Fuel management for commercial vehicles

Fuel management in commercial vehicles mainly refers to filtration and water disposal. The trend toward a so-called world engine—an engine platform for use in every region on earth—gives rise to considerable technical challenges. Depending on the region, this concept is confronted with different biofuel content and fuel quality levels. It is therefore necessary to facilitate optimal fuel treatment in all conditions.

Systems for fuel management

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.

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.

Electrical heaters for fuel systems

These individually adapted heaters are used for cold starts and operation at low ambient temperatures. They are characterized by a low pressure loss during high heat transfer into the medium, a robust design, low energy consumption and high performance up to 600 watts, controllable via integrated electronics or engine management. The PTC heating element with integrated overheating protection offers maximum safety.

Water level sensors

Water level sensors for fuel filter modules determine whether too much liquid are collected in the assembly during operation. With our new technology, the sensor elements are no longer made of metal but of conductive plastic, thereby preventing electrolysis problems. With operating voltages from 9 to 36 volts, the sensors are suitable for a broad range of applications.