THE MANN+HUMMEL CUSTOMER MAGAZINE No. 2/2018 AUTOMOTIVE news

In focus Next generation of filtration

Digital air cleaner monitor for predictive maintenance

Cost-effective plastic-aluminum hybrid design for liquid filter modules

Innovative air cleaner with Flexline technology for Mercedes-Benz 2 AUTOMOTIVE news 3 Contents

Filtration competence 4 Fully integrated 22 for e-mobility for maximum efficiency Expansion of the filter media portfolio for alternative drives Intake manifold with fully integrated charge air cooling for the BMW Group

‘One size fits all’ 6 Next generation 24 does not exist with us of intake manifolds Harald Späth talks in an interview about the Heavy Duty & Industrial sector New concept with numerous integrated functions

Senzit – 10 One compensation element, 26 intelligent air cleaner many advantages Digital air cleaner monitor for predictive maintenance AgileJoint compensates mounting and thermal tolerances

Dear Business Partner, High performance 11 Active 28 centrifuge cell protection Extended oil change interval and easy service Cathode air cleaner for use in fuel cells We are ready for the future. Because with the next gen- with Flexline technology for Mercedes-Benz. Thanks to perfect eration of filtration products and technical plastic parts exploitation of the installation space, the filtration surface area Flexibility uses 12 WAVELOCK - 29 MANN+HUMMEL is set to actively shape the mobility of to- and inflow area are enhanced compared to a rectangular filter installation space easy to service morrow. This is what you will see in this issue of Automotive element fitted in the same space (page 12). Innovative air cleaner with Flexline technology for Mercedes-Benz Revolutionary spin-on filter concept simplifies the filter change News, which includes products for current challenges as well as future-oriented technologies. We are also currently facing political and economic challenges. New state of the art: 14 Global network, 30 These are reflected in the operating profit of the first six months water separation local production We present new products in the area of alternative drives, digitali- of the year. Sales revenue is slightly lower than the level of last Efficient fuel filters with three-stage water separation Additional oil filter module produced locally in India zation and clean mobility. The cathode air cleaner for fuel cell year. From past experience, however, we know that the second vehicles, the digital air cleaner monitor Senzit or the WAVELOCK half of the year at MANN+HUMMEL is stronger than the first half. Vote of 16 Cabin air filters 31 spin-on filter concept are just three examples of our extensive Therefore, we are looking forward to the future with optimism. confidence for buses and trucks development expertise. But as the future always begins with the First series order for a cylinder head cover with RobustPlus pressure regulation valve Cabin air filter for more protection against allergens, mold and fine dust present, our focus is of course primarily on the current challenges We are well prepared to do so: our extensive know-how enables us of our customers. to come up with solutions across different industries and then to Double the 17 Outstanding 32 match these down to last detail to the application requirements of service life references Our strength of being able to recognize these challenges, to our customers. As put clearly in a nutshell by Harald Späth, Vice High performance and durable air cleaner system for CNHTC Complex air cleaner system and charge air ducts for Brilliance find tailor-made solutions and at the same time to think about President Global Sales Heavy Duty & Industrial, in an interview on the further development for future applications is reflected, for page 6, the maxim „One size fits all“ doesn‘t apply to us! However, Systems competence 18 First-class 34 example, by our series intake manifold with fully-integrated, in- „all in one“ is indeed possible with the whole range of subjects for for commercial vehicles oil separation direct charge air cooler for the BMW Group (page 22). On page 24 modern filtration available in a single magazine. Therefore I wish Air cleaner system offers trucks from Ashok Leyland maximum filtration performance Innovative SD oil separator finds application by Mercedes-Benz you can read about how the further development of the current you lots of fun reading. solution helps engines meet the stricter emission regulations Perfect 20 At a glance 36 of the Euro 6d standard. A further example is our air cleaner Your Kai Knickmann connection Cost-effective plastic-aluminum hybrid design for liquid filter modules

IMPRINT MANN+HUMMEL Automotive News; [email protected] Publisher: MANN+HUMMEL International GmbH & Co. KG, 71636 Ludwigsburg, Germany Responsible in terms of German press law: Harald Kettenbach; Editor: Birgit Herbst, Lisa Bürkle Layout: Ralph Dodel Grafikdesign, 73066 Uhingen, Germany Production: Gmähle-Scheel Print-Medien GmbH, 71336 Waiblingen-Hohenacker, Germany 4 AUTOMOTIVE news 5

