Archives of Past Exhibits:Mahle

Tokyo Motor Show 2015

MAHLE product lineup

Electric drive motor

e-powered technology for two-wheelers

PCU technology

A/C Compact variable compressor

Filter

Evolite and Evotec pistons

-Start mass production in 2017

2015 IAA Frankfurt Motor Show

Electric vehicle display model featuring Company product lineup

Air and liquid filter media

Air and liquid filter media

Mini A/C compressor

Electric drive motor

Thermal management system display model

Renault Twizy electric vehicle

Evolite and Evotec pistons

Starting from upper left, from left to right: 1. evolite orc 2. evolite 3. evotec rcc 4. evotec sc 5. evotec 2 6. evotec 2 rc 7. evotec

2015 JSAE Automotive Engineering Exposition

Plastic lightweight cylinder head cover

Plastic lightweight cylinder head cover

Plastic lightweight cylinder head cover

-New plastic cylinder head cover offering a 20 percent reduction in product weight compared with the Company’s conventional products. -Plastic cylinder head covers feature rib-like projections on the inner side and the side surface that increase product strength. The new product uses fewer ribs and provides additional weight-saving feature.

Intake manifold with water-cooled charge air cooler

-Developed jointly by the Company's filtration division and the thermal management division. -Space saving in the vehicle’s frontend -Smaller intercooler -Integrating water-cooled intercooler into the intake manifold reduces pressure loss.

Intake manifold

Installed vehicle: Nissan "Altima"

Sound creator

Installed vehicle: Toyota "86" Mazda "Roadster" Subaru "BRZ"

Carbon canister

-Supplied to Honda in American market. Developed in Japan and produced in US.

Heat storage tank for radiator coolant

-Prototype

Air-cooled charge air cooler

Installed vehicle: Honda "Amaze" -Mainly developed and produced in India

High voltage PTC heater

Two layer plate

Oil filter module

image 1: Oil filter image 2: Transmission oil warmer

Oil cooler, Oil warmer

Compact chiller for Li-ion battery

Pistons

Connecting rod

Assembled camshaft

-For commercial vehicles in Europe

CamInCam camshaft

Low friction assembled camshaft

-Ball bearing is incorporated.

Map controlled pendulum-slider oil pump

Cylinder head cover for commercial vehicle

-Oil mist separator is integrated (refer to image) -Supplied to Mercedes-Benz

Water-cooled charge air cooler for truck

Electric controlled VISCO coolant pump

Oil cooler for commercial vehicle

Products by Slovenia-based Letrika acquired by Mahle in 2014

Electric motor

Installed vehicle: Renault "Twizy"

Shanghai International Automobile Industry Exhibition 2015

Air intake module with integrated swirl flap system, air intake manifold with variable valve system

Intake manifold integrated with intercooler

Air intake manifold with tumble control system, air intake manifold with tumble control system and variable runner length system

Air cleaner modules with compact air filter elements with PU sealing and guide plate

Air filters

Intercooler

-Installed: Mercedes-Benz V6 engine

Exhaust gas cooler

Thermostats

Electric actuator

Two layer plate to cool Lion batteries, compact chiller

Carbon canister

Active fuel pre-filter module for engines

Oil coolers

Cylinder head cover system with integrated oil drain pipe and oil mist separator

2-level cooling module

Condenser

Condenser

Fan

Front and rear control units

Installed vehicle: Porsche “Macan”

Front and rear control units

Installed vehicle: Audi “A8”

Air conditioner control unit

Installed vehicle: VW “Golf 7”

Center stack

Installed vehicle: BMW “i3”

Center stack

-Installed: BMW

Control unit

Installed vehicle: Mercedes-Benz “A-Class”, “B-Class”

Rear control unit

Installed vehicle: Shanghai GM Cadillac “XTS”

Blower control unit

Control unit

-Installed: Renault-Nissan

Control unit

-Installed: GM

Camshafts

Camshafts

Valves

Piston rings

Pistons

Bearings

Piston pins, threaded liner with undercuts

2014 JSAE Automotive Engineering Exposition

Plastic lightweight cylinder head cover

Plastic lightweight cylinder head cover

Plastic lightweight cylinder head cover

Installed vehicle: Suzuki "Hustler", "Wagon R" -New plastic cylinder head cover with wall thickness of 1.5mm, offering a 20 percent reduction in product weight compared with the Company’s conventional 2mm-thick products. (Industry’s standard wall thickness: 2.3mm-2.5mm) -Plastic cylinder head covers feature rib-like projections on the inner side and the side surface that increase product strength. The new product uses fewer ribs and provides additional weight-saving feature.

