Author: Mahle Official News

11/05/2019MAHLE pushes ahead with its activities in the area of alternative drives

MAHLE pushes ahead with its activities in the area of alternative drives

Stuttgart/Germany and Coimbatore, Tamil Nadu/India, November 5, 2019 – The MAHLE Group is consistently implementing its dual strategy and further expanding its position as a systems provider for alternative drive concepts. In India, the group has increased its holding in the former joint venture MAHLE Letrika Roots India from 50 to 90 percent.

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Press release [PDF; 54 KB]Press picture 1 [JPG; 407 KB]Press picure 2 [JPG; 1518 KB]Press picture 3 [JPG; 8 MB] Shareholding in former joint venture MAHLE Letrika Roots India increased to 90 percent Entry into the promising market for electrically powered two-wheelers in India Start of production scheduled for April 2020The future unit, MAHLE Electric Drives India, based in Coimbatore in the southern Indian state of Tamil Nadu, will initially focus on the development and production of electric traction motors and control units for the new and promising market segments of electric twoand three-wheelers. The first components are expected to leave the production line as early as April 2020. Activities in this area are to be extended to other vehicle segments in the future.
The increase in the shareholding in MAHLE Letrika Roots India comes at a strategically favorable time: in summer 2019, the Indian government announced its plans for a comprehensive subsidy program that will drive forward the expansion of e-mobility in India. For MAHLE, this opens up new opportunities for further sustainable growth in this important market in the future.
In quantitative terms, India is the world’s biggest market for twoand three-wheelers. Like many European and Asian countries, India is currently actively driving the transition to alternative drive concepts with the electrification of its vehicle segments.
About MAHLEMAHLE 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 2018, the group generated sales of approximately EUR 12.6 billion with more than 79,000 employees and is represented in over 30 countries with 160 production locations. At 16 major research and development centers in Germany, Great Britain, Luxembourg, Spain, Slovenia, the USA, Brazil, Japan, China, and India, more than 6,100 development engineers and technicians are working on innovative solutions for the mobility of the future.
For further information, contact:MAHLE GmbH
Margarete Dinger
Corporate Communications/Public Relations
Pragstraße 26–46
70376 Stuttgart
Germany
Phone: +49 711 501-12369
margarete.dinger@mahle.com

10/23/2019MAHLE presses ahead with its global realignment and plans location adjustments

MAHLE presses ahead with its global realignment and plans location adjustments

Stuttgart/Germany, October 23, 2019 – After a thorough review, MAHLE is planning further adjustments to its locations in Italy, France, and Luxembourg. Volatile markets, the flattening of economic growth curves, and a multitude of political imponderables, such as trade policy conflicts or the uncertainty surrounding Brexit, are causing the economic situation to deteriorate significantly. Together with the considerable expenditure involved in the technological transformation, regulatory requirements, and declining sales figures, particularly for diesel vehicles, this calls for further action.

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Press release [PDF; 34 KB] Sustainable corporate positioning and measures to safeguard competitivenessDiverse factors result in planned restructuring measuresSystematic continuation of location auditsThe planned location adjustments, following on from an intensive audit of our locations and structures, will primarily affect production and development locations in Europe. This is due to conditions that are specific to the individual locations, such as an intensified market and competitive situation, or a further decline in demand for diesel engines.
MAHLE is therefore planning to relocate its research and development center in Foetz/Luxembourg. By mid-2021, all activities there will be discontinued and integrated into other MAHLE locations. Development activities at the location are currently focused on air conditioning compressors. Because of the strong trend toward electrified vehicles, the integrated product development of the electric compressor is seen as an important step toward sustainable competitiveness. The organizational merger of the main competences in the areas of mechanics, electric motors, and electronics is already under way with the creation of the new MAHLE business unit for mechatronics and electronics as of January 1, 2020. The existing profit center for compressors will also be integrated into this business unit. The relocation of the development activities from Luxembourg to MAHLE locations with expertise in the areas of electric motors and electronics now also creates the geographical conditions for even more efficient integration and more effective cooperation between the development teams. Currently, 78 employees work at Foetz.
In addition, a location closure is planned for the plants in La Loggia/Saluzzo, Italy. The plants in La Loggia (production) and Saluzzo (foundry) produce exclusively diesel engine pistons. The group of plants has been suffering from declining sales and profit losses for more than a decade. With the continuing fall in demand for diesel engines and the vehicle manufacturers’ change in strategy, the outlook is no longer sustainable and MAHLE is entering into a consultation process with the public authorities and employee representatives. The two locations currently have a total of around 450 employees.
For the production and development location in Rouffach/France, MAHLE is planning a strategic realignment with the aim of safeguarding the plant’s long-term prospects. The group is investing heavily in development and manufacturing competences in the area of PTC heating elements, which will be the location’s focus in the future. In order to create the necessary structures, the production of air conditioners in Rouffach should be discontinued and the activities for the aftermarket relocated. Going forward, this would require the loss of around 240 jobs.
In March 2019, MAHLE launched an internal cost reduction program that supplements the programs already initiated at the start of 2018 to improve profitability. In this context, the group has driven forward measures to continuously audit its locations and structures worldwide.
About MAHLEMAHLE 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 2018, the group generated sales of approximately EUR 12.6 billion with more than 79,000 employees and is represented in over 30 countries with 160 production locations. At 16 major research and development centers in Germany, Great Britain, Luxembourg, Spain, Slovenia, the USA, Brazil, Japan, China, and India, more than 6,100 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/Public Relations
Pragstraße 26–46
70376 Stuttgart
Germany
Phone: +49 711 501-12199
ruben.danisch@mahle.com

