MI, United States
We offer the best product range of heaters air and blow, Air filter modules, Visco fans and Visco fan drives, HVAC modules and vents.
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 200–600 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.
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.
The reduction of pollutant emissions—particularly of nitrogen oxide emissions in diesel engines—is 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 temperatures—and thus improved EGR control—can be achieved.
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.
The development and production of complex oil filter modules has long been one of MAHLE’s 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 materials—especially 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.
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.
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 temperatures—and thus improved EGR control—can be achieved.
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 vehicles—from 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.
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.
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.
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.
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 −40°C to +160°C 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.
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.
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- (12–80V) and high-voltage ranges (200–450V). Most comply with the automotive industry ECE R10-5 standards for EMC emissions and immunity.