Plastic lightweight cylinder head cover

Plastic lightweight cylinder head cover

Plastic lightweight cylinder head cover

Installed vehicle: Honda "N-BOX"

Sound creator

Installed vehicle: Toyota "86" Mazda "Roadster" Subaru "BRZ" -Supplied to Lexus and Nissan vehicles.

Carbon canister

Plastic oil pan

Intake manifold

Map controlled pendulum-slider oil pump

-Supplied to BMW and PSA.

Oil cooler / Oil warmer

Piston for commercial vehicle

Piston for passenger vehicle

Polymer overlay bearing

Low friction assembled camshaft

CamInCam camshaft

Delhi Auto Expo 2014

Air intake, filter module

Tokyo Motor Show 2013

MonoGuide laser welded steel piston

-2-piece type piston by means of laser welding -Compression height is lower than that of aluminum piston -Comparing to conventional piston, the MonoGuide has a longer skirt, which remains decoupled from the piston crown. This design improves the NVH behavior and seems to be well-suited for the use in aluminum engine blocks. -Will be used in a series production passenger car diesel engine for the first time in 2014

MONOTHERM steel piston

TopWeld steel piston

sSC2 aluminum piston with elevated salt core cooling channel

-The cooling channel lowers temperatures at the piston crown and in the region of the first ring land, increasing the load capacity.

Diesel piston with remelted bowl rim and elevated salt core cooling channel (eSC)

-Piston bowl rim is reinforced

EVOTEC SC + RC piston with cooling channel and ring carrier

EVOTEC 2 piston with ring carrier

EVOLITE lightweight piston

Forged piston for series application

MonoWeld and MonoLite steel piston for commercial vehicle

Aluminum piston with remelted bowl rim

NCI piston for commercial vehicle

Aluminum piston with salt core cooling gallery and pin bore bushing

EvoTherm engine valve

-Extended hollow cavity is made by means of electrochemical machining. The valve head is cooled by the shaker effect: the hollow space is not completely filled with sodium, so that it is shaken as the valve moves; the sodium produces greater heat dissipation.

TopTherm engine valve

-Its construction as a rigid and rotation-symmetrical surface with a large sodium-filled cavity leads to lightweight and efficient heat dissipation

Tribological system

Piston pin

Piston pins with Diamond-Like-Carbon (DLC) coating

Piston rings

Bearings with F-polymer coating and Polymer coated connecting rod bearings for commercial vehicle

Power Cell Unit (PCU) for commercial vehicle

-Comprised of MONOTHERM steel piston, cylinder liner, machined connecting rod, piston pin and piston rings

Low friction assembled camshaft for commercial vehicle

Assembled truck camshaft

CamInCam camshaft for 4-cylinder passenger car (DOHC)

CamInCam camshaft for variable valve timing for DOHC

Assembled camshaft with DLC coated steel cam lobes for DOHC (for gasoline passenger car)

Low friction assembled camshaft

-Utilizing ball bearings

Assembled intake and exhaust camshaft for gasoline direct injection

Electrical waste gate actuator

Diesel-fuel heater and Electrical actuator for swirl and tumble flap system

Map controlled pendulum-slider oil pump with plastic suction pipe

-Supplied to PSA

Map controlled pendulum-slider oil pump with plastic slider (thermoset)

-Supplied to BMW

Controlled coolant pump with valve control and integrated hydraulic regulation

Oil cooler

Plastic oil filter module

Diesel fuel filter

Urea filter unit with variable heater concept

Carbon canister for PZEV legislation

Air intake module with integrated cascaded charge air cooler and coolant pump

Air intake module with integrated indirect charge air cooler

Lightweight intake manifold

Intake manifold with power valve and tumble control valve

Cylinder head cover with integrated mist separation and clean gas channel (for commercial vehicle)

Cylinder head cover with integrated mist separation and cylinder head frame (for commercial vehicle)

Lightweight plastic valve cover

Plastic oil pan

Sound generator

Installed vehicle: Mazda "Roadster"

