toward ever lighter components. The MAHLE connecting rods product range accommodates this challenge. With high-strength and innovative materials, MAHLE can more than fulfill the current requirements.
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Camshafts

From a purely mechanical standpoint, the task of the camshaft is to convert the rotary motion of the crankshaft into an oscillating motion of the cam follower by means of the cam profile. The shape of the cam profile defines the valve lift and is thus a fundamental adjustment parameter in the design of the gas exchange and thus of the combustion process.
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Cam Followers

The term cam follower is a generic term for the various elements that are moved directly by the cam lobe. They follow the cam lift and transmit the motion to the downstream valve components. Cam followers include tappets, buckets, and levers in a wide range of designs.
MAHLE develops and produces ready-to-assemble modules for commercial vehicle engines. MAHLE is able to build on many years of experience. By integrating the camshaft bearing, including the rocker arms and rocker arm bearings, the so-called rocker arm assembly is constructed. These MAHLE assemblies offer clear advantages with respect to development effort and logistics, and simplify the complete assembly of the cylinder head and engine.
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Valve Guides

Valves, valve guides, and valve seat inserts work as an assembly to seal off the combustion chamber within the valve train. While the valve and valve seat insert perform the actual sealing function, the valve guide supports the motion of the valve.
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Turbocharging

The significance of exhaust gas turbochargers in future high-efficiency combustion engines is increasing greatly. Almost all modern commercial vehicle diesel engines are turbocharged. Turbochargers do not only guarantee high torque and strong engine output, they are also essential for compliance with ever more stringent emissions limits. This is why MAHLE has been engaged in the joint venture Bosch Mahle Turbo Systems since June 2008, with an emphasis on development and production.
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Water Separation Systems

In order to comply with demanding emissions limits, modern diesel engines typically employ common rail injection systems. These are extremely sensitive to solid particles and diesel fuel containing unsolved water. Since world engines are also used in countries with poor fuel quality and varying shares of biofuel, it is necessary to enable optimal separation of contaminants and water even under these conditions.
For this purpose, MAHLE has developed a solution with the active prefilter module that achieves a separation level of up to 98 percent in new condition.
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Oil Heating And Cooling Systems

As specific and absolute power output levels continue to rise, engines are operated closer and closer to the temperature limits of their materials. Consequently, heating and cooling modules will become ever more critical in the future.

Heat exchangers for heating and cooling modules typically have a lamellar design and ensure an as balanced as possible thermal cycle for lubricating oils in the engine and transmission. This allows the lubricant to heat up quickly, which significantly reduces fuel consumption at cold start. At high oil temperatures, heat exchangers prevent overheating and premature aging of the oil, allowing oil change intervals to be extended.

Current MAHLE heating and cooling modules are able to also handle channel guidance, temperature regulation, and filtering of the coolant flow. An optimized channel guidance and distribution of the coolant flow provides coolant to the heat exchangers of the engine and transmission as well as for fuel as needed.
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Charge Air Coolers

Thanks to re-engineered geometries and enhanced manufacturing processes, we have succeeded in keeping the weight of the new air-cooled EURO 6 charge air cooler constant, in spite of larger cooling surfaces and significantly improved component robustness and durability. Performance density was increased at the same time. The charge air coolers also reduce the installation depth of the cooling module by a further 14 mm, hence optimizing air flow throughout the system. As a result, the power requirement of the fan can be reduced without impairing cooling performance. Furthermore, new design measures must accommodate the increasingly higher thermal and pressure loads that charge air coolers are subjected to.
Indirect charge air cooling systems use extremely compact coolers that are cooled by the coolant of the separate low-temperature cooling circuit. Since the low-temperature radiator has a large front surface and is swept by the cold cooling air flow, very low charge air temperatures can be achieved. Due to their superior efficiency (as compared to a charge airair cooler), they can be designed with very compact dimensions and mounted onto the engine. In transient driving conditions, they provide for a much more stable intake air temperature and thus help reduce fuel consumption.
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Thermostats And Control Valves

The wide variety of engine cooling tasks can be achieved only by intelligently controlling the energy flows that arise. Various systems and engine components must be supplied with coolant as required. In modern systems, this takes place with different temperature levels and separate cooling circuits. Intelligent control systems from MAHLE, such as engine operating map thermostats, ensure demand-actuated and precise temperature regulation and thus promote more efficient operation, reduced consumption, less wear, and lower emissions.
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Evaporators

