Technologies for sustainable transportation

Solutions for fuel cell drive, hybrid drive and internal combustion engine.

Commercial vehicles are the backbone of the global economy. At the same time, they’re a key to a climate-neutral world. However, the transformation of the transport industry depends on many factors: legal requirements in respect of permitted emissions, life cycle costs of alternative drives for road haulers and fleet operators, charging and hydrogen infrastructures, and much more. And there’s a great disparity between these factors in different world regions. That’s why it’s already clear today that no single solution can bring about carbon-neutral transportation of people and goods. We need to find a whole host of different approaches.

Systems provider for sustainable transportation

MAHLE offers a varied, modular systems suite for e-mobility. All systems—from the interior air conditioning and modular thermal management for the drive components to the powerful electric motor—are designed for the different electrical architectures. They are suitable for all regions, vehicle classes, and applications and have a long service life. MAHLE is focusing its development on sustainable technologies with the needs of the customer in mind: cruising range, performance, fast charging capability, and driver comfort are especially important for battery-powered electric commercial vehicles.

The Cooling Module

Depending on the cooling strategy, Cooling Modules regulate the systems at different temperature levels to protect thebattery and power electronics.

The High-Voltage Heater (cabin & battery system)

By heating the coolant, the High-Voltage Heater creates the optimal working temperature for the lithium-ion battery in winter.

The Air Conditioning System

The Air Conditioning System controls the climate in the driver’s cabin with minimal energy consumption, while the CareMetix® Cabin Filter stops fine particulates and pollutants in their tracks.

The Electric Air Conditioning Compressor

The 800 V Electric Compressor delivers the output needed to cool the battery and keep the driver’s cabin pleasantly air-conditioned.

The Chiller

The Chiller optimally cools the temperature-sensitive lithium-ion battery, even at high outside temperatures.

The Battery Cooling Plate

MAHLE’s Battery Cooling Plate is in thermal contact with the cells of the lithium-ion battery and keeps the electric energy storage system within the optimal temperature range at all times.

The Electronics Cooling Plate

The Electronics Cooling Plates protect other electronic components against overheating.

The 24 V Coolant Pump

The 24 V Coolant Pump drives the coolant circuits with up to 700 W, as required.

The SCT Electric Motor (800 V)

This traction motor—the only one of its kind on the market to date—runs indefinitely at high performance thanks to a special cooling concept.

The Oil Management Module

The integrated and compact Oil Management Module cools the traction motor to protect it against overheating.

E-mobility systems suite

Fleet operators are increasingly turning to electric battery and fuel cell drives to help decarbonize their fleets. One goal is to advance climate neutrality in the transport sector. Additionally, electrified commercial vehicles offer high performance combined with a long service life and maximized cruising range. But to achieve this, the components need to be kept at an optimal and constant operating temperature. MAHLE offers integrated and intelligent solutions based on its many years of development experience.

Systemically integrated: the Cooling Module

Systemically integrated: the Cooling Module

Cooling Modules protect batteries and power electronics by releasing much of the heat built up in the system into the environment. Depending on the cooling strategy, the modules could include additional radiators. For over 100 years, MAHLE has been playing a crucial role in advancing development, from simple coolers to complex thermal management

Modular bodyguard for the battery: the High-Voltage Heater

Modular bodyguard for the battery: the High-Voltage Heater

During the cold season, the High-Voltage Heater actively raises the coolant temperature and ensures the optimal working temperature and a long service life for the lithium-ion battery. The battery can only function optimally within a narrow temperature range of approx. 10 °C to 40 °C. Only a small amount of waste heat is generated in vehicles with a battery electric drive. While this does increase efficiency and cruising range, it also poses a challenge during the winter months. An additional High-Voltage Heater with an output of up to 8 kW ensures a comfortable cabin temperature by heating the coolant.

Complex system for efficiency and comfort: the Air Conditioning System

Complex system for efficiency and comfort: the Air Conditioning System

MAHLE’s highly efficient Air Conditioning System ensures the cabin is perfectly climate-controlled while minimizing energy consumption. Working in a pleasant temperature, drivers can focus better and safely navigate the traffic. In addition, the CareMetix® Cabin Filter keeps the cabin free of fine particulates and pollutants, thus protecting the driver’s health.

The heart of the Air Conditioning System: the Electric Air Conditioning Compressor

The heart of the Air Conditioning System: the Electric Air Conditioning Compressor

The Air Conditioning Compressor delivers the output needed to cool the battery, making it fundamental to a long service life for the air conditioning system as a whole. As the only manufacturer offering ultrapowerful 800 V compressors, MAHLE is paving the way for fast charging and full-load operation of heavy-duty, electrified commercial vehicles.

Interface between the systems: the Chiller

Interface between the systems: the Chiller

MAHLE’s Chiller is designed to keep the lithium-ion battery optimally cooled, even at high outside temperatures. This is essential, as the lithium-ion battery is temperature-sensitive and must be kept below 40 °C at all times. This cannot be achieved using coolant alone, especially during the summer months. Therefore, the Air Conditioning System’s refrigerant circuit takes on this important task. In the Chiller, heat is transferred from the battery cooling circuit to the refrigerant circuit to produce the desired effect.