10/15/2019Electric traction motors from MAHLE—scalable and zeroemissions

Electric traction motors from MAHLE—scalable and zeroemissions

Stuttgart/Germany, October 10, 2019 – MAHLE offers manufacturers of electric vehicles sophisticated drive solutions with maximum performance. MAHLE traction motors are suitable for all applications: for mild and full hybrid vehicles and for vehicles with a range extender, as well as for purely batterypowered vehicles or fuel cell vehicles and even two-wheelers. Traction motors from MAHLE make e-mobility reliable and affordable. High power density, efficiency, and a flexible design provide decisive sales arguments for the end consumer: more driving pleasure, long cruising range, and low purchase price.

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Press release [PDF; 248 KB]Press picture [JPG; 4002 KB] MAHLE offers a wide portfolio of traction motors for passenger cars and two-wheelersHigh power density, efficiency, and flexible design are hallmarks of MAHLE traction motorsMAHLE offers traction motors in voltages ranging from 48 to 800 volts, with high power density, a robust design, and optimized cooling. At high power densities and speeds, MAHLE’s wideranging expertise in thermal management is especially effective. MAHLE is continuously developing new technologies to further increase the long-term performance of the motors.
MAHLE traction motors are also available in various designs, thus guaranteeing optimal packaging. They cover a performance range of up to 250 kilowatts.
Up to 40 kilowatts for 48-volt applicationsThe replacement of the 12-volt electrical system by a 48-volt system is already underway for passenger cars. This means that MAHLE 48-volt drive motors are now not only suitable for urban mobility applications, but also for heavy vehicles. It will thus be possible to use 48-volt drives in high-performance or heavy vehicles—e.g., as a mild hybrid—in the future. The major advantage is that the 48-volt drives remain below the voltage limit of 60 volts, eliminating the need for various safety precautions and complicated connector plugs. The costs for the motor and power electronics can also be reduced by about 25 percent in comparison with a high-voltage solution. To further expand the range of application of 48-volt systems, MAHLE has developed a traction motor that has an output of up to 40 kilowatts and is thus able to deliver up to 80 kilowatts to the wheels from a drive unit consisting of two motors.
Two-wheeler drive motors from MAHLE for scooters or pedelecs With integrated high-energy permanent magnets and low-loss materials, two-wheeler drive motors from MAHLE power scooters or pedelecs at over 90 percent efficiency. The motor torque characteristics are especially suitable for direct-belt drive applications and for various transmission solutions. The inverters used achieve an efficiency of 97 percent, are able to regenerate, and, thanks to their field-oriented vector controls, ensure dynamic and quiet driving behavior with maximum efficiency. They are ideal for applications in which space, weight, and efficiency are of high relevance.
Lifestyle meets performance – MAHLE in the pedelecWith the acquisition of ebikemotion® , MAHLE has continued to grow in all areas relating to compact and lightweight rear wheel hub motors, batteries, electronic control units, and other pedelec components that can be integrated unobtrusively into the bicycle. The hardware is supplemented by an integrated connectivity solution featuring mobile and web-based apps. The MAHLE ebikemotion® system is particularly suitable for use in lightweight racing bikes, gravel bikes, and city bikes.
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 2018, the group generated sales of approximately EUR 12.6 billion with more than 79,000 employees and is represented in more than 30 countries with 160 production locations. At 16 major research and development centers in Germany, Great Britain, Luxembourg, Spain, Slovenia, the USA, Brazil, Japan, China, and India, more than 6,100 development engineers and technicians are working on innovative solutions for the mobility of the future.
For further information, contact:MAHLE GmbH
Christopher Rimmele
Corporate Communications/Public Relations
Pragstraße 26–46
70376 Stuttgart/Germany
Phone: +49 711 501-12374
Fax: +49 711 501-13700
christopher.rimmele@mahle.com

