Innovations forsustainable mobility

MAHLE is a leading international development partner and supplierto the automotive industry with customers in both passenger car
and commercial vehicle sectors. Founded in 1920, the technology
group is working on the climate-neutral mobility of tomorrow, witha focus on the strategic areas of electrification and thermal management as well as further technologies to reduce CO2 emissions, suchas fuel cells or highly efficient combustion engines that also run onhydrogen or synthetic fuels. Today, one in every two vehicles globallyis equipped with MAHLE components.
MAHLE generated sales of more than EUR 12 billion in 2022. The
company is represented with approx. 72,000 employees at 152
production locations and 12 major research and development centersin more than 30 countries.
(as of 31.12.2022)#weshapefuturemobility

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Dear readers,
The automotive industry is taking great strides toward sustainable mobility. We areseeing the new registrations of electrified vehicles increasing and the technology
developing rapidly. In the case of passenger cars, the share of battery electric andhybrid drives could rise from 13 percent today to 70 percent in 2035. This trend
will be primarily driven by markets such as Europe, North America, and China. In
other regions, the internal combustion engine will continue to dominate for years
with a production share of up to 60 percent. At MAHLE, we are doing our part toArnd Franz

ensure that the development toward sustainable mobility continues. For fast-acting

Chairman of the MAHLE Management

climate protection, we rely on technological diversity and develop sustainable

Board and CEO

solutions in the areas of electrification, thermal management, and highly efficientgreen combustion technologies.
System expertise is becoming increasingly important: in electric vehicles, forexample, the interaction of the individual component is much more complex thanin vehicles with combustion engines. As an innovative system provider, we areable to offer our customers solutions that are more powerful, more efficient, andat the same time less complex.
In e-mobility, we focus on electric drives and intelligent charging. We are com­mitted to making e-mobility user friendly, reliable, and, above all, affordable.
We constantly demonstrate our innovative strength: in 2022, around 70 percent
of patent applications by MAHLE were in this field.
Efficient electrification does not work without efficient thermal management. MAHLE
is one of the largest suppliers of thermal management systems for batteries,
efficient drives, and sophisticated cabin comfort. We serve all drive types and vehicle
classes. This branch of technology opens the door for further innovations in all
drive areas.
In addition to electric drive forms, highly efficient and sustainable combustion
engines will remain a relevant factor worldwide for years to come. MAHLE will drive
efficiency progress in this segment with state-of-the-art products. This includes theuse of hydrogen and e-fuels. Our customers appreciate that, as part of our strategy,
we will continue to support the combustion engine as long as there is demand.
This diversity will allow us to shape the future of mobility. You can find out what
this looks like in detail in this magazine.
Enjoy reading!
Arnd Franz

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Content
Three paths to green mobility

6

MAHLE on site

8

MAHLE portfolio

10

1. E-mobility
E-volution with a system solution

12

Perfectly coordinated

14

Quiet drives

16

Scalable charging solutions for everybody

18

The best for the electrons

20

2. Thermal management
Comfort all year round22

No E without T28

Climate specialists

30

3. Conventional drives
Moving faster toward sustainable mobility

34

Clean addition

36

High performance from the 3D printer37

4. Sustainability
Moving sustainably

38

Green milestones

40

5. Urban mobility
Freedom ahead42

All in the frame

44

Fully connected 45

MAHLE solutions for Smart Bikes 

46

Scooters and commercial vehicles

48

The street in the laboratory—climatic wind tunnel

50

R&D experts—MAHLE Powertrain

52

Keeping everything running—MAHLE Aftermarket

54

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Three paths to green mobility
MAHLE is focusing even more strongly on electrification, thermal
management, and components for highly efficient, green combustion
engines as this forms the core of the corporate strategy.
All three tracks have one goal: climate-neutral mobility of tomorrow.

The future of mobility is battery-electric or hybrid. This is par-2. More climate expertise: thermal management

ticularly true for Europe, North America, and China. But clean
and efficient combustion engines and hydrogen drives areWith our in-depth expertise in thermal management, an im-

also part of the drive mix of the future. This is because de-portant element of electrification, we are a technology drivervelopments will vary greatly depending on the region of thefor e-mobility. Our strategy is aimed at further expanding ourworld. This applies equally to passenger cars and trucks. In

established status as a systems provider focusing on energy

emerging markets in particular, the market for vehicles withefficiency and air conditioning. MAHLE is one of the largest

internal combustion engines is expected to continue to grow,suppliers of thermal management systems for batteries, effi-

for example in India or South America. Here, sustainable fu-

cient drives, and sophisticated cabin comfort.

els, such as e-fuels or biofuels, will rapidly contribute to thedecarbonization of road transport.
At the core of the new MAHLE 2030+ corporate strategy is
the MAHLE Mission “Efficiency in Motion”, which combines all
the Group’s activities in the three strategic areas and serves
as the strategic lever for implementing the MAHLE Vision “We
Shape Future Mobility.”

1. Electrification: the E-volution continues
Electrification is where the greatest market momentum lies.
Between 2022 and 2026, more than 20 electrified vehicle
platforms from leading passenger car and commercial vehicle manufacturers will be launched on the market that rely on
MAHLE technology and products. Our strategy is primarily
focused on the e-drive and intelligent charging. We electrify
all vehicle classes—from e-bikes and scooters to passenger
cars and commercial vehicles. MAHLE already sells more than
8 million e-drives per year for automotive, industrial, and urban
mobility applications.

A glimpse of the mobile future:“We Shape Future Mobility” video

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3. Open to technology in the future:
modern combustion engines
Highly efficient and clean combustion engines will remain arelevant factor worldwide for years to come. MAHLE pursues a strategy of cost leadership in components for internal combustion engines and thus remains a reliable partner

70 %will be the market share of newly produced
passenger cars with battery electric drives as well
as fuel cell and hybrid drive solutions in 2035.

for its customers. With lean structures, we will be competitive worldwide and take advantage of market opportunities.
MAHLE will drive efficiency progress in this segment withstate-of-the-art products. The internal combustion engine canmake an immediate contribution to climate protection with
non-fossil fuels, such as e-fuels. We see potential for the useof fuel cells and hydrogen engines, especially in the commercial vehicle sector.

40 %of all commercial vehicles worldwide will be
produced as purely electric with battery, fuel cell,or hybrid drive by 2035.

