State-of-the-art mechanical system lowers CO2 emissions

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Assembled camshaft for commercial vehicles

Lightweight assembled camshafts fitted with low-friction rolling bearings offer still significant CO2 savings potential.


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Roller bearing camshaft for commercial vehicles

One further step reduces friction loss in the valve train: rolling bearings are implemented in the camshaft bearings, which are usually hydrodynamically lubricated. This reduces friction and thus the bearing's oil requirement, since splash oil suffices for lubrication. Oil flow rate in the entire cylinder head decreases. The oil pump can be scaled down or excess oil can be made available to other systems. This results in decreased CO2 emissions for the entire engine.


 

Stuttgart, Germany, September 2010—Lightweight assembled camshafts fitted with low-friction rolling bearings offer still significant CO2savings potential in commercial vehicle engines.

For decades, MAHLE has been a large-scale supplier of assembled camshafts for passenger cars, including its variable MAHLE CamInCam® since 2007. MAHLE has now added assembled camshafts for commercial vehicles to its product portfolio. Assembled camshafts are built to withstand high mechanical loads and offer a great deal of freedom in terms of the materials and design used for the driving elements and output elements. Additional positive traits include high possible contact stresses between the cam and cam follower as well as significant weight advantages. Compared to an all-steel camshaft, an assembled camshaft is approximately 50% lighter! MAHLE has already gleaned experience with assembled commercial vehicle camshafts in a number of customer projects and has manufactured these under near-series conditions.

Moreover, assembled camshafts made according to MAHLE's production process offer ideal prerequisites for implementing a low-friction rolling bearing mechanism. The special needle bearings have minimal space requirements and reduce the mechanical bearing friction by up to 40%. In addition, they do not require a supply of pressure oil, since the oil mist present in the cylinder head provides all the necessary lubrication. Consequently the oil pump delivery rate can be reduced. This provides a savings potential of approximately 40%, equivalent to that achieved by reducing the bearing friction. In all, fuel consumption can be lowered by approximately 1–2% using this concept.


The MAHLE Group is one of the 30 largest companies in the automotive supply industry worldwide. With its two business units Engine Systems and Components and Filtration and Engine Peripherals, MAHLE ranks among the top three systems suppliers worldwide for piston systems, cylinder components, as well as valve train, air management, and liquid management systems. The newly formed Industry business unit bundles the MAHLE Group's industrial activities. These include the areas of large engines, industrial filtration, as well as cooling and air-conditioning systems.

In 2009, the MAHLE Group generated sales of approximately EUR 3.9 billion; around 43,000 employees work at over 100 production plants and eight research and development centers.