09/12/2019“E-fuel ready” with MAHLE components

“E-fuel ready” with MAHLE components

Stuttgart/Germany, September 12, 2019 – Alternative fuels from regenerative sources offer substantial potential for reducing transportation-related CO2 emissions. MAHLE is therefore concertedly investigating the compatibility of its engine components and filters with the use of various e-fuels. The results show that many of the MAHLE materials and components that have been tested so far are “e-fuel ready.”

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Press release [PDF; 243 KB] MAHLE tests its engine components and filters for compatibility with e-fuelsMAHLE is thus paving the way for CO2 savings with the use of regenerative fuelsMAHLE is examining the resistance of components and materials when using fuel blends with e-fuels that can be admixed under current fuel standards as well as alternatives such as oxymethylene ether (OME) for heavy-duty commercial vehicles, dimethyl carbonate (DMC) for passenger cars, or methane (CH4) as a gaseous alternative.
Admixtures within the current fuel standards are especially promising due to their backward compatibility, as they include the existing global car population in CO2 reduction. The resulting lever is greater by a factor of about 20, given sufficient availability of regenerative fuel in Europe, than for measures that apply only to new vehicles. This potential should be considered as a supplement to electric mobility in the drive mix of the future.
“The admixture of e-fuels can immediately produce great savings potential. If allowed, this could mean a decisive step toward achieving the 37.5 percent CO2 savings mandated at EU level relative to 2021,” explains Dr. Otmar Scharrer, Head of Research and Advanced Engineering at MAHLE. “Our tests indicate that many of the MAHLE engine components and filters tested to date are ready for the admixture of e-fuels. We are providing our customers with the means to tap this potential.”
As part of the series of test runs, MAHLE is also investigating what proportion of a fuel that is outside of the current standards can be used in operation without changes to hardware or software. The tests have demonstrated that engine performance comparable to the use of purely fossil fuels is possible with the admixture of certain e-fuels as well, while maintaining series production data sets and injection systems. No measurable difference in the combustion process was found for the tested efuels. Emissions behavior was actually even better than for purely fossil fuels in large areas of the operating map. From a thermodynamic perspective, MAHLE therefore assumes that these e-fuels will be technically backward compatible for the admixture of up to 20 percent. This is a very promising approach, but its implementation requires legislative support in terms of expanded fuel standards.
About MAHLEMAHLE 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 2018, the group generated sales of approximately EUR 12.6 billion with more than 79,000 employees and is represented in more than 30 countries with 160 production locations. At 16 major research and development centers in Germany, Great Britain, Luxembourg, Spain, Slovenia, the USA, Brazil, Japan, China, and India, more than 6,100 development engineers and technicians are working on innovative solutions for the mobility of the future.
For further information, contact:MAHLE GmbH
Christopher Rimmele
Corporate Communications/Public Relations
Pragstraße 26–46
70376 Stuttgart/Germany
Phone: +49 711 501-12374
Fax: +49 711 501-13700
christopher.rimmele@mahle.com

08/29/2019High cost savings: new scalable and modular hybrid drive from MAHLE

High cost savings: new scalable and modular hybrid drive from MAHLE

Stuttgart, August 29, 2019 – MAHLE has developed a new, fully integrated and modular hybrid drive that can be tailored to suit a wide range of vehicle applications. The MAHLE Modular Hybrid Powertrain (MMHP) is a fully integrated, plug-in hybrid drive that incorporates a highly efficient 2- or 3-cylinder, turbocharged gasoline engine featuring the latest technologies from MAHLE. In comparison with established hybrid technologies, it offers several advantages: it is more cost-efficient, more compact, and lighter.

