At IAA Commercial Vehicles (Hall 16 A05/FG H97), MAHLE showcases its technologies for modern, low-emission combustion engines, hybrid drives, and fuel cell-powered vehicles.
“We are shaping and accompanying the breakthrough in the commercial vehicle market with solutions that are ready for series production. Independently of the drive type, we always focus on a holistic systems approach. Vehicle components can only run efficiently and reliably throughout the entire service life of a commercial vehicle and tap the full technical potential if they work together perfectly,” says Dr. Jörg Stratmann, CEO of the MAHLE Group.
Internal combustion engine in commercial vehicles
MAHLE e-Waste Heat Recovery System is a true enabler for economically efficient hybrid technology in long-distance hauling and distribution transport. The system for commercial vehicles extracts heat from the exhaust flow. It is then converted into electrical energy that can be used in a 48-volt electrical system to supply electrified auxiliary consumers, or be fed directly into the powertrain via an electric motor. This generates fuel savings of up to 5 percent.
In order to further optimize the efficiency of the combustion engine in commercial vehicles, MAHLE is presenting a new valve train system that supports variable valve timing. It has integrated functions such as engine braking, exhaust gas temperature management, and reduced compression ratio to lower the combustion temperature and pressure level in the valve train.
CNG/LNG drives for commercial vehicles offer substantial CO2 savings potential. To this end, MAHLE presents technologies for cooled exhaust gas recirculation, which reduce the combustion temperatures to protect the engine components from damage and prevent knocking. To achieve optimal results in terms of durability and efficiency with this high-pressure, direct-injection approach, MAHLE is currently developing a special series of pistons, making use of existing expertise in the design of complex piston bowls and cooling channel geometries. These are also on display at IAA.
The hybrid drive in commercial vehicles
Particularly in the commercial vehicle sector, new regulations concerning the reduction of CO2 and emissions will be the technological driver in the ongoing development of the powertrain. Even more than in the passenger car segment, the broad spectrum of drive architectures and application areas will produce a rather heterogeneous environment. Hybridization in all its forms is therefore a highly promising avenue. At IAA, MAHLE presents solutions for the technological transformation, from thermal management to drive motors and power electronics.
IAA Commercial Vehicles is the opportunity for MAHLE to showcase its solutions for the demand-based conditioning of temperature-sensitive lithium-ion batteries. These solutions greatly simplify the design of the cooling module. With the Visco® hybrid fan drive, MAHLE offers a solution tailored specifically to hybrid drives. Its technology combines the advantages of the Visco® drive with those of electric actuation, including demand-based fan performance control, increased efficiency, and energy recuperation.
A strong alternative: the fuel cell drive in commercial vehicles
Throughout the world, the number of vehicles equipped with fuel cell drives is increasing slowly but steadily. This opens up new opportunities for heavy-duty commercial vehicles. Promising avenues include weight savings and extension of the cruising range in comparison with battery-powered solutions.
“Fuel cell concepts may represent an attractive option for long-distance hauling, which requires heavy loads and large cruising ranges. Therefore, over the past years, we have specifically developed near-series systems tailored for the tough conditions that commercial vehicles are exposed to every day. We are making great progress in this area, while keeping costs under control thanks to a modular approach,” says Stratmann.
The result of this holistic systems approach is the plastic exhaust air pathway optimized by MAHLE for fuel cell vehicles; it is exhibited at the IAA Commercial Vehicles. It offers weight savings of around 70 percent in comparison with steel designs and dramatically reduces audible resonance while retaining as much design freedom as possible.
The use of fuel cell technology increases the need for sophisticated thermo-management solutions. At IAA Commercial Vehicles, MAHLE presents series production solutions for the temperature control of batteries, electronics, and electric motors as a complete system including solutions for monitoring the fuel cell stack.
Adsorption air conditioning system
With its entirely new air conditioning concept, MAHLE is demonstrating at IAA Commercial Vehicles that it’s possible to make standstill air conditioning powerful, engine-independent, and thus very quiet. The cycle of evaporation, adsorption, condensation, and desorption means that MAHLE’s solution is extremely low-wear and totally noise-free, making it more efficient and powerful than conventional systems.