System reliability + Filtration competence 1 100 percent synthetic filter media with high chemical resistance

Life time + for e-mobility 2 Depth filtration for high dust holding capacity

System security + 3 Filter media without bypass for fast and permanent particle separation For some people electric mobility is the concept for the future. For others it is at least an important component of a drive mix which is environmentally Energy efficiency + 4 Gradient structure and drainage grid friendly. MANN+HUMMEL is open to all options and selectively develops for low differential pressure products which support emission-free mobility. Structure of the new filter media class MULTIGRADE eM with drainage grid

Heat is also the core issue with fuel cell electric vehicles. In contrast The MULTIGRADE eM-CW filter media class is also efficient when to batteries, fuel cells are not used for energy storage, but for the used for the filtration of water-based cooling liquids which find purpose of conversion. The energy is created through the reaction application in the thermal management of fuel cell packs. Due to of hydrogen carried in the fuel cell tank with atmospheric oxygen. the fact that flow rates of up to 15,000 liters per hour are required Water vapor forms through catalysis. In this process, energy and for the purpose of cooling, the filter element has to be stable under also heat is generated. It is possible to extract the heat from pressure and also designed to reduce differential pressure. A Even though more and more European and Asian countries have battery packs and fuel cell packs by means of indirect cooling stainless steel grid ensures that the filter element is characterized announced their plans to slowly phase out combustion engines, m] 200 realized with cooling channels filled with a mixture of water and by excellent mechanical stability. The selection of appropriate there remains uncertainty about the alternatives. In addition to the glycol. However, it is also possible to directly cool individual materials for all components reduces the washing out of ions purely battery-powered approach, there are also electric hybrid battery cells using non-conductive media. In this respect, specially (dissociation or ion discharge) to a minimum and therefore helps 150 concepts such as 48 volt hybrids, mild hybrids and full hybrids, developed cooling oils can ensure uniform heat dissipation. to protect the fuel cell against a loss in performance. The which are included in the focus of the development activities of For both methods it is essential to make sure that particles in the MULTIGRADE eM-CW 180 separates 99 percent of all particles vehicle manufacturers. In purely battery electric vehicles (BEV) the 100 cooling liquid do not block the fine cooling channels, or contribute from the size of 180 micrometers. drive energy is derived from the battery cells carried on-board, to increased wear of the pump. whereas with fuel cell electric vehicles (FCEV) the drive energy is 50 generated on-board from hydrogen. Both approaches have one Designed to reduce differential pressure Challenges and success thing in common: they require customized solutions for the The MULTIGRADE eM-CO filter media developed by MANN+HUMMEL In order to bring these new, pioneering filtration solutions to the market, 0 respective requirements with regard to thermal management and [ µ particle size at efficiency % filtration 99.5 especially for use in battery electric vehicles meets the require- new test benches have to be set up and new test methods have to be the efficient filtration of cooling circuits. MANN+HUMMEL has now MULTIGRADE eM-CO 50 MULTIGRADE eM-CO 140 ments with regard to lower differential pressure and higher dirt developed. Here MANN+HUMMEL can draw on its decades of ex- extended its existing range of filter media to include electric MULTIGRADE eM-CO 100 MULTIGRADE eM-CO 180 holding capacity. The fully synthetic media offer a high chemical pertise and quickly create the conditions to already test products mobility (‘eM’) with MULTIGRADE eM-CO and MULTIGRADE resistance to the low viscosity oils and dielectric fluids used in during the development stage under conditions which are close to eM-CW for the filtration of coolants based on oil and water in MULTIGRADE eM-CO filter media portfolio for different customer needs battery electric vehicles. The mechanical stability of the filter ele- series conditions. In 2017 the first prototypes with MULTIGRADE battery electric vehicles and fuel cell electric vehicles. ment is ensured by a drainage grid on the clean side which serves eM-CW were delivered to customers to enable validation tests on to maintain the ideal distance of the pleats. As a result, the whole a test bench with virtually field conditions. The filters are currently It‘s all about cooling whereby the heat distribution has to be as homogeneous as filter surface is permanently available for use. This leads also at low undergoing vehicle tests for the filtration of cooling oil used to cool The requirements for new drive concepts with regard to thermal possible. High, inconstant temperatures lead to a loss of storage temperatures and high flow rates to a low differential pressure. battery cells. MANN+HUMMEL has already won series orders for both management are very challenging. The lithium-ion cells used in capacity and therefore to a reduced range for the vehicle. Ex- The filter media class MULTIGRADE eM-CO with a separation filtration applications. In addition to the discussed cooling applica- battery electric vehicles which have a high storage capacity can treme overheating of the battery pack can even lead to a thermal efficiency of 99.5 percent currently covers particles in the range tions the media class MULTIGRADE eM-CO has been successfully only be operated within a strictly limited temperature range, runaway resulting in the complete destruction of the system. of 50 to 180 micrometers. tested for its use in e-Axles and is currently in vehicle testing. 6 AUTOMOTIVE news 7