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Press release [PDF; 140 KB]Press picture [JPG; 930 KB] Integrated, scalable hybrid solution for vehicles from B-segment through to large J-segment SUVsModular approach for tailoring performance to a specific application, while retaining maximum component commonalityNewly developed, highly efficient combustion engine especially designed for use within hybrid drives The performance of the electric powertrain used in MMHP reduces the requirements for the combustion engine, enabling the development of a cost-optimized “Dedicated Hybrid Engine (DHE).’’ The engine concept was designed exclusively for hybrid applications and benefits from the latest innovations made with the passive MAHLE Jet Ignition (MJI®) system. The passive MJI® system consists of a small prechamber, which houses a conventional spark plug fitted within the engine’s combustion chamber. It generates hot radical jets, which create a very short combustion event within the engine’s cylinder, thus enabling a high compression ratio and a high exhaust gas recirculation rate, leading to reduced fuel consumption. The use of port fuel injection (PFI), a single overhead camshaft (SOHC) without variable valve timing control, and simple two-valve per cylinder technology serve to minimize the costs.
“In order to avoid penalties, vehicle manufacturers must comply with the EU’s legislative target of fleet average CO2 emissions of 59.4 g/km by 2030. Electrification is leading the way as the industry’s chosen technology to achieve this,” says Dr. Martin Berger, Director at MAHLE Powertrain, MAHLE’s Engineering Services business area. “The advancement of hybrid technology is crucial for the industry as a whole to achieve future emissions targets. As a result of the focus on reduced emissions and strict schedules, new vehicle and technology development must occur within a much tighter timeframe. The MAHLE Modular Hybrid Powertrain (MMHP) offers vehicle manufacturers a low-cost and quick, off-the-shelf solution, easing the process.’’
The dual-mode hybrid arrangement has been selected for the MMHP, as it combines the best features of both series and parallel hybrid architectures. It allows for flexible vehicle operation, while providing optimal NVH behavior. When battery SOC is high, the vehicle can operate as a pure EV, whereas when SOC is low and at slow driving speeds it can switch to series hybrid mode. At higher vehicle speeds, however, the combustion engine can be connected directly to the wheels in a parallel hybrid arrangement.
Thanks to a gearbox with customizable transmission ratios, the engine can run flexibly at any given vehicle speed. Options for 1-, 2-, and 4-speed transmissions are available, depending on application requirements. As a result, the fully integrated, electric traction motor is directly connected to the wheels at all times, facilitating uniform performance and a dynamic driving experience with uninterrupted torque delivery. The motor can also be designed with different power/torque outputs. Coupled with optimized battery sizing, this allows full scalability of the hybrid powertrain for all applications.
“The modular hybrid powertrain from MAHLE features the perfect combination of efficiency, performance, and range without jeopardizing driving pleasure,” concludes Dr. Berger. “The powertrain’s compact size can also help comply with design-related packaging constraints, while the relatively low weight enhances efficiency and performance.”
The hybrid drive is suitable for a variety of applications—from B-segment through to large J-segment SUVs. The engine itself has achieved ultralow specific fuel consumption figures of 207 grams per kilowatt hour in early stage testing. In the future, fuel consumption of around 195 grams per kilowatt hour in lean operation is realistic by using an active MJI® system. When applied to a compact crossover SUV, WLTP-weighted CO2 emissions are calculated at 18 grams per kilometer. The weight of the hybrid powertrain is similar to a current 4-cylinder gasoline engine with 6-speed manual transmission. The specially designed combustion engine offers potential cost savings of up to 30 percent.
About MAHLEMAHLE 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 2018, the group generated sales of approximately EUR 12.6 billion with more than 79,000 employees and is represented in over 30 countries with 160 production locations. At 16 major research and development centers in Germany, Great Britain, Luxembourg, Spain, Slovenia, the USA, Brazil, Japan, China, and India, more than 6,100 development engineers and technicians are working on innovative solutions for the mobility of the future.
Further queries:MAHLE GmbH
Christopher Rimmele
Corporate Communications/Public Relations
Pragstraße 26–46
70376 Stuttgart
Germany
Phone: +49 711 501-12374
Fax: +49 711 501-13700
christopher.rimmele@mahle.com

08/14/2019New battery housing from MAHLE reduces weight and CO2 footprint of electric vehicles

New battery housing from MAHLE reduces weight and CO2 footprint of electric vehicles

