Mahle Unveils Innovations for Decarbonizing Commercial Vehicles at IAA Transportation

Mahle showcases innovations for decarbonizing commercial vehicles, featuring fuel cell technology, SCT motors with 480 kW and 92% efficiency, an evaporative cooling system, and a bionic fan that reduces noise by up to 4 dB(A).

Hanover/ Stuttgart, Germany- At the IAA Transportation event in Hanover, Mahle GmbH., is taking significant strides toward the rapid decarbonization of the commercial vehicle sector. With a focus on sustainable transportation, the company is presenting groundbreaking technologies aimed at enhancing the efficiency and eco-friendliness of heavy-duty vehicles.

Climate protection hinges on the transportation sector, with road transport volumes projected to rise over 40% by 2030 compared to 2019. This growth positions commercial vehicles as vital for achieving carbon-neutral mobility. Mr. Arnd Franz, CEO of MAHLE, emphasized this commitment at IAA Transportation in Hanover, where the company showcased a complete fuel cell truck system, including peripherals, thermal management, and a heavy-duty electric axle.

MAHLE is actively involved in developing components for battery-electric and fuel cell vehicles, with the commercial vehicle sector representing about one-fifth of its OEM business. The increasing electrification of transportation presents significant opportunities, with MAHLE's components being essential in these vehicles. Franz highlighted the company's dedication to technological diversity to rapidly decarbonize transportation, ensuring that their products are ready for volume production to meet varying global needs.

MAHLE has integrated two SCT electric motors into a heavy-duty electric axle, showcasing its capabilities in commercial vehicle electrification. The SCT (Superior Continuous Torque) motor delivers 480 kW and 92% efficiency, making it ideal for heavy-duty applications. This system provides 35,000 Nm of torque, enabling a 35-tonne fuel cell truck to travel 10% faster than a diesel truck on the Brenner pass, saving 3.5 minutes. The motor is compact, lightweight, and can be customized to exclude rare earths, suitable for various vehicles and machinery.

MAHLE is unveiling its innovative evaporative cooling system at IAA Transportation, designed for optimal thermal management in fuel cells. This system utilizes the cooling effect of evaporating water, spraying it onto the coolant cooler to maintain ideal temperatures. Key benefits include up to 50 kW more cooling performance in the same space and a reduced fan rating, which allows for a smaller fan motor and an additional 25 kW of propulsion power an 8% increase for a 300 kW fuel.

MAHLE has introduced a bionic high-performance fan designed to reduce noise in commercial vehicles, particularly during full load or overnight charging. Inspired by the noise-reducing feathers of owls, this fan reduces truck noise by up to 4 dB(A), more than halving the sound pressure level. Key features include a 10% improvement in efficiency, a 10% weight reduction, and a power rating range from 300 watts to 35 kW, making it suitable for a wide array of applications, from small electric cars to heavy-duty commercial vehicles.