The job of the evaporator, which is housed in the HVAC module, is to rapidly cool down the air in the vehicle cabin. The refrigerant passes from the condenser to the evaporator, where it is expanded at the evaporator outlet. It is thus cooled down to a temperature below that of the ambient air. The evaporation of the refrigerant has a cooling effect on the components. As a result, heat and moisture are absorbed from the cabin air. Our flat tube evaporators deliver high performance in spite of their compact and lightweight design. Our patented BehrOxal coating technology modifies the aluminum surface such that it assumes hydrophilic properties. As a result, water runs off more easily, enabling the evaporator to dry more quickly. This makes the evaporator more resistant to corrosion and less prone to unpleasant odors.
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Heater Cores

In order to heat the vehicle cabin, the heater core has to make use of the heat emitted by the engine, i.e., the coolant temperature. Behr heater cores are perfectly adapted to the respective engines and their heat output. They are characterized by their compact size and low pressure drop on both the coolant and the air side.
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PTC Auxiliary Heaters

Todays fuel-efficient engines do not always deliver sufficient waste heat to enable rapid heating of the vehicle cabin, particularly for cold starts and in certain driving conditions. To keep the windows clear and ensure optimum thermal comfort in these situations, additional heating is provided by electric PTC auxiliary heaters that run on energy from the vehicle electronics. The heaters are available with or without an integrated controller.
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Blowers

Thermal and acoustic comfort is crucial in vehicle air conditioning. However, the blower is one of the main sources of noise in the vehicle cabin. Our current blower design concepts meet three separate requirements: they save valuable package space in spite of increased air flow performance, they are highly efficient, and they form the basis for excellent HVAC system acoustics.
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Cabin Air Filters

Cabin air filters reliably protect against dust, pollen, spores, soot, and tire particles. Integrated activated carbon absorbs unpleasant odors, gaseous pollutants, and even high levels of ozone in the ambient air. All MAHLE cabin air filters are distinguished by low pressure loss and long service life. The filter media used offer a large effective surface and filter even smallest particles such as soot particles.

The latest generation of MAHLE filter media offers very good soot particle retention and can be used regardless of the direction of flow. The measures that were previously necessary to ensure correct installation orientation can thus be eliminated.
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Condensers

The condensera component of the air conditioning circuitis integrated into the engine cooling module, where it is used to cool down and condense the compressed, gaseous refrigerant from the compressor. We produce brazed, flat tube condensers that deliver high performance in spite of their compact and lightweight design. They ensure rapid cooling of the passenger compartment thanks to optimum matching of heat transfer and pressure drop on both the coolant and the air side.
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Electric Wastegate Actuator

The electrical actuator can reach any desired wastegate position in a flash, regardless of the negative or positive system pressure. Its high clamping force ensures minimal leakage and consequently rapid boost pressure build-up. The result is very spontaneous responsiveness. Another advantage of the electrical actuator is the ability to open the wastegate completely. This allows the catalytic converter to light off quickly, thereby reducing exhaust gas emissions and fuel consumption, which is crucial to customers.
MAHLE has successfully produced wastegate actuators in series since 2009, and presented an advanced variant in 2013 that has also been launched in series.
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Alternating Current Generators

MAHLE permanent-magnet alternating current generators are connected directly to the combustion engine crankshaft. They generate electricity that can be used to charge the battery, for instance, or to power electronic control units. The external circumference of the alternator is fitted with a ring gear that is probed by a sensor. As the alternator rotates, the probe relays signals to the ignition management system, which are used by the electronics to calculate the engine speed. The moment of inertia of the rotor in the alternator has a stabilizing effect on the engine speed, and the combustion engine runs more smoothly as a result. MAHLE voltage regulators convert the alternating current generated in the alternator to direct current, while at the same time ensuring a constant battery charge voltage.
MAHLE alternators thus combine several engine functions, reducing complexity and cost, as well as weight.
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Fuel Injection Systems

MAHLE fuel injection systems match the fuel quantity and timing to the specific operatingload condition so that the engine delivers the required performance, coupled with low emissions and low consumption. The MAHLE system comprises the electronic control unit, sensors, fuel pump, injectors, and throttle valve. MAHLE fuel injection systems are available in a battery-powered or battery-free concept.
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Cylinder Head Covers