Stuttgart/Germany, August 14, 2019 – A key factor in the acceptance of electric vehicles is sufficient cruising range. Instead of achieving this by using ever larger batteries, MAHLE offers a newly developed battery housing with integrated thermal management as a solution for increasing the rapid chargingcapability of the battery. This allows traction batteries to be about 40 percent smaller and thus recharged very quickly. MAHLE is thereby not only reducing the CO2 footprint of the electric vehicle, but also lowering the demand for raw materials for battery production, which are becoming increasingly scarce worldwide,

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Press release [PDF; 156 KB]Press picture [JPG; 770 KB]

08/08/2019MAHLE makes fuel cells mobile

MAHLE makes fuel cells mobile

Stuttgart/Germany, August 08, 2019 – The companies that are defining the mobility of the future must respond quickly to changing conditions. This is the only way to bring new technologies to economic viability and series production internal structures and bundling the expertise of various development fields in one fuel cell project house. This is a place where all fuel cell topics come together.

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Press relase [PDF; 152 KB]Press picture 1 [JPG; 1630 KB]Press picture 2 [JPG; 4367 KB]Press picture 3 [JPG; 4664 KB] MAHLE bundles fuel cell expertise in agile structureFuel cell project house acts as a central contact point across all systems related to fuel cellsThe importance of an overall system perspective for the safety and competitiveness of fuel cell vehicles can be illustrated by simulating the dynamics of fuel cells in interplay with battery size or by the reciprocal development of ion exchangers and heat exchangers. The air pathway, also known as the cathode air system, is one of the central systems in the periphery of the fuel cell. The relationships and interactions are complex and can only be predicted through elaborate simulations.
The team at the fuel cell project house analyzes the results and defines the design of the peripheral components, which leads to a cost-optimized vehicle. MAHLE is transferring expertise from a wide variety of research and development areas of conventional mobility to the fuel cell project house, enabling thermal, air, and liquid management and filtration to work together purposefully.
Another example of close interaction among various development centers is the joint development of heat exchangers and ion exchangers. This is where our technical expertise in the areas of thermal management and filtration comes together. The coolant used to cool fuel cell stacks must be deionized so that it loses its electrical conductivity. If it were conductive, then not only could explosive gas form, but undesired and dangerous currents could be discharged. The deionized cooling medium flows through the bipolar plates of the fuel cell to cool it. The deionized cooling medium is highly reactive, however, and corrodes components that come into contact with it, so this must be avoided. For this reason, MAHLE passivates the heat exchanger and makes it resistant to leaching ions. This produces a durable cooling system and reduces the load on the ion exchanger, ensuring high-voltage safety under all conditions.
The exhaust air pathway in the fuel cell vehicle also requires extensive expertise. An intelligent system for water disposal ensures that water disposal occurs only at high speeds. This prevents water from freezing in awkward locations, such as in parking garages or inner cities. The water that is discharged at high speeds is atomized. This functional integration is typical of the development of engine components as an overall system at MAHLE, combining expertise from the areas of engine peripherals, flow simulation, and filtration.
About MAHLEMAHLE 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 2018, the group generated sales of approximately EUR 12.6 billion with more than 79,000 employees and is represented in more than 30 countries with 160 production locations. At 16 major research and development centers in Germany, Great Britain, Luxembourg, Spain, Slovenia, the USA, Brazil, Japan, China, and India, more than 6,100 development engineers and technicians are working on innovative solutions for the mobility of the future.
For further information, contact:MAHLE GmbH
Christopher Rimmele
Corporate Communications/Public Relations
Pragstraße 26–46
70376 Stuttgart/Germany
Phone: +49 711 501-12374
christopher.rimmele@mahle.com

08/01/2019MAHLE is making engine components intelligent

MAHLE is making engine components intelligent

Stuttgart/Germany, August 01, 2019 – Intelligent engine components are not just a valuable tool for engine developers but could in the future be used as “early warning systems” in engines for monitoring operating conditions and ensuring a long service life. Intelligent bearings from MAHLE keep track of operating conditions in real time, providing an accurate view of the temperature in the bearing. The same measurement method forms the basis for an innovative piston monitoring concept, in which measurement data is transmitted wirelessly and the energy consumption of the sensors covered by the motion of the piston via “energy harvesting.”