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MAHLE on site
152 production locations
12 major research & development centers
71,947 employees*

Major research anddevelopment centers
EuropeNorthampton / Great BritainŠempeter pri Gorici / Slovenia
Stuttgart, Bad Cannstatt / Germany
Stuttgart, Feuerbach / Germany
Valencia / Spain

North America
27 production locations
14,769 employees*
Canada, Mexico, USA

North / South America
Buffalo / USA (Amherst, Lockport)
Detroit / USA (Farmington Hills, Troy)São Paulo, Jundiaí / Brazil
Asia / PacificPune / India
Shanghai / China
Numazu / JapanTokyo / Japan (Okegawa, Kawagoe)* As at December 31, 2022

South America
8 production locations
8,763 employees*
Argentina, Brazil

9Europe57 production locations
31,165 employees*
Austria, Bosnia and Herzegovina,
Czech Republic, France, Germany,
Great Britain, Hungary, Italy, Poland,
Portugal, Romania, Slovakia,
Slovenia, Spain, Türkiye

Asia / Pacific
58 production locations
16,432 employees*
China, India, Indonesia,
Japan, Philippines, Singapore,
South Korea, Thailand

Africa2 production locations
818 employees*
South Africa

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MAHLE portfolio

Filtration andEngine Peripherals
To increase the efficiency and service life of engines and reduce emissions, MAHLE manufactures filters and oil coolers for motor and transmission applications for combustion engines as well as for alternative drives. MAHLE isdeveloping solutions for active fuel cell drives in the areaof alternative drives. The engine peripherals often differ even

Electronics and Mechatronics

with an identical basic engine due to different regional emissions laws, individual body shapes, and different powerclasses.

Electronic and mechatronic components play a decisiverole in increasing the efficiency of the powertrain and thefurther development of electromobility. MAHLE alreadyoffers the right solutions here with its product ranges ofelectric drive systems, actuators, and auxiliary units aswell as control and power electronics. They are used inmany different applications and markets and are closelyinter­linked technically. This means economies of scale andsynergies can be achieved, which is a crucial success factor in the automotive industry. MAHLE already sells morethan 8 million e-drives and electric auxiliaries per year for automotive, urban mobility, and industrial applications.

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Thermal Management
Innovative products from the field of thermal management
for batteries, fuel cells, power electronics, and electric actuators enable long cruising ranges, high efficiency, anda long service life and thus play a decisive role in shaping
the path toward zero-emissions drives. And in the case of
combustion engines, more efficient cooling systems sig­­­ni­­
ficantly drive the reduction of fuel consumption. Innovations in air conditioners enable novel design concepts in thecabin and contribute to a high level of climate comfort in thevehicle as well as to increased efficiency.

Service Solutions
We use the expertise of our business units to offer the market
innovative workshop equipment and complete solutions forthe professional maintenance and care of vehicles. The range
includes solutions for all drive systems and vehicle classes.
In addition to tools for classic vehicle diagnostics and for
determining the condition of traction batteries, the portfolio

Engine Systems andComponents
The development of piston systems and cylinder and valve
train components has been one of the core MAHLE businesses for decades. We understand the interaction of all engine
components and can therefore offer our customers optimal
solutions. Our products are used worldwide in two-wheelers, passenger cars, commercial vehicles, and large engines.
MAHLE will drive efficiency progress with state-of-the-art
products. We are also developing engine components for theuse of sustainable fuels such as hydrogen and e-fuels.

also includes complete packages for testing of exhaust emis­sions and the digital calibration of driver assistance systems.

12E-mobility

E-MOBILITY

E-volution
with a systemsolution
The number of electric vehicles on our roads
is growing rapidly. Car manufacturers aroundthe world are making further improvements
to the technology this development requires.
MAHLE is able to support them thanks to
decades of experience with electric, electronic,
and mechatronic components from a wide
variety of fields.

Whether in passenger cars, commercial vehicles, e-bikes,
or forklifts—electric drives of all sizes have become an indispensable part of the mobility landscape. That’s why e-drives
are already a core part of MAHLE’s business. This applies
not only to purely battery-powered vehicles but also to hybrid
vehicles of all performance levels.

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E-mobility

Perfectly coordinatedWe continue to make great strides towards the widespread electrificationof mobility. At the product level, this means offering customers advantages
with system competence. A look inside the glass vehicle shows how thecomplex interaction of the individual components works.

6

Efficient drives and smart charging are two crucial areas forvehicle manufacturers and, of course, end customers. We
are working on this at MAHLE to make e-mobility affordable,user-friendly, and reliable. This is primarily achieved with system solutions in which the individual components are always
designed to work together. The module’s integrated functions
simplify processes and reduce costs for customers.
One area in which MAHLE sees great potential for more efficiency is thermal management. Ultimately, the performance,

4

cruising range, and service life of an electric vehicle also depend on the sophisticated management of heat flows. Keeping the battery and motor always at the right temperature
prevents wear and tear. MAHLE develops solutions for thevehicle cabin, the powertrain, and the peripheral systems.
Thermal management is required for all drive forms. The importance of battery electric vehicles and vehicles with fuelcells is increasing significantly.

3 Air conditioning (HVAC)
1 Fluid management module for electric vehicles
Purified and demand-adjusted tempered fluid increases boththe cruising range and service life of the e-drive.
> More on p. 31

2 Cabin filter
Conventional cabin filters with and without activated carbon arepart of the HVAC (heating, ventilation and air conditioning) andremove dirt particles, gas molecules, and viruses from the air forpassengers.
> More on p. 32

Two- or three-zone temperature regulation and air distribution withadjustable footwell temperature and best-in-class acoustics create
a feel-good climate.

4 Cooling module
Highly efficient and compact—MAHLE cooling modules ensure
perfect temperatures in the battery electric vehicle.

5 Electronics cooling plate
MAHLE cools power electronics for systems with high power
closer to the component, thus also increasing the service lifeof the electrical components and interfaces.

15
11

5

1

3

10

7

2

9

8

9 Electric compressor
The heart of the air conditioning and refrigerant circuit: MAHLE
offers air conditioning compressors for all relevant performance
ranges and vehicle types.
> More on p. 31

6 Chiller

10 The on-board charging system (OBC)

The chiller with the MAHLE electric expansion valve transfers
coolant between different cooling circuits.

The on-board charging system ensures safe and efficientcharging while continuously monitoring the temperatures.
> More on p. 20

7 Battery cooling plate

11 MCT e-motor (Magnet-free Contactless Transmitter)

The temperature control keeps the battery temperature below
40 °C and increases the service life of the battery.

8 Indirect condenser
An indirect condenser is cooled with water during air conditioning and conversely heats coolant for heating purposes in heatpump mode.

The innovative drive motor from MAHLE does without rareearths. The central feature of the new motor is the inductive
and thus contactless power transmission. This allows the motor
to function without wear and tear and ensures exceptional
efficiency at high rpms. The efficiency is over 95 percent in themost frequently used driving conditions of the drive system.
> More on p. 16

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E-mobility

Quiet drives

The perfect e-motor
MAHLE has succeeded in developing two bench­­mark technologies for electric motors over the
past two years. For the first time, it is now possible
to combine the MCT (Magnet-free Contactless
Transmitter) and SCT (Superior Continuous Torque)
technologies. The result is a unique modular
system for electric motors that enables customized
solutions for our customers. The perfect electricmotor with the combined technologies combines
permanent high peak power with contactless,wear-free power trans­mission. It dispenses withrare earths and dem­on­strates maximum efficiency
at all operating points.

