MAHLE has affirmed its commitment to decarbonization, with plans to present technologies for accelerating electrification and reducing CO2 emissions at the upcoming IAA Mobility in Munich.
As shared in a recent press release, the company intends to focus its efforts on hybrid vehicles and advanced range extenders to boost the ranges of electric vehicles. This will be part of three strategic areas the company calls “Efficiency3”: a range extender to boost the range of
electric vehicles; a compact thermal management module with integrated heat pump to
significantly extend the range of electric vehicles; and ethanol-compatible engine components.
Range Extender System
MAHLE’s new range extender has a rated continuous output of 85 kilowatts, and consists of a high-voltage generator powered by a compact internal combustion engine. Within the 800 V generator is an electric generator with a fully integrated cooling system. The design also features direct cooling of the rotor, reducing the need for heavy rare earth elements.
The company claims this system is capable of a high peak efficiency of over 97%, and a high continuous performance density exceeding 50 kW per liter.
Within the range extender is a boosted internal combustion engine, containing MAHLE jet ignition combustion technology, direct injection, turbocharging, and Miller valve timing. MAHLE has said the engine is capable of a high efficiency of more than 42% in range extender operation, with low noise levels.
Thermal Management Module
MAHLE’s new thermal management module aims to boost the system efficiency of an electric vehicle, and consequently the range available from a full battery charge.
As the central interface for the entire cooling and refrigerant cycle of the vehicle, it’s designed to keep each component of the drive and energy storage system is maintained at the right temperature at all times, under all climate conditions.
To compensate for winter conditions, MAHLE integrated a high-efficiency heat pump in the thermal management module. An air conditioning compressor, heat exchanger, refrigerant pumps, sensors, and valves are all contained within a single unit, reducing space requirements and development work.
The module is designed for R1234yf—the refrigerant currently used—but can also be operated with the alternative future refrigerant R290 (propane) with minor modifications.
The system is currently being developed and series production will start within the next two years.
Bionic Radial Blower
Also being released is a radial blower for automotive air conditioning systems, designed to help with efficiency as well as noise levels. The product has been developed especially for vehicles
with challenging installation space conditions. The aerodynamic shape of the blower blades is inspired by the flippers of a penguin.
The bionic blower is four decibels—or 60%—quieter than a conventional component, according to MAHLE, with a 15% boost in efficiency. The bionic radial blower can be used in
all types of passenger cars as well as light and heavy commercial vehicles.