Depending on the customer's requirement, MAHLE delivers plastic cylinder head covers either as integrated in the intake system or separately as a functional or design component. These products stand for strongest stability and low weight. They meet high requirements with respect to engine acoustics and leak tightness, as well as the increased design demands by vehicle and engine manufacturers. The latest generation of MAHLE cylinder head covers for commercial vehicle has even more to offer: it allows functional integration, such as an integrated oil mist separator, and is modular in design so that it can be used cost-effectively in engines with different numbers of cylinders.
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BLPM Motors

  • ranges 200–450V
MAHLE brushless permanent magnet motors with ferrite or rare earth magnets on the rotor combine high performance and reliability with a simple design, resulting in optimal price-performance ratios. The multipole motors offer high efficiency (> 90%) over a wide speed range and high torque at low speeds. Using a special motor design, the cogging torque level is extremely low. The motor has no commutator and brushes, nor slots and windings on the rotor. This ensures very low acoustic noise and torque ripple. This type of motor is powered and controlled by separate or built-in BLPM ECUs, whose basic function is to provide the electronic commutation to stator phases based on the rotor position (detected by an integrated absolute encoder).
Communication fromto external electronic devices is done by using analog signals, digital IO, PWM signals, or CANOpen communication. Integrating the ECU in the motor housing creates a single, compact drive unit. Typical applications for such motor versions are steering applications and small traction motor drives. BLPM drive systems are available in both low- (1280V) and high-voltage ranges (200450V). Most comply with the automotive industry ECE R10-5 standards for EMC emissions and immunity.
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Starter Motors

  • displacement ranging 0.8 to 19 liters
This product line includes a wide range of starter motors designed for all types of internal combustion engines with a displacement ranging from 0.8 to 19 liters. Different starter motor families are manufactured in 12 V versions with output from 0.8 kW to 5.5 kW, and in 24 V variants with output from 1.4 kW to 9 kW. With regard to power output, the excitation of the motor part is performed through permanent magnets or electrically by means of windings.
We manufacture directly driven starter motors as well as modern reduction gear starter motors. Various versions of these starter motors ensure long life under adverse operating conditions. They provide outstanding resistance to salt, fog, humidity, water, dust, mud, vibration, extreme temperatures, and aggressive liquids.
Their design complies with the standards of electromagnetic compatibility (EMC) and with other international directives and standards. Our starter motors are produced using environmentally conscious technologies and materials.
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AC Induction Motors

  • ranges 200–450V
MAHLEs AC induction motors are four-pole motors with an aluminum cage rotor and three-phase winding on the stator. The stator and rotor laminations are specially designed for low-voltage applications used in different electric vehicles. Induction motors offer excellent dynamics over a wide speed range and very low noise operation. The motors are powered and controlled by an AC ECU, which converts the DC voltage to three-phase voltage at the required amplitude and frequency. Thanks to additional settings of the ECU parameters, it can be well adjusted to the requirements of various installations and applications.
Advanced diagnostics and communications are provided through the CANOpen bus. AC induction motors with corresponding ECUs represent the best traction solution for battery-powered electric vehicles, such as golf carts, airport luggage carts, small electric cars, and other applications. Several motors are available in higher IP protections. AC induction motor drives are available in both low- (2480V) and high-voltage ranges (200450V). Most comply with the automotive industry ECE R10-5 standards for EMC emissions and immunity.
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ALTERNATORS

alternators are designed to meet a wide range of engineering specifications and applications. They are used on petrol and diesel engines fitted in trucks, buses, agricultural and construction machinery as well as in the automotive industry. The product range includes two basic designs with regard to the cooling of the electric motor: compact alternators with internal fans and classic alternators with external fans. Individual families of alternators are available with 14 V and 28 V DC rated voltage and output current up to 270 A.
External fan alternators are specially designed for operation under adverse environmental conditions, such as dust, mud, salt, high-frequency vibrations, and high electrical and thermal load, which are standard for agricultural and construction equipment. Compact alternators are designed for a wide range of applications where lower noise, compact design, and operation at higher rotational speeds are specifically required; for example, in automotive and commercial vehicle applications.
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Electric Power Steering

It is pleasing to note that the reduction of fuel consumption in some applications amounts to 6 percent, which corresponds to approximately 8 grams less of CO2 per kilometer. Extremely low cogging torque, low noise operation, and high power density are the main advantages of MAHLE EPS motors. To comply with functional safety, additional options like dual winding on the stator are available
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  • Robert Chaston (Mahle Behr)
  • 2700 Daley Dr., MI, United States
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