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Press release [PDF; 279 KB]Press picture [JPG; 13 MB] Intelligent engine components from MAHLE monitor operating conditions in real timeApplication as a development tool enables the precise design of cooling and engine componentsWhen used as a development tool, intelligent engine components from MAHLE facilitate the precise analysis of temperature and pressure conditions for moving components, such as pistons, valves, or bearings. The necessary lubricating oil supply and cooling of engine components can thereby be designed for specific operating points so that no damage results from excessively high temperatures or inadequate lubrication, while allowing the amount of cooling or lubricating oil to be set as low as possible. This avoids any unnecessary friction losses and increases the engine’s efficiency.
By measuring the relevant temperatures and pressures in situ—for example, in the bearing gap of the bearing or in the cooling gallery of the piston—not only can the operating limits of the components be determined more precisely under real conditions, but the engine can be adjusted and calibrated to operate reliably much closer to its limits without any increase in risk. As a result, previously untapped potential can be used to improve thermodynamic and mechanical efficiency.
To prevent damage to the engine from external influences, such as fuel quality or intake air temperature, an increased safety factor must be maintained in the current design without intelligent sensors. By contrast, a piston with sensors would not only permit higher ongoing utilization, but also prevent a transient overload of the piston in the warm-up phase.
Intelligent engine components from MAHLE are currently used as development tools during engine development. After the successful transfer to large-scale production, use in massproduction engines is also under consideration—on the one hand to exploit the component limits in any engine, and on the other, to enable an emerging damage scenario to be recognized early on and a prompt response triggered.
About MAHLEMAHLE 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 2018, the group generated sales of approximately EUR 12.6 billion with more than 79,000 employees and is represented in over 30 countries with 160 production locations. At 16 major research and development centers in Germany, Great Britain, Luxembourg, Spain, Slovenia, the USA, Brazil, Japan, China, and India, more than 6,100 development engineers and technicians are working on innovative solutions for the mobility of the future.
For further information, contact:MAHLE GmbH
Christopher Rimmele
Corporate Communications/Public Relations
Pragstraße 26–46
70376 Stuttgart/Germany
Phone: +49 711 501-12374
Fax: +49 711 501-13700
christopher.rimmele@mahle.com

07/30/2019Changes to the MAHLE Management Board

Changes to the MAHLE Management Board

Stuttgart/Germany, July 30, 2019 – The MAHLE Group is adding a new business unit for electronics and mechatronics, thereby further developing its strategic orientation toward alternative powertrain technologies. Corresponding changes to the MAHLE Management Board will be effective as of January 1, 2020.

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Press release [PDF; 50 KB]Press picture [JPG; 1664 KB]CV Martin Weidlich [PDF; 31 KB] New business unit for electronics and mechatronicsStrategic orientation toward new powertrain technologiesWilhelm Emperhoff to take on new business unitMartin Weidlich to join the MAHLE Management Board“In taking this step, we’re actively reinforcing our innovative strength in the field of alternative drives,” says Prof. Dr. Heinz K. Junker, Chairman of the Supervisory Board of MAHLE GmbH. MAHLE has concentrated all its electrics and electronics activities in its Mechatronics division, which has grown significantly in the last few years. “By transferring these activities into a business unit and combining it with the product areas of compressors and pumps for strategic purposes, we are focusing all our efforts on further growth and the ongoing development of our product portfolio for the mobility of the future,” adds Dr. Jörg Stratmann, CEO of the MAHLE Group.
Wilhelm Emperhoff (57), who is currently responsible for the Filtration and Engine Peripherals business unit, the Mechatronics division, and the Pumps profit center on the Management Board, has been appointed as head of the new business unit. In the future, this segment will include the present Mechatronics division, the Compressors profit center, and the Pumps profit center.
Martin Weidlich (48) was appointed by the Supervisory Board to succeed Wilhelm Emperhoff as the head of the Filtration and Engine Peripherals business unit and as a new Member of the MAHLE Management Board. Both of these personnel changes will be effective as of January 1, 2020.
Wilhelm EmperhoffWilhelm Emperhoff, born on October 26, 1961, in Regensburg/Germany, graduated as an electronic engineer from Regensburg University of Applied Sciences in 1987. From 1989, he worked in various roles at Siemens Automotive before moving to Continental AG in 2007 to become Executive Vice President of the Gasoline Systems business unit. He served as the Chief Executive Officer of Behr-Hella Thermocontrol GmbH between 2009 and 2012, and has been a Member of the MAHLE Management Board since October 2012.
Martin WeidlichMartin Weidlich was born in Cologne/Germany on March 5, 1971. Weidlich is a graduate industrial engineer (Dipl.-Wirt.-Ing., FH) and began his career at the Ford Motor Company in 1991. In January 2001, he moved to Getrag Magna Powertrain (formerly Getrag) where he held numerous positions, ultimately acting as Vice President Research & Development and Director Core Engineering from 2010 to 2013. Martin Weidlich joined Benteler Automobiltechnik in January 2014, and is currently the company’s Executive Vice President Western Europe.
About MAHLEMAHLE 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 2018, the group generated sales of approximately EUR 12.6 billion with more than 79,000 employees and is represented in over 30 countries with 160 production locations. At 16 major research and development centers in Germany, Great Britain, Luxembourg, Spain, Slovenia, the USA, Brazil, Japan, China, and India, more than 6,100 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/Public Relations
Pragstraße 26–46
70376 Stuttgart/Germany
Phone: +49 711 501-12199
ruben.danisch@mahle.com