‘One size fits all’ does not exist with us

As Vice President Global Sales Heavy Duty & Industrial, Harald Späth has to meet a wide range of expectations. In an interview he reveals how he manages to integrate all of these, discusses current trends and indicates where he sees potential for growth.

Harald Späth talks in his interview about the commercial vehicle and industrial business of MANN+HUMMEL

Mr. Späth, you have already had several What are the advantages of the restructuring And how can commercial vehicle customers management roles at MANN+HUMMEL. in the HD&I sector? benefit from industrial know-how? What‘s the difference between those previous positions and your current position? I can best explain that with an example: In relation to filtration tech- If we can successfully define our standard products so that they nology, when a vehicle drives on the street, meaning on-road, this are also suitable for their applications, commercial vehicle manu- There is tremendous range in the area of Heavy Duty & Indus- is comparable to when a vehicle drives three meters away from the facturers will also benefit. We have economies of scale and the trial (HD&I) and that‘s exciting. We have reorganized the original road meaning off-road. In both cases there is a requirement for all products are available at short notice. In the field of commercial equipment business unit. It comprises the automotive and in- ‘We are currently kind of air and liquid filtration. Naturally there are differences, for vehicles there are also applications which are very suitable for dustrial filtration business. Here we have combined the com- example, in terms of volume demands. In the industrial filter busi- standard products. In particular, a dedicated development process mercial vehicle and industrial business in the so-called HD&I working intensively ness these are usually lower. Accordingly, completely developed is not economically viable for niche applications. When the tech- segment. The industrial area is very heterogeneous. In a global on how we can make standard products find application. For our truck customers, on the nology is comparable, we can ideally exploit synergies because we market environment, we operate in a wide variety of industries other hand, we mainly offer customized solutions. But the great thing have integrated the responsibilities in a single team. But one thing and work with customers who only have local operations as well our products more is that due to interconnections in the new area we are perfectly able is important for me here: despite this, we must not lump every- as customers who are global players. The applications are to combine viewpoints, market requirements and our experience. thing together. There is no ‘One size fits all’ with us and something broadly diversified including railway, marine, machine tools, intelligent.’ This allows us to benefit from synergies and as a result become which works for one customer may be the wrong solution for the compressors, industrial engines, and also agricultural and quicker. That is an important advantage for the customers. other customer. construction machines or even special applications such as dust filters for industrial smoke detectors or garbage trucks Harald Späth, How can this advantage actually be exploited? What competition do we have in the HD&I sector? for the protection of workers and the environment. However, Vice President Global Sales Heavy Duty & Industrial in the commercial vehicle business the processes are com- There is a very good example. In the automotive area many manu- We are operating in a highly competitive market environment. There parable to the passenger car business and although we have facturers have been working for some time with so-called platform are competitors with a global presence such as ourselves. But there to deal with a lower number of customers, these customers have strategies. These concepts have now found their way to the areas of are only a few who are able to serve all the markets and with the kind a global presence. We want to understand all our customers, construction and agricultural machines. Here we can draw on sound of wide product range we have at our disposal. Based on our vision of meet their requirements and hence offer them the best expertise and efficiently support customers with their strategies, ‘Leadership in Filtration’ we want to offer innovative and competitive possible service. in the ideal case from early on in the development process. filtration solutions with a corresponding added value to our customers. 8 AUTOMOTIVE news 9

