In the future, vehicle electrification will make an increasing contribution toward efficient mobility. Starting with the conventional standard powertrain, MAHLE sees potential for a CO2 reduction of up to 65 percent thanks to the many options that electrification including plug-in hybrids offer. The consideration must not be restricted to immediate support of the combustion engine, with boosting, start-stop functionality, or hybridization, for instance; rather, it must also entail advanced measures in the vehicle, such as thermal management or the electrification of engine accessories.
Even relatively small steps in electrification can achieve a sustainable effect in the combustion engine powertrain with a conventional 12 V electrical system. For example, electric actuators enable faster and more precise control of the combustion engine. Simply by replacing the pneumatic wastegate actuator with an electric variant, which MAHLE has been supplying for large-scale production applications since 2009, CO2 savings of approximately two percent can be achieved. Rounded out by additional “light” electrification steps, such as electric thermostats, EGR valves, power steering motors, and stop-start functionality, CO2 savings of up to eight percent in total can be demonstrated, without intervention in the electrical system and without electric drive motors.
The electrification of engine accessories provides further off-loading and support of the combustion engine. When uncoupled from the belt drive, not only do these provide packaging advantages owing to discretionary placement options, but mechanical losses in the combustion engine are also eliminated. The energy for electric engine accessories can be produced by means of recuperation. In addition, they operate independently of engine speed and pressure and can therefore be designed purely based on specific requirements and with extreme precision. For example, an electric main cooling pump provides the possibility of completely suppressing the coolant flow during the engine’s warm-up phase simply by remaining disabled. The combustion engine can thus reach its optimal operating temperature more rapidly, and critical cold-start emissions can be drastically reduced. The coolant pump then operates with fully variable control based on the driving situation. Its use results in a possible CO2 reduction of up to five percent in total. Particularly in conjunction with the 48-volt electrical system, MAHLE anticipates a high prevalence of electric engine accessories and is continuously expanding its portfolio to include electric coolant pumps, air conditioning compressors, radiator fans, among others.
With full hybridization at the latest, and right through to plug-in hybrids, thermal management in the vehicle is facing new challenges: lithium-ion batteries, in particular, must be continuously maintained within a temperature window. MAHLE was a pioneer in this field, with series production of the first refrigerant-based battery cooling systems already in 2009. Today, MAHLE’s thermoelectric battery conditioning is almost ready for series production. But cooling and temperature control of drive components are not the only crucial factors in high-voltage applications; interior air conditioning must also be maintained while the combustion engine is turned off. High-voltage PTC heaters and electric air conditioning compressors from the MAHLE portfolio are essential systems for this purpose.
The various degrees of drive and vehicle electrification will become more widespread in conjunction with the vehicle class and its price sensitivity, thereby making a contribution toward increased efficiency. With its comprehensive portfolio in the areas of thermal management, electric actuators, engine accessories, and electrics, MAHLE has been present on the market in countless series production applications for many years and continues to prepare for the future continuing electrification of the powertrain in various forms. This includes further expansion of the company’s comprehensive systems expertise and portfolio, and thus added value. This applies to fuel cell powertrains as well, where MAHLE has been a series supplier for air and thermal management systems for many years and will continue to expand its activities. As the automobile becomes increasingly electrified, MAHLE will therefore be ready, providing significant contributions.
