MANN+HUMMEL premieres intake manifold with fully integrated intercooler at Frankfurt Motor Show

Ludwigsburg/Frankfurt, September 12, 2017 – a more constant and effective intercooling and a resulting reduction of CO2 emissions of up to 3% are the advantages of indirect intercooling which are convincing more and more vehicle manufacturers. In comparison to direct intercooling, a reduced charge air volume and a quicker build-up of boost pressure improve the engine response. MANN+HUMMEL, the filtration expert from Ludwigsburg, has now raised this technology to a new level. At the 2017 Frankfurt motor show the company will celebrate the world premiere of the first intake manifold with a fully integrated intercooler.

Full integration versus stand-alone concept
The new system exploits all the advantages of indirect charge air cooling and requires a lower number of components in comparison to stand-alone concepts which work with separate components for the intercooler and intake manifold. This reduces the number of interfaces and the handling costs for automobile manufacturers. In addition, a lower pressure drop and the smaller charge air volume serve to improve the engine response.

Full integration versus mounted units
With full integration the cooler is completely enclosed by the intake manifold shells. This gives the whole system a higher stability in comparison to mounted solutions as there is no sealing surface to the outside. The system enables excellent temperature distribution with a maximum temperature difference of two degrees Kelvin over all six cylinders. In this process, the whole system has to withstand high temperature differences between the air inlets and air outlets of up to 90 degrees Kelvin.

Two-component seal
The seal consisting of two components between the cooler and intake manifold shells is characterized by good resistance to chemicals and low leakage values. It is made from a plastic frame in the particularly strong polyamide 6 with a 35% glass-fiber component (PA6 GF35) and an elastomer seal in fluorinated rubber which has a good resistance to temperature and media. A positive-locking fit keeps the polyamide and elastomer firmly and securely together.

Maximum stability
Absolute charge pressures of up to 2.7 bar place high requirements on components. The large surfaces of the plastic shells are subject to considerable stress. Using modern simulation technology, internal prototype construction and intensive testing, the engineers at MANN+HUMMEL were able to enhance the right design through the use of ribbed plastic shells to ensure the highest stability and at the same time to minimize weight.

Guiding ribs in the assembly ensure an even air inflow to all the cylinders through an optimum air flow. At the same time the component design serves to minimize pressure drop. The use of hot-gas welding enables more narrow welding seams which are also stronger. A positive side effect is the increased cleanness of the component due to the fact that with this process there is no fluff resulting from friction.

About MANN+HUMMEL

MANN+HUMMEL is a leading global expert for filtration solutions. The company group with its headquarters in Ludwigsburg, Germany, develops solutions for motor cars, industrial applications, clean air in interior spaces and the sustainable use of water. In 2016 the group achieved sales of approx. 3.5 billion euros worldwide with more than 20,000 employees at more than 80 locations. The products manufactured by the group include air cleaner systems, intake manifold systems, liquid filter systems, plastic components, filter media, cabin filters, industrial filters and membrane filters.

 

Press contacts:

Harald Kettenbach
Tel.: +49 7141 982583
Email: harald.kettenbach(at)mann-hummel.com

Miriam Teige
Tel.: +49 7141 983354
Email: miriam.teige(at)mann-hummel.com

Patrick Löffel
Tel.: +49 7141 982391
Email: patrick.loeffel(at)mann-hummel.com 

Source: MANN+HUMMEL

Mahle unveils MEET concept at Internationale Automobil-Ausstellung (IAA) Frankfurt

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Stuttgart – In a world debut, MAHLE presents the vehicle concept “MEET” (MAHLE Efficient Electric Transport) to the public at IAA Cars in Frankfurt/Germany. MEET is systematically aligned to the needs of urban mobility. The concept combines maximum efficiency, individual comfort, driving pleasure—and is still affordable.

  • Maximum efficiency: seven days in day-to-day city traffic without charging
  • Comfortable: individual comfort zones implemented at less cost to the environment
  • Driving pleasure: agile and networked through the city
  • Affordable: 25 percent lower costs in the powertrain

Efficient and highly integrated—MAHLE twin-power drive unit

MEET makes use of the new MAHLE 48-volt twin-power drive unit. It combines two electric motors, the transmission, and a 48-volt electronics system. The MAHLE IPM (Interior Permanent Magnet Synchronous Motor) traction drive provides maximum efficiency and dynamics in a wide speed range. The MEET demonstrator vehicle initially contained a MAHLE drive unit comprising two motors each with 14 kilowatts of mechanical continuous output and 36 newton meters of torque. At the IAA we are demonstrating the next evolutionary step with 20 kilowatts of continuous output and 80 newton meters of torque per motor. The motors drive the rear wheels via a central transmission.