Where do you see opportunities for growth? Which general trends do you see in the HD&I sector? We see clear potential for growth in all areas. This includes on- road, off-road and also industrial applications. There are many Our customers are very interested in alternative drives. They also varied applications for our products at a global level in all have to react to current topics such as the air pollution in cities markets and market segments. We currently also take regional by considering the use of clean drive technologies. Commercial drivers of growth into account. China, for example, is currently vehicle manufacturers have started to present vehicles with an introducing new emission control legislation, the so-called electric drive and also the first agricultural machines with an China 6. This will necessitate the development of new engines electric drive have been presented. We are developing new pro- and accordingly the requirements for many components will ducts to take these trends into account. At the International increase. The expectations with regard to filtration will also Motor Show in Hannover in 2018 we will present coolant fluid correspondingly increase. Drawing on our experience and com- particle filters, venting units for high-voltage battery systems, parable products from other markets we can efficiently support and cathode air cleaners for fuel cells. our customers and grow together with them – in Asia, in America and also in Europe. What role does digitalization have to play?

What are the challenges dealing A very big one! Digitalization in all forms is a trend. For example, with different regions? let‘s take the area of agricultural machines with autonomous driving and control systems. We are currently working intensively Naturally, we cannot implement a global strategy and think that on how we can make our products more intelligent to allow them something which is successful in Europe will automatically be to communicate with other products in future. With the smart successful in America and Asia. Each market has its own device called Senzit we launched a retrofit solution last year. This challenges. We must always consider the respective competi- digital product measures amongst others the condition of the air tive environment and local legislation and align our strategy cleaner and predicts when the element will have to be replaced. to the region or the respective country. To lump everything to- The next step will be to develop smart products such as this for gether in Asia would also be a mistake. This is because India original equipment manufacturers in the HD&I area. Here we will cannot be compared to either Japan or China. also involve external specialists to consider together how the Harald Späth explains the trends in the Heavy Duty & Industrial sector

filtration product of tomorrow will look like and develop a cor- Which solutions are you thinking of? responding business model. We are currently conducting detailed market research and are engaged in discussions with all our cus- WAVELOCK is such a product. This product has already received Professional profile tomers to understand the direction in which they are thinking. an innovation award from John Deere, a leading manufacturer This is very exciting because customers are also undecided about in the area of agricultural machines. For this concept we further Harald Späth studied mechanical engineering and how to proceed. There is a lot here which is uncharted territory. developed a spin-on filter which has been in series for many industrial engineering. He joined MANN+HUMMEL in And we are confronted with completely new questions such as years. Now we no longer attach the filter to the engine block via 1995 and his positions included seven years as Vice how to handle the data which is collected. a thread, but instead use a bayonet lock. The system has a President Global Sales and Project Management for really simple function: Using the bayonet connection, tools are the passenger car sector. After his position as But you are also prepared to enter uncharted territory no longer needed to remove and install the filter. Another key Managing Director of MANN+HUMMEL in England he with new products such as the fine dust eater … feature is that we pre-fill the oil filter with oil so that during the took on responsibility for global sales for the industrial filter change a part of the oil is also changed. This removes the filter business at that time. In September 2017 he Absolutely! Fine dust pollution is a big problem and with our fil- need for an oil change. And it just takes 30 seconds. A was appointed Vice President Global Sales for the tration products we can also make a positive contribution here. second example is the new VarioPleat air cleaner concept. restructured area of Heavy Duty & Industrial. In all the areas of on-road, off-road and industrial applications Thanks to production technology which is unique in the world, we can offer new solutions to reduce fine dust levels. That also filter pleats can be produced to different heights to enable the includes our brake dust particle filter. This product has sparked a ideal exploitation of the available installation space. These high level of interest with on-road and also off-road customers. examples impressively illustrate how excellent engineering But I am also convinced that we can further develop our existing expertise can be used to introduce new ideas into so-called Harald Späth, Vice President Global Sales Heavy Duty & Industrial range of products with intelligent solutions. mature products. 10 AUTOMOTIVE news 11 Senzit – High performance intelligent air cleaner centrifuge

Senzit is a smart air cleaner monitor which measures the status of air Oil centrifuges separate soot particles from engine oil to reduce engine cleaners in real time and transfers service-relevant information to users wear. The system developed by MANN+HUMMEL with a plastic centrifuge via an app. The optimal planning of maintenance saves time and brings can do more. It simplifies servicing, lengthens service intervals and integra- many advantages to the customer. tes further important engine functions.