MCT E-motor —The magnet-free among motors
The magnet-free MCT-E motor (Magnet-free Contactless Transmitter) was a revolution in electric motor development when
MAHLE presented it in 2021. This is because it does not re­­quire any rare earths. Another plus point is the wear-free powertransmission. This means that it functions contactlessly on
the inside. Where nothing touches, nothing can wear out! At
the same time, the motor achieves 95 percent efficiency in all
speed ranges. And last but not least, it is so flexible that it canbe used in everything from small cars to commercial vehicles.

17

force to the rotor shaft. This comparatively slim component
must therefore be designed to be extremely robust and lightweight at the same time. Because weight ultimately costs
expensive range. The laser-welded rotor shaft from MAHLE
is an impressive 30 percent lighter than comparable standard
shafts. Nevertheless, it transmits torques of up to 1,000
newton meters or withstands 20,000 revolutions per minute.
Thanks to the option of integrated oil cooling, it always remains within the optimum temperature window.

SCT E-Motor —Technological leap toward sustainability
With the SCT E-Motor (Superior Continuous Torque), MAHLE
presented a true world-first in 2022. The traction motor—
unique on the market—can run indefinitely with high performance, representing the first, true alternative to combustion
engines. This technological leap is made possible by a new
cooling concept. The new electric motor is unrivaled in its
small size, light weight and efficiency, and can also be built
without the use of rare earths at the customer's request. The
new development is suitable for passenger cars, commercial
vehicles, construction machinery and tractors. With the SCT
E-motor, MAHLE becomes a full-range supplier in the field ofelectric drives and covers all needs from e-scooters to heavycommercial vehicles, offroad and industrial applications.

X20 e-bike drive system —The lightest drive for gravel, road or urban bikes
The innovative X20 from MAHLE is the lightest e-bike drive
system on the market. It weighs only 3.2 kilograms, including the drive unit with a weight of only 1.4 kilograms, the integrated battery, and the HMI. It is thus the benchmark for
the weight/power ratio of e-bike drives. The drive delivers 23
Newton meters directly to the wheel. In operation, this power

Rotor shafts for e-motors —Incredibly light. Incredibly strong.

is comparable to a mid-mounted motor, which has a torqueof 55 Newton meters. The X20 system is complemented by
the new e185 range extender. Weighing just 1.1 kilograms, it

E-vehicles sound so quiet and light that it is easy to forget that

too is currently the lightest on the market. Fully charged, its

the same forces are at work as in conventional combustion

171 watt hours can fully support the integrated battery for up

engines. In e-vehicles, the e-motor transmits the generated

to 60 kilometers.

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E-mobility

Scalable charging
solutionsfor everybody
MAHLE chargeBIG offers scalable charging
systems from one source. Three different
solutions are available to municipalities, thehousing industry, or fleet operators. Allof them follow a new approach: The aim is
not to charge as quickly as possible, but toprovide as many charging points as possible
in an intelligent and low-cost way.

19Intelligent infrastructure for fleets and municipalities
Charging solutions for larger parking areas are an importantfactor for the spread of e-mobility. This applies to city centers,
airports, trade fairs, or employee car parks. ChargeBIG18-36
offers a scalable, centralized infrastructure for all these cases.
It can be integrated into the existing network infrastructure
and into existing buildings at low cost and without lengthy
conversions. The basic idea: “Charge as fast as necessary,
not as fast as possible.” The chargeBIG system is therefore
the optimal solution for locations where electric vehicles parkfor longer. It offers 18 to 100 or even more charging points, andoperation and cost accounting work simply via smartphoneusing an app, meaning it is intuitive and in compliance withcalibration regulations.
In addition to charging hardware, the complete package also
includes installation, maintenance, service, and operation if
desired. The maintenance effort is significantly reduced by
the central arrangement of the electronics.
For smaller requirements, there is the MAHLE chargeBIG6
variant. The system is optimized for the charging management of residential complexes, workshops, and smaller businesses. It can charge up to six electric vehicles simultaneously at an existing house connection with up to 11 or 22
kilowatts. ChargeBIG6 is simple to install, inexpensive, andeasy to expand. The charging system consists of a central
control unit: the chargeBIG6 charging distributor. Billing isdone via the already installed electricity meter.

For smart fast charging networks
We round out the offer with chargeBIG POWER. It is a smart
and easily integrated charging infrastructure solution thatmanages loads intelligently. Together with a suitable bufferconcept, it helps to quickly set up a smart fast-charging network that meets demand. The direct current charging system
for hubs and highways boasts impressively simple operation
and a superior charging performance.

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E-mobility

The best for the electrons
Proper charging is a crucial issue for theuser-friendliness of electric vehicles. MAHLE
is therefore focusing on smart charging
solutions. They bring the electrons most effectively to where they are needed: from thecharging point to the load unit in the electricvehicle, from there to the electric storage
unit, all the way to the most important component, the electric drive.

High power charging cooling unit —fast charging under all conditions
In order for fast charging stations to conduct the electricity
to the vehicle batteries as quickly as possible, ideal temperatures are required, especially on hot days. MAHLE has developed thermal management modules specifically requiredfor cooling fast charging stations. This makes fast charging
efficient and quieter in any environment.

Cool all round—immersion cooling for lithium-ion
batteries
The faster a battery charges, the more it heats up. Immersion
cooling from MAHLE offers a new solution for this: a nonleaky fluid circulates around the individual battery cells, which
lowers the temperature quickly and evenly. This particularform of cooling has three positive effects: Firstly, it extends
the service life of the battery. Secondly, immersion coolingenables very fast charging. This improves the long-distancesuitability and thus the attractiveness of electric vehicles. And
thirdly, with immersion cooling, smaller batteries can be used.
This will make e-cars cheaper, lighter, and more resource-efficient. In order to find the ideal battery configuration for every
requirement, MAHLE offers innovative cooling with three cell
types: prismatic cells, round cells and pouch cells.

On-board charging system—safe and efficient
Whether at the socket with slow alternating current or at
the charging station with faster direct current: The onboard
charging system from MAHLE adapts to any charging situation and ensures safe and efficient charging. To do this, it
keeps a constant eye on the temperature of the battery andthe power electronics and monitors correct grounding as wellas possible leakage currents. The electricity can be routed toother consumers inside and outside the vehicle, for example
to the cell phone charging in the car or to the oven at home.

