The ever more complex processes in the engine entail increasing demands on the intake systems. Exhaust gas regulations and fuel consumption provisions, shorter model cycles and increasing performance expectations accompanied by ever smaller installation spaces are essential requirements in any modern development. These challenges have to be met by state-of-the-art development tools and consistent project management.
As early as the mid nineties, MAHLE had broken new ground with the development of switchable intake manifolds. Produced cost effectively in a plastic multiple-shell design and with resonance charging or with variable runner length charging via flaps or sliding sleeves. As a result, the engine achieves a high torque even at low speeds, yet enabling high speeds and a high maximum power. In the area of direct-injection gasoline engines, this technology is combined with intermediate flanges and their tumble flaps specially developed by MAHLE. These produce a tumble flow in the combustion chamber of the engine. This enables the mixture formation and rate of combustion to be improved, which in turn leads to less exhaust gas emissions and lower fuel consumption.
MAHLE has set a further milestone in the development of intake modules with its new three-level resonance system, which can be engaged via two flaps integrated in the intake manifold. The resonance charging is effective at three speed levels over a wide speed range. It provides advantages even at up to 7,000 rpm. The new system was optimized using charge exchange calculations and was verified virtually before the first prototypes confirmed its functionality. In addition to the electrical actuator units for the resonance system, the overall scope of the intake module comprises a crankcase ventilation system with oil mist separation, pressure regulation and supply to the intake module.
Mechatronic components
An optimized charge exchange, reduced emissions, and lower fuel consumption in the internal combustion engine require novel and reliable actuators in the engine compartment. For this purpose, MAHLE develops electric actuators for charge movement flaps, resonance flaps, and variable-length runners, which have been optimized to the conditions in the engine compartment. For emissions in diesel engines, an electric EGR valve with extremely high opening force ensures precise metering of the exhaust gas flow recirculated in the intake pipe.
Due to their modular design, these actuators can be easily integrated in the intake module concepts and fulfill even the toughest customer requirements. The consistent implementation of actuators in all-plastic enables an efficient and cost-effective production process. Depending on customer specifications, the actuators can perform continuous motions or can be used as control elements. Optimized position sensors or integrated control electronics expand the application range of these components to include even smart systems.