07/22/2019MAHLE reduces winter cruising range loss for electric vehicles by up to 20 percent

MAHLE reduces winter cruising range loss for electric vehicles by up to 20 percent

Stuttgart/Germany, July 22, 2019 – Modern electric vehiclespresent complex challenges for efficient thermal managementthroughout the year. It should place as light a load on the drivetrain battery as possible, particularly in wintertime. MAHLE hasdeveloped a compact and economical system based on a heatpump (Integrated Thermal System—ITS) that can increase thewinter cruising range by up to 20 percent. In addition tosignificantly reducing battery power consumption, it is easy tocontrol and can be readily adapted to future vehicle architectures.

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Press release [PDF; 147 KB]Press picture [JPG; 113 KB]Press picture 2 [JPG; 108 KB] Up to 20percent increase in range in comparison with conventional systems due to integrated system based on heat pumpSignificantly lower battery power consumption and good adaptability to vehicle architectureDue to the lack of steadily available waste heat from the engine, most electric vehicles today rely on direct resistive heating by electric heaters to heat cabin and traction battery in wintertime. This extra load on the drive train battery in cold temperatures can reduce the cruising range of a fully charged electric vehicle by up to half. In summer as well, the cruising range is shortened by the additional energy required for cooling the drive train battery and the interior of the vehicle.
In field tests with a compact electric car, MAHLE has demonstrated that its ITS reduces the loss of cruising range substantially, especially at cold ambient temperatures. The original vehicle used, equipped with conventional electric heating, started with a cruising range of 100 kilometers. When the vehicle was equipped with the ITS, the cruising range increased to 116 kilometers.
“With the ITS from MAHLE, we can improve cruising range by between 7 and 20 percent, depending on the design, which drastically reduces the loss of cruising range in wintertime in particular,” says Laurent Art, Director Advanced Engineering Thermal Management at MAHLE.
The ITS from MAHLE combines various thermal components into one system that functions in several modes. Central to its architecture is a semi-hermetic refrigerant circuit, comprising a chiller, a coolant-cooled condenser (i-condenser), a thermal expansion valve, and an electric drive compressor. The icondenser and the chiller have the same function as the condenser and evaporator in a conventional refrigerant circuit. In this case, however, instead of exchanging heat with air, the refrigerant exchanges heat with the coolant, thus generating hot and cold coolant flows. The ITS uses R1234yf as a refrigerant and the conventional vehicle coolant as the medium for heat transport between the cooling circuit and the various heat sources and sinks in the vehicle.
In addition to the low cost and environmental benefits, the ITS presents design flexibility and adaptability as added advantages. Tests for control optimization and other purposes are currently being run in the MAHLE climatic wind tunnel with the ITS installed in the vehicle. Together with American OEMs, MAHLE is working on implementing additional performance and cost optimizations.
About MAHLEMAHLE 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 2018, the group generated sales of approximately EUR 12.6 billion with more than 79,000 employees and is represented in more than 30 countries with 160 production locations. At 16 major research and development centers in Germany, Great Britain, Luxembourg, Spain, Slovenia, the USA, Brazil, Japan, China, and India, more than 6,100 development engineers and technicians are working on innovative solutions for the mobility of the future.
For further information, contact: MAHLE GmbH
Christopher Rimmele
Corporate Communications/Public Relations
Pragstraße 26–46
70376 Stuttgart/Germany
Phone: +49 711 501-12374
Fax: +49 711 501-13700
christopher.rimmele@mahle.com