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Source: Siemens

Wireless charging—simple and convenient
The current features of smartphones will soon make it easierfor electric vehicle owners to charge their batteries: inductive charging. Siemens is developing the infrastructure, and
MAHLE is handling the automotive engineering and the user-­friendly positioning system. A “transmitter” coil is placed at thebottom of the garage or parking space for this. If a vehicle
parks on it, a magnetic field is generated and transmits theenergy to the “receiver” coil in the car. The battery charges
with a charging power of 11 kilowatts and a 92 percent effiReceiver coil for mounting on the vehicle

ciency—and without cables!

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Thermal management

THERMAL MANAGEMENT

Comfort all
year round23

The inside temperature in a vehicle always runs
contrary to the outside temperature: in cold
weather it should be comfortably warm inside,and in summer pleasantly cool. Especially inthe transformation to e-mobility, this presents
engineers with new challenges.

No cold fingers in winterAnyone who drives to work in winter or rolls through snowcovered landscapes wants to be warm in the cabin, evenin an electric vehicle. Offering this comfort without muchloss of cruising range is technically demanding. “Even if anelectric motor is working on both axles, the waste heat is
not sufficient for a warm cabin,” says Dr. Harald Straky, Vice
President Product Development Electronics and Mecha­tronics at MAHLE. A heat pump helps with this. It draws energy from the ambient air and heats the cabin. Less energy
from the high-voltage battery of the e-car is needed for heating. “An efficient heat pump means the reduction in cruising
range in winter is up to 20 percent less,” says Dr. Busch.
The heat pump does not provide the entire heating performance. The difference is taken over by a heater that reaches the desired temperature both quickly and efficiently. As
soon as a charging stop is necessary, powerful high-voltage
coolant pumps play an important role because battery cells
also like to be pleasantly warm in winter. Before the charging
stop, the battery’s cooling system is used to heat the battery
cells up to temperature. Then the charged electrons find theirplace in the anode more quickly. The e-car reaches its maximum charging power faster. A charging stop with a preconditioned battery is shorter, gets you back on the road faster,and keeps you warm.

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Thermal management

A cool head in urban traffic
Manila, Philippines. Here, the average daytime temperature ismore than 31°C. Efficient cooling is therefore one of the mostimportant features of a vehicle. And for pleasantly tempered air
to flow through the cabin, it needs energy from the high-voltage battery. Fortunately, higher temperatures make for somewhat less energy consumption. But there are other challenges.
“In a quiet e-car, you don’t want to hear the hum of pumps,
compressors and fans,” says Dr. Roger Busch, Corporate
Executive Vice President Sales at MAHLE. The air conditioning auxiliary elements have to do their work as quietly
as possible. And regardless of the temperature, perfect air
conditioning also includes fresh air in the cabin. The nanofleece and activated carbon in the air filters of the MAHLE
solution frees the incoming air from pollutants and unwanted
particles. So you can breathe freely with a relaxed ride.
From the manufacturer’s point of view, there are two further
points: every compressor and pump require valuable installation space and must be supplied with energy. The developers’
challenge is thus to make them small, quiet, and energy-efficient. Our answer to this is the compact thermal management
module. It combines, for example, a heat exchanger, coolant
pumps, condenser, chiller, sensors and valves in one unit.
This saves installation space, development effort, and costs.

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Thermal management

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Efficient in the futureDetached from drive technology, regulating temperature circuits is always also about performance and efficiency. For example, all vehicles need electric oil pumps. They can be usedin hybrid drive systems, electric motors, and fuel cell drives toensure lower emissions. The more precisely the pumps regulate oil quantity and oil pressure, the lower the fuel consumption. “Oil pumps continue to perform an important task inclassic traction motors,” says Dr. Uli Christian Blessing, Vice
President Product Development Thermal Management at
MAHLE. With regard to the holistic view, he continued: “Thecomplete thermal management system also protects against
overheating.” For this purpose, heat is transferred from the oilto the coolant circuit.
Thermal components can also help reduce emissions withclean combustion technology. One example is the use of carbon-neutral fuels such as ethanol. With over 100 years ofexperience, MAHLE has developed engine components thatmeet the special requirements in terms of wear and blow-by
effect. That means gas that enters the crankcase during the
combustion of ethanol or hydrogen is directly enriched withair by a high-pressure impactor. This means no ignitable gas
mixtures are created. This turns the internal combustion engine into a safe and clean solution.

28

Thermal management

No E without T
Heating and cooling in electric vehicles is an essential technology field
for electrification—and a MAHLE core business. New innovations
increase the cruising range and fast-charging capability of batteries andbring more comfort to vehicle cabins. The chart shows that MAHLE
always has the whole system in mind.

Refrigerant circuit
Coolant circuit

4

1
1 Thermal management module> More on p. 30

2 Electric compressor> More on p. 31

3 Cooling module
4 Air conditioning (HVAC)
5 MCT E-motor> More on p. 16

6 Fluid management module> More on p. 31

7 On-board charging system (OBC)> More on p. 20

8 Battery cooling plate

3

2

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In the case of e-cars, end customer acceptance also depends on thermal management as the service life of the battery, the cruising range of the e-car, the performance of thedrive system, and the fast-charging capability affect the driving experience. Components of the drive system require thecorrect temperature at all times. At the same time, thermal
management ensures a feel-good climate in the vehicle cabin. Both processes require an understanding of the complete
system.

57

MAHLE has developed a new thermal management module
based on this. It combines, for example, a heat exchanger,
coolant pumps, condenser, chiller, sensors and valves in one
space-saving unit. Efficient and quiet electric fans and power­

6

ful air conditioning compressors complete the offer. Anothersuccessful product is battery cooling plates, which ensure fast
charging, long range and long service life for sensitive lithiumion batteries. Innovative heat pump systems reduce the energy consumption of an electric vehicle and make it possible to8

install smaller and lower-cost batteries. MAHLE is thus using
its strengths to further advance sustainable mobility.

The advantage for customers: MAHLE also continues to use its many
years of know-how in cooling and heating in the combustion engine.

30

Thermal management

Climate specialists
Compared to combustion technology, the demands on thermal management
in electric vehicles are significantly higher. MAHLE therefore already has
new solutions that make battery-electric vehicles and hybrids more efficientand also help in conventional vehicle types.

Thermal management module—
All for one, one for all
The thermal management of modern electric vehicles consists of complex, closely coupled fluid circuits. Refrigerants
and coolants perform different tasks in them. All critical components—interior, battery, electronics and electric motor—
must be kept within the optimum temperature window. In thecold season, in turn, a highly efficient heat pump helps saveheating energy. Compared to the standard system, this increases the range by up to 20 percent. MAHLE has reduced
the many components required in this complex interaction toa single module: the thermal management module. Maximum
performance and compact integration are the hallmarks ofthis approach.