The air cleaner monitor Senzit saves time and nerves for users. This is because using Senzit the air cleaner will in future communicate when a service is necessary. Thanks to extensive assistance functions, users receive important information via an app on the passes through the high speed rotor the resulting centrifugal smartphone or tablet. This means that information on service- forces ensure that particles are deposited in layers on its interior relevant factors such as load status or remaining service life of wall. The cleaned oil then flows back to the oil circuit. the filter element is available at any time. Senzit determines this information from numerous sensors which measure vehicle data Clean service from below and the ambient conditions. That simplifies the planning of Another highlight of the system from MANN+HUMMEL is the maintenance times and protects against unplanned machine plastic cover screwed into the housing from below. Incorporated is downtimes. This clever solution changes conventional filters an intelligent drain system to prevent oil spillage during service. Senzit fitted to IQORON VP 25 air cleaner with VarioPleat air filter element into smart products and enables them to be easily monitored. Service-friendly centrifuge with plastic rotor This allows the rotor to be changed from underneath and enables However, Senzit makes life more difficult for vehicle thieves a clean service. A mounting aid ensures the correct positioning of because with Senzit, as well as knowing where and for how long Soot particles penetrate the lubrication film and increase friction the new rotor. Senzit application example: the vehicle has been in use, users are also able to locate their and wear. MANN+HUMMEL has developed a centrifuge for a major Air cleaner IQORON VP 25 vehicle if it has been stolen. Scandinavian commercial vehicle manufacturer which spins a Multiple functions offer advantages plastic rotor to remove these particles. The rotor is light and can be The module includes many additional functions. A connection pipe  Two-stage air cleaner for extremely dusty conditions Smart product, easy to handle environmentally disposed of. With a service life of approximately pressed into the aluminum housing forms the interface for the oil  Excellent performance thanks to innovative Using Senzit is absolutely easy. The monitor is installed directly on 100,000 kilometers the centrifuge considerably lengthens the return flow from the turbocharger through the centrifuge housing VarioPleat technology the service connection of the air cleaner housing and thanks to interval between oil services. to the oil sump. An integrated oil reservoir prevents the back flow  Short air duct through 45 degree air inlet port extensive accessories is easy to fit. Senzit functions on all terrain of de-oiled air into the crankcase ventilation system. In addition, a  Compact design saves up to 15 percent including under the most extreme conditions. Initially a retro-fit The centrifuge is fed with high pressure oil from a bypass circuit. pressure control valve reliably protects the centrifuge and other installation space solution will be available. There are already plans for the intro- When passing through the rotor body the oil escapes through two engine components against excessive pressure in the oil circuit.  Quick and easy servicing duction of a product for integration in a telematics system. At the nozzles on the underside of the rotor. As a result, the rotor is driven The integration of these functions turns the oil centrifuge into a end of 2018 the first samples will be available. at high speed without the need for an external drive. When the oil multifunctional engine interface. 12 AUTOMOTIVE news 13

Flexibility uses installation space

When the application is complex, it‘s time for Flexline. The air filter solution from MANN+HUMMEL even fits into very tight installation spaces. Mercedes- Benz is now the first vehicle manufacturer to use the innovative solution in a series application.

Mercedes-Benz A-Class with MANN+HUMMEL air cleaner system (Photo: Daimler AG)

