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Products-Mahle Thermal Management

Revolutionizing Air Management in Passenger Cars with MAHLE Thermal Management Solutions

Tailor-made Air Management Systems

As the space available under the hood of passenger cars continues to shrink, the need for efficient thermal management systems is paramount. MAHLE offers tailor-made air management solutions that cater to the evolving needs of customers. These systems not only excel in filtration performance but also ensure optimal flow and thermal management, all while maintaining an extremely compact design.

Innovative Systems for Air Management

With the engine processes growing in complexity, the demands on the intake system have significantly increased. Factors such as emissions regulations, consumption specifications, shorter model cycles, and the need for enhanced performance in compact packages drive modern development. MAHLE's groundbreaking development includes the integration of charge air cooling in the air intake module, marking a substantial advancement in the design for modern combustion engines.

High-performance Air Filters

The ever-decreasing space constraints necessitate higher filtration performance, particularly concerning particle retention efficiency. To address this trend, high-performance filters, intricate flow guidance designs, and innovative filter element concepts are vital. As a leader in plasticized filter elements, MAHLE offers a wide range of design types to adapt flexibly to various package constraints.

Cutting-edge Technologies for Thermal Management

MAHLE's portfolio includes electric blow-by heaters, electric wastegate actuators (EWG), actuators for turbochargers with variable turbine geometry (VTG), resonators/sound generators, oil mist separators, engine and cylinder head covers, air ducts, and exhaust gas recirculation (EGR) systems. These technologies ensure optimized heating functions, efficient turbocharger performance, reduced oil mist contamination, lightweight components, and compliance with stringent emissions regulations.

Advancements in Emissions Control

To meet stringent emissions regulations, MAHLE provides solutions like exhaust gas recirculation (EGR) systems. By incorporating cooled EGR, a portion of the exhaust flow is extracted, cooled, and reintroduced into the intake air stream, reducing nitrogen oxide (NOx) emissions. MAHLE's laser-welded exhaust gas heat exchangers offer exceptional corrosion resistance, and switchable options disable EGR cooling in specific driving scenarios to maintain low pollutant emissions.

Enhancing Performance and Efficiency with Mahle Thermal Management Cylinder Components

Bearings

In modern engines, the demand for higher operating temperatures, pressures, speeds, and lower emissions has never been greater. This necessitates the use of innovative concepts and materials in cylinder components to enhance performance. One crucial component, bearings, must improve load capacity and reduce wear and friction to meet the evolving requirements for CO2 reduction. The challenge intensifies in stop-start or hybrid systems where the engine frequently switches on and off, subjecting the bearings to high loads during the starting process.

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Enhancing Engine Efficiency with MAHLE Thermal Management Valve Train Solutions

Valve Train Systems and Components

Valve train systems play a crucial role in controlling the gas exchange process within an engine, offering significant opportunities for optimizing combustion. Components within the valve train system are exposed to high mechanical loads, compounded by increasing combustion pressures and temperatures. MAHLE Thermal Management offers a range of solutions, including intake and exhaust valves in forged and hot-extruded versions for gasoline and diesel engines of varying sizes. These valves are available in a multitude of materials and can be strengthened, hardened, nitrided, or chrome-plated depending on the stress levels.

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MAHLE Thermal Management Solutions for Commercial Vehicles

MAHLE EMC Battery Filters

MAHLE offers EMC Battery Filters designed to reduce EMC interference in batteries with 400 V and up to 190 A nominal current. These filters have a filter bandwidth of 150 kHz to 300 MHz, providing maximum insertion losses of 60 dB at a frequency of 1 MHz. They enhance the HV battery's immunity from high voltage vehicle transients and comply with automotive standards while maintaining a compact and robust design. Custom designs ensure a perfect fit to battery impedance and client requirements.

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Mahle Thermal Management: Enhancing Comfort and Safety in Vehicle Air Conditioning

HVAC Modules

MAHLE's HVAC modules are specifically designed to meet the requirements of vehicle manufacturers. The focus on enhancing efficiency, reducing weight, minimizing pressure loss, and optimizing acoustics highlights the commitment to continuous improvement. The use of standardized components and design features ensures the development of robust and high-performance HVAC modules that offer exceptional value to the vehicles they are installed in.

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Enhancing Passenger Car Performance with MAHLE Thermal Management Solutions

Optimizing Engine Lubrication and Cooling

In the realm of passenger cars, ensuring reliable lubrication of moving parts with oil is crucial to reduce mechanical friction and prevent damage in the engine and transmission. A key aspect of this process is the oil circuit, which serves as a mechanism for dissipating heat. MAHLE's oil management solutions focus on enhancing the overall system of engine lubrication and cooling by integrating various functions. These functions include filtration, cooling of the lubricating oil, oil mist separation, pressure and temperature control sensors, oil pressure regulation, crankcase pressure regulation, and the option for a fuel cooler. By utilizing advanced materials, particularly high-performance plastics, MAHLE achieves significant cost and weight savings. Additionally, the incorporation of environmentally friendly filter elements that are easy to replace and dispose of contributes to sustainability. Modern filter media and manufacturing processes used in long-term filter elements extend service intervals, improving overall efficiency and performance.

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