Air filter element with cellulose meltblown filter media

Exhaust gas turbocharger with waste gate

*Turbo chargers are manufactured by Bosch Mahle Turbo Systems, a 50-50 joint venture with Robert Bosch

Exhaust gas turbocharger with variable turbine geometry

Range extender

-Technical specification: 900 cc. in-line 2-cylinder, 4-stroke, gasoline, 30 kW peak power at 4,000 rpm. Generator is integrated

Demonstration of downsizing engine

Engine cooling module

HVAC module

Installed vehicle: Mercedes-Benz "S-Class"

VISCO coolant pump with increased torque capacity and efficiency

-Supplied to Mercedes-Benz Truck

Compact chiller to cool Li-ion battery

High voltage PTC heater

Installed vehicle: Nissan "Leaf"

Multi layer plate for power electronics cooler

Two layer plate to cool Li-ion battery

Multi layer plate to cool Li-ion battery

EGR cooler for gasoline engine

Air filter module for Euro IV

2013 IAA Frankfurt Motor Show

Turbocharger

All-plastic oil filter module

Fuel filter

Air intake module

Air intake module

Air cleaner module

Cylinder head cover system

Air intake module

Oil mist separator

Cabin air filter

Camshaft

Valve

Camshaft

Rings

Camshaft

Bearings with F polymer coating

Piston

Piston

Power Cell Unit/Piston

2013 JSAE Automotive Engineering Exposition

Piston

Power cell unit

Valve

Law friction cam shaft

Cam-in-cam

Sound creator

Installed vehicle: Mazda "Roadster" -Installed in Lexus

Plastic head cover

Plastic oil pan

Variable oil pump

Oil cooler / Oil warmer

Oil filter module

SUS oil cooler

Carbon canister

Intake manifold

JSAE 2012

Piston Intake manifold
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Sound creator Carbon canister
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Plastic head cover Plastic oil pan
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Oil cooler / Oil warmer Oil filter module
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Range extender
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Auto China 2012

Bosch Mahle TurboSystems
Diesel turbocharger (TDI) Variable turbine geometry(VTG)
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CamInCam camshaft Plastic intake manifold
Installed vehicle:
Nissan
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Valve cover system with integrated
oil drain pipe and oil mist separator
Electrical wastegate actuators
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Air intake module with integrated tumble
flap system for gasoline applications
Aluminum oil cooler for 6-speed automatic transmissions
 
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Aluminum oil cooler for CVT

Fuel filter
 
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Oil pump proportional solenoid valve Pistons
 
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Connecting rod Bearings
 
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Delhi Auto Expo (India) 2012

Piston for gasoline engines Power Cell Units for commercial vehicles
   
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All-plastic oil pan with pick-up tube and windage tray Map controlled pendulum-slider oil pump with plastic slider & All-plastic oil filter module with map-controlled thermostatic valve for coolant
   

 

Fuel filter Carbon canister, LEV2 and PZEV
   

 

Air cleaner module  
     
       

Tokyo Motor Show 2011

Range extender Piston for gasoline engines
   
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Piston for diesel engines Map controlled pendulum-slider oil pump with plastic slider
   

 

All-plastic oil filter module with map controlled thermostatic valve for coolant All-plastic oil filter module with engine oil heat exchanger, transmission, oil heat exchanger, and thermostatic control for heating and cooling the transmission oil
   

 

All-plastic oil pan with pick-up tube and windage tray
Aluminum oil cooler for spin-on oil filter module
   

 

Aluminum oil cooler for 6-speed  automatic transmission Aluminum oil cooler for CVT  automatic transmission
   

 

Aluminum oil cooler for truck application
Air intake module with integrated swirl flap system for diesel applications
   

 

Electrical wastegate actuator Air intake module with integrated tumble flap system for gasoline applications
   

 

Plastic intake manifold Sound creator
   

 

Air cleaner module with cylindrical filter element (cellulose) Valve head cover system with integrated oil drain pipe and oil mist separator (impactor)
   

 

Valve head cover system with integrated oil mist separation
Urea filter unit with variable heater concept (without/electrical heater/coolant)
   

 

All-plastic fuel filter with preheating valve, priming pump, water level sensor, and water drain screw Fuel filter for truck application
   

 