31

Oil management module—
Highly integrated, extremely compact
The cooling of traction motors is of major importance. They
are the true “power packs” and must be protected from overheating. MAHLE’s oil management module is a highly integrated, extremely compact component especially designed
for this important task. In a heat exchanger, the heat from theoil is transferred to the coolant circuit. The oil pump is integrated into the module.

800-volt e-compressor—
The heart of thermal management
The e-compressor is important for the temperature control ofthe e-drive and thus crucial for the service life, high charging
speed and range of the battery. It also ensures the high levelof interior comfort and pleasant interior acoustics. MAHLE
currently offers its extremely compact high-voltage compressor in voltages of up to 900 volts, displacements of up to
57 cubic centimeters and outputs of up to 18 kilowatts. Its
compact design, combined with its high performance, meansthat it can be used in all vehicle classes-from passenger cars
to heavy commercial vehicles.

32

Thermal management

800-volt PTC heater—
Comfortable temperatures, even in the cold season
Battery electric vehicles lack the heat from the combustion
for interior heating in the cold season. Here, a highly efficientheat pump can often provide pleasant interior comfort. But
every now and then, additional heating must be provided
electrically. The 800-volt PTC heater from MAHLE heats theinterior air directly. This is fast and highly efficient, with up to
eight kilowatts of heating power.

Cabin air filter with nano-fleece and activatedcarbon layer—Clean cabin air for perfect cabin
comfortPerfect cabin comfort includes cabin air that is free of pollutants and undesirable particles. The new cabin air filter from
MAHLE consists of two highly efficient filter layers: the nanofleece and the activated carbon layer. The nano-fleece effectively filters coarse dust, soot particles, and pollen from theair. It separates the smallest fine dust particles in the size ofone micrometer up to 99 percent. But it also retains evensmaller particles of 0.1 micrometers very well. The active
carbon layer, on the other hand, effectively adsorbs harmful
gases such as hydrocarbons, nitrogen oxides or sulfur dioxide. At the same time, the filter medium is only around 2 to
3 millimeters thin, which means that the pressure loss of theconditioned air through the filter is extremely low.

33

Fluid pump (12/24 V)—
As fast as necessary
The fluid pump from MAHLE drives the coolant circuits. The
pump is operated demand-driven with up to 650 watts at 12
volts. Demand-driven means: In order to save precious electrical energy, the pump always runs only as fast as conditions
currently require. In the MAHLE concept, the pump bearings
are also actively lubricated and the electronics are cooled.
This protects against wear and ensures a long service life.
MAHLE also offers the pump in a 24-volt version.

Electric oil pump family—
Suitable for every application
Whether purely battery-electric drives, hybrid drive forms, orfuel cell drives: MAHLE offers the right electric oil pump forevery application. The oil pump family from MAHLE is scalable in terms of power as well as the number of suction andpressure stages. Thus, power ratings of up to 250 watts are
representable, with 24-volt drive power. MAHLE offers optional 24-volt and 48-volt systems. Controlled via LIN or CAN
interface, the product family covers all typical requirementsof e-drive axles. If necessary, the pump can be individuallyadapted to the respective customer requirements.

34

Conventional drives

CONVENTIONAL DRIVES

Moving fastertoward sustainable mobility
E-mobility is the key solution for climate protection in road traffic. However, to reduce CO2
more quickly, all technically possible solutions
are necessary. Also with a view to the existing
fleet with combustion engines.

Which powertrain technologies will get people and goods totheir destinations reliably, efficiently, and cleanly in the future?
Not a simple question. E-mobility is the key solution for climate
protection in road traffic, but the diversity of regional requirements calls for solutions that are open to technology. Globally, the combustion engine will remain the most common
drive form for the next few years, especially for commercial
vehicles. MAHLE is equally dedicated to conventional and alternative drives in order to exploit all opportunities to reduce
emissions in road traffic quickly and effectively.
Alternative fuels from renewable sources offer great potential for precisely this purpose. The enormous advantage isthat an immediate effect on climate protection is achievedin the vehicle fleet that exists worldwide. In many countries,
for example, green ethanol is available as a fuel. But greenhydrogen is also part of the energy transition, for example forheavy-duty and off-road applications that are currently difficult to convert to battery-electric and fuel cell drives.

35

36

Conventional drives

Clean addition
Ethanol power cell unit—
Classic drive. Re-thought.
MAHLE uses its expertise in combustion engines to makecomponents for this classic form of drive fit for use as a
CO2-neutral solution in global applications. This means thatthey can continue to be used with sustainable and CO2-neutral fuels such as ethanol in a highly efficient manner and witha long service life. The Power Cell Unit (PCU) is optimized tomeet the specific requirements of ethanol, for example withregard to blow-by, i.e. the escape of combustion gases fromthe PCU. Ethanol also places special demands on wear resistance. MAHLE has developed particularly exposed components such as valves and valve seat inserts accordingly.

High pressure impactor for hydrogen power cell
units—Active and safe
During combustion in the cylinders, a small portion of gas
always ends up in the crankcase—the so-called blowby gas.
The high-pressure impactor actively flushes the crankcase
with air, thus preventing alternative fuels (e.g. hydrogen) fromaccumulating here so that they can ignite.

37

High performance from the 3D printer
MAHLE has had initial success in producing ahigh-performance aluminum piston using 3D
printing. The test shows that the specia lcomponent increases engine output and efficiency.

MAHLE is leading the way technologically in design and production with additive production of highly loaded drive components. It offers the possibility of implementing functional
integration as well as bionic design in a MAHLE component.
In the production of high-performance pistons, more material is used only in loaded areas, following nature’s example.
This makes the 3D-printed piston up to 20 percent lighter
than its conventionally manufactured counterpart, while still
ensuring greater rigidity. For this purpose, the MAHLE developers have introduced a specially shaped cooling channel and used a new aluminum alloy. This was melted by laser
beam and built up in fine layers. A piston blank was ready inabout 12 hours and about 1,200 layers.

Quality confirmed in tough test run
Tested and finished, it then went into a real endurance test:
six pistons were installed in the motor of a Porsche 911 GT2
RS. On the test bench, the drive unit successfully completed
200 hours of the endurance test under the harshest conditions. The result of the elaborate tests was that the quality ofthe printed piston corresponds to the usual high quality of aconventionally manufactured production piston. It thus combines efficiency and peak performance in a new dimension.

New 3D printing center
MAHLE sees additive production as the future, especially forthe faster development and even series production of components in the field of electric vehicles and alternative drives.
A new 3D printing center was opened in Stuttgart for thispurpose.

22 kW

of extra power is produced by the Porsche 911 GT2 RS
engine thanks to the special piston.