The requirements for cars are increasing, also demanding comfort A lot of development expertise also went into the clean air duct of soft base material of the blow molded part. The engineers solved functions for small and compact cars, low emission values, and maxi- the diesel application. The clean air duct uses an injection molded this problem by improving the wall thickness at the corresponding mum performance. And as a result the number of components bellow from high temperature-resistant plastics instead of a bel- positions and created new geometries which enable a better competing for space under the hood is going up. Consequently, in- low manufactured in a blow molding process. This new innovative connection between the components. The removal of the need for stallation space is valuable and MANN+HUMMEL with Flexline now feature is a challenge in terms of production engineering, but one a welding process means that customers benefit from two ad- exploits the available installation space more efficiently. In contrast to which has decisive advantages. Up to now the thinner wall thick- vantages: higher quality and lower costs. conventional air filter elements, which mostly either have a trapezium nesses which were necessary for the flexibility of the bellows were shape, are rectangular or have a polygon shape and usually have not compatible with the required collapse robustness at negative straight sides, the rounded edges of Flexline filter elements allow pressure. Apart from that, the noise emissions increased with excellent design flexibility. This enables completely new shapes. It is the reduction in the wall thickness. The injection molded bellow, therefore possible to efficiently match the filters to the inter- however, is able to manage the balancing act between the re- ference contours in the engine compartment and perfectly exploit quired flexibility and stability and is able to reconcile the opposing the available installation space, even when this is very complex. requirements with regard to decoupling, acoustics and collapse robustness under high temperatures. MANN+HUMMEL has pro- Increase performance, reduce noise duced injection molded bellows with a thermoplastic elastomer The innovative air filter system from MANN+HUMMEL is now going (TPE) in series for a number of years. The special feature of the into series production for Mercedes-Benz. The vehicle manufacturer new bellow for Mercedes-Benz is the use of high temperature Air cleaner system with innovative Flexline solution for is using Flexline for its MFA2 platform (modular front architecture). the 4-cylinder diesel engines of the Mercedes-Benz A-Class resistant polyamide. This pushes the maximum possible appli- The air filter system celebrates its premiere in the new A-Class cation temperatures considerably upwards. and scores points on several fronts. The filtration surface area and the inflow area are enhanced thanks to perfect exploitation Sophisticated production technology Overmolded inserts for higher quality of the installation space. The result is a service life which is The air filter system for Mercedes-Benz consists of the air filter and MANN+HUMMEL also presented a special solution to Mercedes- increased by approximately 20 percent and also an improved the dirty and clean air ducts. For the acoustic damping the en- Benz for the clean air duct of the gasoline application. In order to filtration performance. Apart from that, the increase in volume gineers used an over-molded fleece material for the dirty air duct. reduce the number of welded parts, the engineers designed a is also advantageous for the acoustics. The damping is improved The porous structure enables the equalization of local pressure bracket in the form of an overmolded insert part. The challenge Compact air cleaner system for the 4-cylinder by roughly 20 percent. peaks to prevent undesired resonance in the line. here was the connection of the hard material of the bracket to the gasoline engines of the Mercedes-Benz A-Class 14 AUTOMOTIVE news 15

New state of the art: discharge is possible from below are fitted with a water drain plug. These solutions simplify servicing and reliably protect the injection water separation systems for the entire service life of the filter element. New and pioneering An openable fuel filter with aluminum die-cast housing is fitted to bigger passenger car models, such as family vehicles, sports utility vehicles and sedan cars. A technical highlight here is the so-called half-moon seal which replaces two O-ring seals which are usually used. The newly developed seal is fitted directly to MANN+HUMMEL further expands its range of fuel filters. In the new genera- the filter element and seals to the housing and the housing cover. tion of diesel engines the car manufacturers are extensively using fuel Its special design with an elliptical geometry combines a radial and filters with excellent three-stage water separation from MANN+HUMMEL. axial sealing effect. This reliably fulfills the high sealing and pres- sure stability requirements. The half-moon seal also enables a simpler and less expensive servicing. On the one hand the re- Openable fuel filter with a plastic bracket for SUVs and pick-ups duced fitting and removal forces make it easier to replace the filter element and on the other hand the service technician like fuel heating. As a result, a non-openable fuel filter is used in does not have to insert an additional seal. The design also elim- one variant with a flanged sheet metal design. The fuel filter for inates the risk of fitting the filter element without a ring seal. vans is equipped with an enlarged filter volume and a metal bracket. For the SUV and pick-up models an openable fuel filter is used With the common part strategy, the efficient and flexible fuel with a plastic bracket. Despite all the differences, the filter types filters from MANN+HUMMEL can be integrated into a number of are designed to enable them to be manufactured on the same final models in order to continue to achieve economic advantages The automotive industry certainly agrees on one point: The diesel assembly line in the Czech production plant in Okrisky. in the future. will also be an important component in the drive mix of the future. This is also the view of MANN+HUMMEL, which is further Uniformly efficient expanding its competences for diesel fuel filters. The experts at The basic design of the fuel filter elements for the separation of MANN+HUMMEL have developed a range of fuel filters for the new particles and water is the same for all filter variants. All of the generation of Ford vehicles with a diesel engine which meets the high named types are fitted with the particle filter media MULTIGRADE requirements necessary for the use of modern diesel fuel. It effi- F-MB 25 and are thus able to combine excellent filtration per- ciently protects the injection system against particles and water. formance with a high dirt holding capacity. Depending on the size of the used filter element, the fuel filter variants achieve a service Compact fuel filter for passenger cars interval of 60,000 to 80,000 kilometers. All the designs also have an electric heating system integrated in the housing cover. This For the variety of new vehicle models of an US-American car prevents a clogging of the filter media at cold temperatures. manufacturer customized solutions were developed to meet the individual requirements. In all the variants the innovative three- Just as previously, MANN+HUMMEL has equipped all of the new stage water separation is used. In addition, MANN+HUMMEL fuel filter types with high efficient three-stage water separation. established a common-part strategy to reduce complexity and This enables the separation of even the smallest water droplets costs in the production process and therefore ensures economic down to a size of 10 micrometers and a separation efficiency production. which is considerably over 90 percent – even with a fully loaded filter element until the service interval is reached. Individually equipped The numerous model variants and respective associated require- Sensors detect when the water collection bowl beneath the filter ments presented a challenge to the engineers at MANN+HUMMEL. element is full and the water has to be professionally discharged The varying amount of installation space in the models and the from the fuel circuit. Depending on the installation space situation access to the components for servicing required different housing and accessibility for servicing, the water discharge for the respec- designs. Besides, it was necessary to come up with suitable con- tive variant has a different design. Designs with access from above Fuel filter with metal bracket for vans cepts for the water discharge and to integrate additional functions are fitted with a water discharge pipe. Variants where the water Openable fuel filter with half-moon seal for numerous passenger car models 16 AUTOMOTIVE news 17 Double the Vote of confidence service life