Carbon canister, LEV2 and PZEV Bushingless connecting rods
   

 

Ultra light weight conrod version approx 25% less weight Power cell units - Aluminum piston with cooled ring carrier
   

 

Power cell units Piston rings
   
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Piston pins Pb-free bimetallic thrust washers with either a "flat" or an engineered ramp and pad hydrodynamic profile
   
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Pb-free bimetallic bearings Bushings
   
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Frankfurt Motor Show 2011

Engine with Mahle components and Audi racing car Air cleaner module with plasticized U-shape filter element(cellulose)
   
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Air intake module with integrated tumble flap system for gasoline applications Air intake module with integrated swirl flap system for diesel applications
   

 

All-plastic oil pan with pick-up tube and windage tray Fuel filter module with highly efficient pressure side water separation
   

 

All-plastic oil filter module with map-controlled thermostatic valve for coolant Power Cell Unit
 
       

JSAE 2011

Carbon Canister
Sound Creator
 

 

 

Installed vehicle :
Mazda ROADSTER
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Oil Cooler
Oil Filter Module

 

 

 
Intake Manifold Plastic Head Cover

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Plastic Oil Pan
Piston and related products

 

 


PCU - Power Cell Unit EvoTec Piston -
lightweight gasoline piston
Spray-jet cooling Salt-core cooling

Elevated

salt-core cooling

Cooled ring carrier Cooled ring carrier with pin bush MONOTHERM
steel piston for
passenger car diesel engines
Lightweight hollow valve CaminCam Low Friction Camshaft(LFC) Controlled pendulum slider oil pump

JSAE 2010

Piston Cam shaft
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Oil pump Carbon canister
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Oil cool, oil filter module Head cover
 
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Intake manifold Sound creator
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2010 Delhi Auto Expo

MAHLE Filter Systems India Ltd.

Oil mist separator Oil filter



For Suzuki
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Oil filter module Roll filter
For Ford

For Nissan
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Fuel filter Fuel filter
Installed vehicles :
Suzuki "Alto"
Suzuki "Wagon R"
Installed vehicle :
Suzuki "Swift"
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Air filter Air filter
Installed vehicle :
GM "Chevrolet Aveo"
Installed vehicle :
Suzuki "Wagon R"
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Air intake manifold  
     
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Mahle IPL Ltd.

Piston Piston
For Ford "DV4" engine For Fiat "1.3L SDE"
(Small Diesel Engine)
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Piston Piston
For Maruti Suzuki
"K10B" engine
For Ashok Leyland
"Neptune" engine
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Piston Piston
For Tata Cummins
"6BT" engine
For Mahindra & Mahindra
"Acteon" engine
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Piston  
For Tata 2.2L
"Dicor" engine
   
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2009 IAA Frankfurt Motor Show

- Highlighted at the exhibit were various engine products, which contribute to reducing CO2 emissions.

<Downsizing>
Mahle downsizing engine as technology demonstrator Turbocharger for modern gasoline engine
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-Reducing displacement while simultaneously adapting all the systems and components relevant to engine performance and emission behavior characteristics

-Shifting frequently used engine operating points to areas of higher specific engine load, thereby reducing fuel consumption.

-High temperature resistance using materials such as cast steel in the turbine housing or exhaust manifold module, and nickel-based superalloys for the turbine rotor.

-Electrical actuators for wastegate and VTG control to optimize performance

-Turbine wheel with direct inflow from the exhaust port, using CamlnCam control (additional impulse charge)

       
Electrical wastegate actuator
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<Charge exchange>

Cylinder deactivation with switchable roller finger follower CamlnCam camshaft for 4 cylinder engine
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-Exhaust camshaft + Inlet camshaft
-Increase in torque and performance of up to 10%

       

<Frictional Loss>

Assembled camshaft

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-Simple replacement for the standard camshaft
-Considerable reduction in friction losses in the valvetrain and oil circuit

   
Lightweight valve All-plastic transmission oil filter module
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-Up to 50% lower weight compared to conventional solid shaft valve
-Less wear on the valve seat and valve seat insert

 
- The company also displayed controlled pendulum-slider oil pump as well as EGR valves designed to lower CO2 emissions.

