Research & development highlights

MAHLE Powertrain has developed a modular battery module based on its own design. In the new architecture called M3x, the individual battery cells can be arranged horizontally, vertically, in single or double rows, depending on the application. The temperature-sensitive Li-ion cells are perfectly protected thermally, without any restrictions in terms of flexibility.

The Air Conditioning Compressor delivers the output needed to cool the battery, making it fundamental to a long service life for the air conditioning system as a whole. As the only manufacturer offering ultrapowerful 800 V compressors, MAHLE is paving the way for fast charging and full-load operation of heavy-duty, electrified commercial vehicles.

This new traction motor for electric vehicles with 140 kW power is wear-free, particularly efficient and requires no rare earths.

By immersing battery cells directly into a dielectric fluid, we prevent overheating during fast charging and ensure uniform temperature distribution.

MAHLE makes the air conditioning system intelligent by moving the sensors directly into the HVAC. There, in the middle of the main air flow, they allow the system to be regulated in real time. Combined with the right MAHLE filter media, this approach reliably keeps harmful influences away from the interior.

Fuel cells need clean air. Modular air filters from MAHLE are available off-the-shelf. They reliably keep ammonia and harmful gases away from the cell, enabling an economical use of catalysts and protecting the cell from damages.

Cooling Modules protect batteries and power electronics by releasing much of the heat built up in the system into the environment. Depending on the cooling strategy, the modules could include additional radiators. For over 100 years, MAHLE has been playing a crucial role in advancing development, from simple coolers to complex thermal management

MAHLE’s highly efficient Air Conditioning System ensures the cabin is perfectly climate-controlled while minimizing energy consumption. Working in a pleasant temperature, drivers can focus better and safely navigate the traffic. In addition, the CareMetix® Cabin Filter keeps the cabin free of fine particulates and pollutants, thus protecting the driver’s health.

MAHLE’s Chiller is designed to keep the lithium-ion battery optimally cooled, even at high outside temperatures. This is essential, as the lithium-ion battery is temperature-sensitive and must be kept below 40 °C at all times. This cannot be achieved using coolant alone, especially during the summer months. Therefore, the Air Conditioning System’s refrigerant circuit takes on this important task. In the Chiller, heat is transferred from the battery cooling circuit to the refrigerant circuit to produce the desired effect.

MAHLE’s many years of development experience in lithium-ion battery cooling is incorporated into its Electronics Cooling Plate Design. In addition to the electric powertrain, other electronic components such as the inverter also have to be cooled. These are protected against overheating by the Electronics Cooling Plates and coolant circuit.

The 24 V Coolant Pump drives the coolant circuits. A pumping performance of up to 700 W can be delivered if required. In other words, the pump only ever runs as quickly as the conditions necessitate in order to save electrical energy. In MAHLE Coolant Pumps, the coolant also actively cools the pump drive, thereby reducing wear and tear and extending their service life.

The traction motor is a “powerhouse” that has to be protected against overheating. MAHLE’s integrated and compact Oil Management Module cools the motor, with a Heat Exchanger transferring the heat from the oil to the coolant circuit. The Oil Pump needed for this is already integrated into the module.

Fuel cells need pre-moistened air. The MAHLE humidifier removes the water from the exhaust air line and feeds it into the supply air in a cross flow. This ensures a long life of the cell through optimal humidification.

Vehicle electrification poses new challenges for thermal management. A temperature below 40 degrees Celsius is needed in order to cool the lithium-ion batteries in hybrid and electric vehicles.