Making battery systems robust and sustainable: the Battery Cooling Plate

Making battery systems robust and sustainable: the Battery Cooling Plate

MAHLE has been developing cooling systems for lithium-ion batteries for more than a decade now, making it a pioneer in this technological field. The Battery Cooling Plate is in thermal contact with the cells of the lithium-ion battery and keeps the electric energy storage system within the optimal temperature range at all times. For this purpose, the coolant in the Cooling Plate flows in fluid channels that have been individually adapted to the respective battery architecture.

Protecting the power electronics: the Electronics Cooling Plate

Protecting the power electronics: the Electronics Cooling Plate

MAHLE’s many years of development experience in lithium-ion battery cooling is incorporated into its Electronics Cooling Plate Design. In addition to the electric powertrain, other electronic components such as the inverter also have to be cooled. These are protected against overheating by the Electronics Cooling Plates and coolant circuit.

Energy-efficient and powerful: the 24 V Coolant Pump

Energy-efficient and powerful: the 24 V Coolant Pump

The 24 V Coolant Pump drives the coolant circuits. A pumping performance of up to 700 W can be delivered if required. In other words, the pump only ever runs as quickly as the conditions necessitate in order to save electrical energy. In MAHLE Coolant Pumps, the coolant also actively cools the pump drive, thereby reducing wear and tear and extending their service life.

Highly integrated systems competence: the Oil Management Module

Highly integrated systems competence: the Oil Management Module

The traction motor is a “powerhouse” that has to be protected against overheating. MAHLE’s integrated and compact Oil Management Module cools the motor, with a Heat Exchanger transferring the heat from the oil to the coolant circuit. The Oil Pump needed for this is already integrated into the module.

Sustainable transformation with alternative technologies

Today’s e-mobility technologies and drive concepts still frequently hit their limits. That’s why MAHLE is turning to hydrogen engines, fuel cells, and other alternative powertrain technologies in the commercial vehicle sector.

A Humidifier for fuel cells

A Humidifier for fuel cells

Fuel cells are technically very complex and extremely sensitive. They need humid air in order to operate optimally. MAHLE’s Flat Membrane Humidifiers increase efficiency and protect the cells from damage. In addition, reliable humidification is important for the efficiency and service life of this high-quality key component. The German Federal Ministry for Economic Affairs and Climate Action is providing funding for the development of the Flat Membrane Humidifier by MAHLE and its partners.

The Modular Air Filter for fuel cells

The Modular Air Filter for fuel cells

Fuel cells must be shielded from particles and harmful gases in order to operate optimally. MAHLE Air Filters reliably protect the fuel cells—not just from dust and particles, but also from harmful gases such as sulfur and nitrogen compounds. And it does so over the vehicle’s entire service life. Its modular concept makes it a simple and inexpensive solution.

The High-voltage DC/DC Converter for fuel cells

The High-voltage DC/DC Converter for fuel cells

In fuel cell vehicles, the fuel cell and a buffer battery with electrical output supply the electrical consumers, such as the traction motor. The output voltages are not always the same, as they depend on the charging status and load conditions at the time. As with a transmission, the output voltage must be aligned with at least one source of voltage by means of a DC/DC converter. MAHLE’s High-voltage DC/DC Converter stands out on account of its very high output of up to 180 kW with an efficiency of more than 97percent and a particularly high power density.

The Water-to-water Cooler for fuel cells

The Water-to-water Cooler for fuel cells

The fuel cell is the heart of the fuel cell drive and requires constant cooling. However, the coolant cannot be electrically conductive as this would cause irreparable damage to the fuel cell. Accordingly, the heat from the fuel cell’s coolant is transferred to the powertrain’s coolant in MAHLE’s Water-to-water Cooler. This prevents mixing that would cause the water to become conductive and keeps the volume in the fuel cell circuit as small as possible.

The Cooling Module for fuel cell commercial vehicles

The Cooling Module for fuel cell commercial vehicles

The optimal temperature within the fuel cell is approximately 70 °C. Maintaining this temperature is important for its efficiency and durability. MAHLE’s highly efficient radiator and powerful fan are perfectly matched for this, even at high outside temperatures.

The High-performance Coolant Pump for fuel cell applications

The High-performance Coolant Pump for fuel cell applications

The fuel cell needs high cooling performance. MAHLE’s 800 V High-performance Coolant pump, with an output of up to 2.5 kW delivers approximately 300 L of coolant per minute, without contaminating it with ions or generating undesired conductivity.

The Hydrogen Power Cell Unit

The Hydrogen Power Cell Unit

MAHLE is using its combustion engine expertise to optimize its components for climate-neutral operation with hydrogen. Hydrogen engines may prove an important technology en route to the widespread use of hydrogen. With over 100 years of experience, MAHLE is developing engine components that are able to use the carbon-free fuel in a highly efficient manner and over a long service life. Thanks to lower peak pressures, aluminum can be used as a material instead of steel. The Power Cell Unit minimizes blowby, that is, the slight leakage of hydrogen into the crankcase.

The High-pressure Impactor for Hydrogen Power Cell Units

The High-pressure Impactor for Hydrogen Power Cell Units

Hydrogen forms an ignitable mixture over a wide concentration range. During combustion in the piston, a small amount of the gases enters the crankcase, which is known as blowby gas. The High-pressure Impactor actively flushes the crankcase with air, thereby preventing a build-up of ignitable hydrogen there.

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