Tokyo Motor Show 2005

<Highlights>
Lightweight Valves
・Made from sheet metal
・Scheduled to be mass-produced in 2006

Camshafts
 Front: Assembled Camshaft
 Center: Adjustable Camshaft installed in the Ferrari V8 engine
 Back: Cast Camshaft installed in Porsche Cayenne

Pistons
 For diesel engines: for EU models
 For gasoline engines: Cast Pistons

Power Cells

繝サSinter-forged connecting rods are supplied by other manufacturers. 
   Installed in the Chevrolet Corvette.
繝サForged connecting rods, which are produced in-house, are being installed in GM's HF V6 engine.

Cylinder Liners
Aluminum: For gasoline engines
Gray Cast Iron: For diesel engines
Steel: For SUV models in the EU and Japan

Tokyo Motor Show 2004

Exhibited New Filter Module


The Company presented its new filter modules for lubricating oil and fuel. In addition to saving space, they offer an increase in efficiency and service life.

The combination of an efficient two-stage water separator and new separating media provides the KM 35 fuel filter module with reliable protection for modern diesel injection units like time controlled distributor injection, unit injectors, pump line injector systems and common rail systems - in even the smallest of spaces. The new oil filter module uses an efficient jet centrifuge in the bypass that is especially effective against dirt caused by soot.

<Fuel management systems>

While in the past the fuel systems of a commercial vehicle included a pre-filter, in some cases with a water separator and a main filter, the Company's current diesel fuel filter modules combine these and many other functions into a single module.

Function and filtration
To maximize the service life of modern commercial vehicle engines, the Company's filter systems prepare fuel optimally for the combustion process. Very precise component tolerances in modern diesel injection systems require highly separating filter media. Another trend is longer maintenance intervals. The Company also offers multi-layer filter media for operation under severe conditions, for example construction site vehicles or poor fuel quality.

The first melt-blown filter layer, consisting of extremely thin synthetic fibers, acts as a deep end filter, which is used together with an ultra fine filter made of cellulose carrier materials. These multi-layer filter elements offer a higher level of particle separation than earlier conventional cellulose materials and last at least as long.

Water separation
A two-stage water separation system was implemented in the Company's fuel filter module, the KM 35, which is use in medium to heavy commercial vehicles. It also disperses very fine and stable emulsion effectively.

The coaxial arrangement of the particle filter creates an integrated coalescence effect. A final hydrophobic separator ensures a multi-level separation process, a reliable fuel supply while protecting the engine under all operating conditions.

The standard range of the KM 35 module also includes an automatic filter drain when changing elements for prefilters and main filters as well as elements for metal free filters. Maintenance indicators are optional, as are electrical heaters, water level sensors, manual pumps, fuel coolers, bypass valves for prefilters and dirt cans for main filters.

The range of options includes both cost optimized, additional heaters and intelligent self-regulating heat modules that are activated in the filter depending on how much paraffin is present. The wide selection of additional electrical heaters is rounded out by bimetallically controlled preheater valves and thermostatic controllers with expandable wax elements.

Easy maintenance
To increase ease of maintenance when changing elements, dirt cans with automatic drain function may also be used. A new pump design ensures reliable suction of fuel even at the lowest operating temperatures when filling or venting the filter. A wide range of maintenance indicators also takes into consideration applications with alternative fuel filters such as FAME (fatty acid methylester) or biodiesel.

Advantages of the Company's fuel filter modules
-Multi-layer melt-blown filter media for the separation of extremely fine particles
-Efficient water separation in a compact design
-Service friendly maintenance possible
-Environmentally friendly metal free filter insert
-Customer specific applications
-Modular system structure


<Modern oil filtration: centrifugal force and new media>

Against a background of dramatically increased requirements for oil filters, the Company's latest development projects aims to further extend service intervals and provide optimal protection for engine components.

Longer service interval
Mixed fiber filter media consist of cellulose fibers in to which up to 30% plastic fibers are mixed. In addition to a considerable increase in dirt capacity, this also results in an improvement in resistance to aging of the oil. This makes it possible to achieve service intervals of up to 50,000 km in passenger car applications, and as much as 150,000 km for commercial vehicles.

Fully synthetic
The Company offers a fully synthetic filter element with a filter medium made from a combination of actual filter materials, polyester fibers and plastic support fabric. Embedded in plastic end disks, it is completely metal free and therefore fully able to be incinerated completely.