38

Sustainability

Moving sustainably
It was already important to the founders Hermann and Ernst Mahle tocombine entrepreneurial vision with social commitment. That legacy
continues today and will also determine our future path.

Ethical attitudes and corporate governance, environmental protection, safety at the workplace, and economic efficiency are elementary values for our self-image as a foundation-owned company. We know that we bear a great responsibility for climate
protection, society, our customers, and our employees. And wewant to preserve what makes our lives worth living for the nextComprehensive information about our sustainability
activities can be found in the current Sustainability
Report:generation.
Due to our large portfolio, we can have a noticeable impact on
CO2 emissions. We are represented in almost all areas related
to mobility, from automotive and urban mobility to industry. We
develop technologies that contribute to making mobility as envi-

mahle.com/en/news-and-press/publications

ronmentally friendly and climate-friendly as possible for our customers in these segments.
Our strategic focus is on e-mobility, thermal management, andclean combustion engines powered by e-fuels and hydrogen.
Because our goal is to decarbonize the mobility of tomorrow asquickly as possible.

Further reducing emissions
E-mobility continues to progress, and we are helping to shape
this path with our portfolio. But more solutions are required
to reduce emissions quickly and in all areas. The combustion
engine will probably continue to play an important role forseveral decades in some markets and for certain application
scenarios. That is why we continue to work on making thispowertrain technology even cleaner and more efficient in order to reduce emissions and save energy because we needto meet all legal requirements together with our customers
and to continue to reduce pollutants, greenhouse gases, andnoise today.

39

Achieving climate-neutral
production

agement ranks, new five-year targets have been set for the
proportion of women at both levels below the management
board: The target is to increase the proportion of women
globally to 10% at the first management level and 15% at the

MAHLE aims to have climate-neutral production at all its loca-

second level by 30 June 2027. A mix of different HR mea-

tions worldwide by 2040. To this end, we have drawn up ansures, such as a more targeted focus on female successors in

ambitious roadmap, one goal of which is to increase our own

succession, development and recruitment, women’s advance-electricity production. A good example of how we can com-ment programs as well as a range of flexibility offers shouldbine our decarbonization technologies with our CO2 targets is

contribute to the achievement of the objective.

the cooperation with Sunmaxx PVT from Dresden. The startup is developing photovoltaic-thermal systems, which create
power and heat from solar energy. MAHLE supplies a coolingplate for this purpose, which was developed with know-how
from automotive engineering. It becomes the key component
for energy efficiency and increases energy production by up
to 80 percent in the Sunmaxx PVT photovoltaic system. A
pilot installation in the MAHLE plant in Vaihingen an der Enz isalready being planned.

Further increasing the proportion of women
A central element of our diversity and inclusion strategy is
the promotion of women in managerial positions. In order toachieve a more balanced gender ratio in the company’s man-

2022 was marked by many global, geo­
political, and economic challenges.
The fact that we were nevertheless able tostick to our sustainability activities andachieve important goals is a testament to
the effectiveness and resilience of oursustainability strategy.
Kathrin Apel
Global Head of Sustainability & HSE at MAHLE

20%of the MAHLE Supervisory Board are women.
With this value, MAHLE 2022 was able to achieve
an important milestone in the area of diversity.

In 2027,

10 percent of the first and 15 percent of the second
executive level should be women.

40

Sustainability

Green milestones
In 2022, we reached important milestones in the fight against

By 2030, we want to reduce greenhouse gases in this area

global warming: We were able to reduce our CO2 emissions

by 28 percent compared to 2019 and by 2040 we plan to befrom the use of fossil fuels (Scope 1) and emissions from thecarbon-neutral in our production. To underline our commit-

use of purchased electricity (Scope 2) by 12 percent in com-ment to achieving the goals of the Paris Climate Agreement,

parison with the previous year. In addition, we expanded ourwe submitted our Scope 1–3 targets by 2030 to the Scienceobjectives for Scope 3, i.e. emissions along the supply chain.

Based Targets Initiative (SBTi) for external validation.

Scope 1 & 2
Emissions caused by the company
itself and consumption of purchased
electricity and heat

Scope 3
Greenhouse gas emissions along the
supply chains and product use

41

Ethanol instead of gasoline
Since July 2022, we have managed to halve the CO2 emissions of ourcorporate fleet in Brazil. Since most company cars have a flex fuelmotor that can run on both fuels, the changeover was simple. On thecompany fuel card, only the option to pay for gasoline had to be
blocked. As a result, 70 percent of gasoline consumption could be
replaced with the environmentally friendly alcohol, which is a successful
example of sustainable mobility with the combustion engine.

2021

2030

2040

MAHLE in Germany
CO2-neutral

MAHLE worldwide-49 % CO2*

MAHLE worldwide
CO2-neutral

2030
MAHLE worldwide-28 % CO2*

2020

2030

2040
* In relation to 2019

42

Urban mobility

URBAN MOBILITY

FreedomaheadLightweight, sporty, and connected—these
are the characteristics that set eBike systems
from MAHLE apart. New solutions for the
Smart Mobility and a variety range of accessories complete our innovations for Smart
Bikes. More than 90 top-rate brands acrossthe world have featured the technology
supplied by MAHLE SmartBike Systems intheir electric bicycles. For Urban, Gravel
and Rod cycling.

43

44

Urban mobility

All in the frame
The lightest eBikes featuring drives from MAHLE combine

The latest MAHLE systems innovations and technologies cre-powerful assistance with a low weight and discreet integra-

ate the best support at any cadence, whether racing at top

tion, making it possible to configure SmartBikes under 10 kg,

speeds or climbing up a mountain to drive the rider and theideal for the steepest and longest rides, ensuring high per-whole industry forward.

formance motor assistance. Furthermore, the riders who canmanage without the motor’s help don’t feel resistance in thepedals when the system is turned off.
Ulta-compact smart systems offering a wide range of new
possibilities for riding and manufacturers when designing theframe since the system is concealed withing the bike’s frame
and rear hub, ensuring that electric bikes retain the appearance of conventional bikes.

10 kg
is how much the lightest eBikes fittedwith MAHLE drive systems weigh.

45

Fully connected
One of MAHLE’s key focus areas is the complete connectivityof its drive systems. Two Apps are already available that canconnect the Smart System to digital devices. An online dashboard also allows users to check key ride data or their SmarteBikes general status at any time. It’s also a useful feature forbrick-and-mortar specialist retailers, as they can offer servicing to meet the rider’s particular requirements.
With this new form of connectivity, MAHLE is creating an
unprecedent development of the entire SmartBike solution
strengthening the relationship between the product, customers, manufacturers, and specialist retailers.
New features are among the future possibilities. For example,
via intelligent sensors on the eBike or ANT+LEV communication protocol, MAHLE aims to raise the safety of riding andthe ability to be permanently connected.
The development of the entire SmartBike solution also involves new technologies such as the Smart Assist which
adapts the system’s level assistance depending on what therider needs at any moment to enhance the riding experiencein more active way.