Go further comfortably—seven days with no need to charge

In the urban application area, the technical focus of MEET is on maximum energy efficiency. The interaction of various energy-saving technologies in the fields of powertrain and thermal management increases efficiency and significantly extends the cruising range of the vehicle.

As in all vehicles with a purely electric powertrain, one of the biggest challenges with respect to energy storage is heating the interior, particularly in winter. Indeed, by eliminating local emissions, the system lacks the most important heat source—the combustion engine. As a result, any temperature-related output such as the heating of the heating air places a burden on the battery and therefore on the vehicle’s cruising range.

Maximum efficiency without compromises—and even with improvements—in comfort are therefore a top priority in MEET. MAHLE achieves thermal efficiency through measures such as a thermoelectric heat pump and surface heaters with individual comfort zones in combination with dual-zoned air conditioning. As a result, MEET achieves up to seven days of inner city trips—with just one charge. Expressed in figures, innovative thermal management increases the cruising range by 5 percent in summer and by as much as 50 percent in winter.

Driving pleasure redefined—zippy, agile, intuitive

In urban traffic, maximum speed is not what counts. With a top performance of 40 to 60 kilowatts—depending on the model of the motor—MEET is very zippy in the relevant speed range. The basic model of MEET accelerates from 0 to 50 km/h in five seconds. When using the new MAHLE motors each with a peak power of 30 kilowatts, this time drops to less than three seconds. Maneuvering and parking are supported by the torque vectoring functionality of the MAHLE twin-power drive unit: MEET is rendered exceptionally agile thanks to the selective wheel torque output of the two electric motors.

The innovative operating concept ensures that the driver is not distracted while driving but can still use all the functionality safely. Handling MEET is intuitive and simple—despite a wide range of functions such as controlling the navigation, sound, and air conditioning systems, or accessing the technical status of the vehicle. This is where the comprehensive expertise of the MAHLE subsidiary BHTC comes into play. The operating concept enables a contact-free, gesture-based control, haptic feedback, and personalized comfort settings as well as the preconditioning of the interior, for example via a smartphone app during charging.

 Affordable—designed for the end customer

Despite its technical sophistication, MEET is an affordable vehicle concept. There are several reasons for this:

  • MEET is a platform concept. The modular approach can be flexibly transferred to a range of vehicle concepts.
  • Economies of scale are generated. For example, the modular drive unit may also be easily used as an e-axle in a 48-volt hybrid system. In addition, MAHLE believes that all the technologies in MEET can be carried over into large-scale production.
  • The 48-volt approach requires fewer safety measures in comparison with high-voltage systems, reducing the cost of the drive by 25 percent.

MAHLE combines expertise for new directions in e-mobility

MEET, MAHLE Efficient Electric Transport, is the vehicle concept for tomorrow’s urban mobility. With MEET, MAHLE is actively addressing the current challenges of the automotive industry. MEET combines the broad MAHLE portfolio and expertise in the fields of thermal management, powertrain, electronics, and user interfaces, and convincingly demonstrates today what the new directions in e-mobility will be.

MEET and its overall concept will be presented by MAHLE for the first time at IAA 2017, Stand C40 in Hall 8.0. The MAHLE press conference will take place on September 12, from 2:45 p.m. to 3:10 p.m. at the MAHLE stand.

Short Q&A sessions will be held immediately after the MAHLE press conference, giving journalists an opportunity to learn more about the technical details from the MAHLE product experts themselves. We look forward to your visit!

About MAHLE

MAHLE is a leading international development partner and supplier to the automotive industry as well as a pioneer for the mobility of the future. The MAHLE Group is committed to making transportation more efficient, more environmentally friendly, and more comfortable by continuously optimizing the combustion engine, driving forward the use of alternative fuels, and laying the foundation for the worldwide introduction of e-mobility. The group’s product portfolio addresses all the crucial issues relating to the powertrain and air conditioning technology—both for drives with combustion engines and for e-mobility. MAHLE products are fitted in at least every second vehicle worldwide. Components and systems from MAHLE are also used off the road—in stationary applications, for mobile machinery, rail transport, as well as marine applications.

In 2016, the group generated sales of approximately EUR 12.3 billion with about 77,000 employees and is represented in 34 countries with 170 production locations. At 15 major development centers in Germany, Great Britain, Luxembourg, Spain, Slovenia, the USA, Brazil, Japan, China, and India, 6,000 development engineers and technicians are working on innovative solutions for the mobility of the future.

For further information, contact:

MAHLE GmbH
Ruben Danisch
Corporate Communications
Pragstraße 26–46
70376 Stuttgart
Germany

Phone: +49 711 501-12199
Fax: +49 711 501-13700
ruben.danisch@mahle.com

Source: Mahle