46

Urban mobility

MAHLE solutions for Smart Bikes
The X20 System is the lightest and most awarded drive system on the market.
Weighing in at only 3.2 Kg, it is also the most advanced in its class, with aseamless start and cutoff to the assistance and creating the best support at
any cadence. Ultracompact, light and smart system that creates a full rangeof new riding possibilities offering a natural cycling sensation while making
eBikes look & feel indistinguishable from high performance bikes.

1 X20 hub motor
The lightest drive unit on the market. Lightweight at only
1.399 kilograms, the rear hub motor is designed to reach amaximum performance level, applying power directly to
the wheel and is completely unnoticed until feeling the 55Nmof torque. It includes the AMC system (Automatic Motor
Connection, pending patent) that gets rid of motor cables
and allows the wheel to be positioned naturally, fixing it
through a standard 12 mm thru-axle.

2 HMI
Communication between rider and the Smart Bike takes
place via the Head Unit Information System through a brightness sensor and 3D accelerometer, without inter­­­­­­­ering withthe design and the riding experience. The Head unit allows,
at a glance, to check battery level, assistance power, warnings,
and alerts so the rider can focus on what is really important,the ride.

3 Smart batteries
The new smart batteries, 236Wh and 350Wh power the motorand can be supplemented with the external 171Wh Range
Extender, providing, and assisting ride autonomy that can
go beyond 140km, optimizing consumption thanks to the newgeneration of integrated motor controls. Integrated in the
downtube, they can be quickly charged.

4 Torque and cadence sensor
The X20 System includes a sophisticated sensor package thatmeasures each watt of power you apply, offering the rider theright support at any cadence, adapted to un­­­expected changes.

1

47

6
2
7

3

5

4

5 Range extender
MAHLE e185 is the only range extender that fits into a standard
water bottle. Weighing only 1.1 kilograms, it has 171Wh ofpower to achieve the best weight-to-capacity ratio in this class.
Fully charged, can support the integrated battery in the frame,
extending the electric range for up 60 kilometers.

6 Wireless PulsarONE display
For detail-oriented riders, the wireless PulsarONE display
provides detailed information of eBike’s key data. It’s easy tooperate and can also be used to change the level of assistance.

7 eShifters
At MAHLE, safety is a top priority. That’s why we developed theeShiter, the perfect curved handlebar solution. They provide therider with improved and seamless control of their bike, including
two small control buttons, vibration technology and flexible
placement of the included silicon bands.

48

Urban mobility

Scooters and commercial vehicles

Two-wheel drive systems for scooters
E-scooters are agile, lightweight, and flexible. But there’s also

nous motors) and extremely space-efficient electronics. Eachvery limited space for the drive system. That’s why MAHLE

scooter is also fitted with a hybrid controller. It combines ro-offers highly compact powertrain solutions for these mo-tational speed and torque control for a dynamic handling ex-

torized two-wheelers. Less powerful models generally use

perience. Larger and more powerful drive systems are usually

air-cooled IPM motors (interior permanent magnet synchro-liquid-cooled.

Low-voltage drives from MAHLE for scooters and three-wheelers with outputs of 5–14 kW

49

Induction motors for commercial vehicles and golf carts
MAHLE induction motors with the corresponding drive con-

If required, the controllers can also contain drivers for braking

trollers are the ideal solution for electric micro commercial

resistors, which are used to brake the vehicle when the bat-vehicles and golf carts. An algorithm regulates traction andtery is fully charged.

adapts the torque smoothly and precisely to all ground andload conditions.

Low-voltage drives from MAHLE for commercial vehicles and golf carts with outputs of 10–20 kW

50

The street in the laboratory
How can I increase the range of electric vehicles through optimal thermal
management? How must systems for the heat pump be set up? Or: How doheat or cold affect the fast charging of Li-ion batteries? These and many otherquestions are asked by developers of almost all vehicle categories. They
answer these questions in the MAHLE climatic wind tunnel in Stuttgart.

51

The first of its kind

For a clean future

As early as 1937, Manfred Behr built the world’s first wind

Alternative drives based on hydrogen and battery-electric

tunnel for the automotive industry. A year later, he used it todrives will determine road traffic in the future. The MAHLE

help the legendary W 154 Silver Arrow achieve a radiatorclimatic wind tunnel is gearing up for the future: Relevant

design that set standards. As a pioneer in this field, MAHLE

tests, measurements, and simulations can be carried out

has continuously developed the measurement section to this

there without any problems.

day. The climatic wind tunnels enable realistic, precise, andrepeatable measurement and test conditions for diverse ap-

100 km cruising range in five minutes

plications. Therefore, they are the secure basis for smoothtechnology transfers, quality assurance, cost reduction, andOver 40 degrees Celsius heat, the sun burning on the car,time saving in the interest of the customers.

almost no reprieve from the wind. These are difficult conditions for the temperature-sensitive Li-ion battery. If an e-car

In the highly modern system, all conceivable conditions inis then charged quickly, the battery can become too hot anddriving practice can be precisely configured and reproduced.

be damaged. To be able to test this realistically, MAHLE has

This means a wide variety of combinations and sequences

now equipped its climatic wind tunnel in Stuttgart with a di-of temperature, humidity, solar load, and street load are pos-rect current fast charging system. This allows up to 350 kW

sible. Measurements can be carried out under real weather

DC and 1,000 V to be charged in all climatic conditions. The

conditions for vehicle sizes up to trucks on the generously

10-meter long cable reaches all charging ports without any

dimensioned measurement section.

issues. This allows the vehicle to be charged or discharged
for a 100 km cruising range in under five minutes. The fastcharging station offers individual solutions for the wind tunnel, including monitoring and control from the control room.

New test procedures with hydrogen
Dealing with hydrogen in vehicle powertrains poses newchallenges for manufacturers and for the climatic wind tunnel. Due to the chemical properties of hydrogen, the security
concepts must be realigned, since an explosive mixture already exists at a hydrogen concentration of more than 4%
by volume. The MAHLE experts carry out the corresponding
tests on air-gas concentration in the climatic wind tunnel. Air
movements during critical driving conditions become visible
and can be analyzed. The ultimate goal is to conduct the
tests with future drive concepts safely and under all climaticconditions.

52

R&D experts—
MAHLE Powertrain
The next generation of drive technology will be more varied thanever before. As an experienced specialist in powertrains of all kinds,
MAHLE Powertrain supports automobile manufacturers as theytake their next step forward. Engine, transmission, hybrid unit, software, and operating strategy—MAHLE Powertrain handles it all.

If you’re looking for expert engineering and consultancy services, MAHLE Powertrain is the partner for you—whatever
the drive system. Its broad range of services includes thedesign, testing, development, calibration, and integration of
hybridized internal combustion engines and electrified powertrain systems. In all projects, the ultimate goal is to achieve
real innovations or advance to the next level of technology
for solutions suitable for series production. As they move into
the future, the experts are always there to support vehicle
manufacturers as partners for cutting-edge research, devel-

wheels, while a thermal soaking system makes it possible toopment, and application.

test e-drives in a wide temperature range.

Advanced testing

Battery engineering partner

To stay one step ahead of the latest technology trends,

State-of-the-art simulation and testing are just two of MAHLE

MAHLE Powertrain continuously invests in state-of-the-art

Powertrain’s strengths. Thanks to in-depth understanding ofdevelopment and test infrastructure. This is also the case at

new technologies, our experts also support the internation-

the e-drive test center in Fellbach near Stuttgart / Germany,

al automotive industry as a development partner. In the two

where the team is developing and testing e-axles and e-drive

battery development centers—one in Stuttgart and one inunits for a wide range of electric and hybrid vehicles. To en-

Northampton, England—we work on innovations for everything

sure compatibility with all potential vehicle drive applications,to do with batteries. At the same time, engineering services insystems are operated with high-voltage and low-voltage

this area are increasingly in demand. The newly developed 48-

batteries. Highly specialized permanent-magnet synchro-volt battery pack from MAHLE is a successful example of thisnous electric motors replicate the loads applied by the driven

within the MAHLE Group. It was designed with the support of53

MAHLE Powertrain for repeated high-level charging and discharging to maximize the potential for energy recovery during
deceleration and braking. The basis was data from the analysisof the driving behavior of a typical mid-range vehicle.

International presence
As the MAHLE Group’s Engineering Services subsidiary,
MAHLE Powertrain supports customers independently of theparent company in the selection of the most appropriate tech­
nologies or components for specific requirements. MAHLE
Powertrain is represented internationally with eight locationsin the UK, Germany, the USA, and China. This means that
customers in the world’s major automotive markets can work
directly with our experts on site.

3
6

million euros were invested by MAHLE in thetest bench for electric motors in Fellbach.

international centers offer customers on-site expertisein the UK, Germany, the USA, and China.

54

55

Keeping everything running
MAHLE offers its expertise throughout the life cycle of its vehicle
technologies. That means high-quality spare parts and many
services—from motorsports to workshop equipment. This is why
we have the Aftermarket, Profit Center, and Services areas.

Sustainable outfitters: Aftermarket
With the growing series production of alternative drives,
the spare parts and service business is also developing: A
strong range here ensures long-lasting and more sustainable
technologies. Thermal management in particular is gaining inimportance as the number of electric and hybrid vehicles increases significantly. Across all technologies, workshops canrely on MAHLE equipment for vehicle diagnostics, battery
testing, and service work to maintain air conditioning systems
and automatic transmissions. MAHLE also supplies partners
in the trade and engine repair, as well as electronic trading
platforms worldwide with original equipment quality products. The aftermarket range is completed by services suchas technical support at more than 30 locations worldwide as
well as individual training courses and service information for
all customers.

New challenges
The growth of e-mobility poses an unprecedented challenge
to the automotive aftermarket and workshops in terms of thecost and complexity of battery systems. The battery itself canrepresent over 25 percent of the total vehicle cost. The shareof vehicles with electric drive systems will rise to 95 percent inEurope, 90 percent in China, and 75 percent in North America
by 2035. Battery service could therefore soon account for halfof the total services provided by workshops. This makes it all
the more important to develop suitable diagnostic and maintenance solutions.

New development partner
MAHLE is leading the way in this area, among other things via
its cooperation with the US company Midtronics, Inc. The aimof the partnership is to provide workshops with a safe, simple,
and effective service for the all-important Li-ion battery. The
offer is intended to cover the entire life cycle of batteries andvehicles, irrespective of brand.

56

Workshop of the future
It is the workshops that ensure the mobility of millions of people
worldwide every day. Our solutions take the load off the workshop
operators’ backs. Especially at a time when mobility is changing
rapidly and different drive concepts are being developed, reliable
and innovative partners are needed.

Calibrating with AI

Maximum diagnostic possibilities

MAHLE has released an update on the increasing calibra-

The MAHLE RemotePRO can help as a supplementary di-tion effort in workshops for driver assistance systems. The

agnostic system where universal diagnostic tools reach their

TechPro® Digital ADAS 2.0 system uses artificial intelligence.

limits. This is because it combines a large number of man-This recognizes the vehicle together with the control unit andufacturer diagnostic tools virtually on one server. This allows

automatically adapts the digital calibration panel from MAHLE

independent workshops to use the same range of functions

to the respective vehicle. This saves several process steps

as branded workshops, even on vehicles that are very rare

per vehicle. To simplify the learning process, the application

or difficult to diagnose. This includes reading and erasing thefeatures 3D tutorials.

fault memory, calibration, programming, and maintenance ofvarious systems.

57

All-round healthy batteries
Since March 2023, MAHLE has been the first provider worldwide to enable independentworkshops to carry out battery diagnostics on electric vehicles. For this purpose, ourAftermarket specialists have equipped their TechPRO® diagnostic tool with new software.
But there is more to the complete package for healthy batteries.

E-ScanThe status of the battery can be monitored and printed in the

MAHLE diagnostic technology also makes it possible tocorresponding report. The new function will be installed on

combine charging and diagnosis. The E-Health Charge fea-

the BRAIN BEE CONNEX and MAHLE TechPRO diagnostic

ture provides reliable information about the “health” of thetools. The E-Scan is connected to the vehicle and detects all

high-voltage battery while it is charging. The measurement

existing fault codes in an average of 30 seconds.

takes just a few minutes too.

E-Health

E-CareE-Health means that in the future traction battery diagnostics

Vehicle and coolant manufacturers set certain replacement

will also work via the charging plug in addition to the exist-

intervals for the coolants used. MAHLE offers a new service

ing OBD port. The process lasts about 15 minutes. The soft-

unit for the maintenance of cooling circuits. This enables

ware evaluates the measured data in the cloud, regardlessworkshops to offer additional services related to the supplyof what data the vehicle manufacturer provides via the OBD

of electric vehicles.

®

port. This makes the measurement particularly neutral andindependent. In addition, the tool generates a forecast of theremaining expected life of the battery. The product launch isscheduled for the year 2023.

Pragstraße 26-46
70376 Stuttgart/Germany
Phone: +49 711 501-0
www.mahle.com

00007878EN8/23

MAHLE International GmbH