RobustPlus is an innovative membrane material developed by MANN+HUMMEL CNHTC, the leading Chinese manufacturer of heavy duty trucks, for pressure regulation valves which sets new standards with regard to its required a stable, high performance and durable air cleaner system. chemical resistance. Just one year after its market introduction, a large series MANN+HUMMEL developed a customized solution which impresses order from an US-American manufacturer confirms the success of the solution. with maximum performance.

The requirements from the China National Heavy Duty Truck Group (CNHTC) for the air cleaner system to be used in its heavy duty The development of the RobustPlus regulation valve by trucks were a low pressure drop, excellent dust holding capacity and MANN+HUMMEL represents a pioneering breakthrough. The a long service interval. A high air flow rate of 36.7 m³/min is the membrane made from a new fully fluorinated polymer convinces reason why these requirements are necessary. The vehicles are also with an almost universal resistance to chemicals and therefore used in mines with extremely high dust levels. This was no easy task, solves the problem the automotive industry has been faced with but MANN+HUMMEL developed a system with two separate air up to now. The pressure regulation valve is resistant to aggressive filter elements and in this way fulfilled all of the requirements of acids present in combustion residues and has achieved excellent the customer.

Cylinder head cover with integrated fine oil separator and results with regard to control behavior, tightness and burst RobustPlus pressure regulation valve pressure during tests. Maximum stability Thanks to the used cellulose filter media the filter elements achieve Up to now pressure regulation valves have been a weak point for These are convincing facts for a large North American customer. a high dust holding capacity of nine kilograms of coarse dust. With the crankcase ventilation systems used in gasoline engines. The Just one year after the introduction of the product, a large series two cyclones fitted upstream the dust pre-separation is significantly limited chemical resistance of their membranes mostly made from order has been won. From 2021 MANN+HUMMEL will annually increased and in combination with the two filter elements the service fluorosilicone rubber in connection with the aggressive chemical produce 600,000 cylinder head covers with an integrated SD oil life is more than doubled even under extremely dusty conditions. substances produced in the combustion process leads to ageing. separator and RobustPlus pressure regulation valve for fitting to a Furthermore, the two safety elements protect the clean air side In particular in markets with poor oil and fuel quality this can in 1.5 liter turbocharged gasoline engine for a period of five years. against dirt particles during servicing or when a main filter element the worst case lead to the formation of cracks and ultimately the The components will be produced in two MANN+HUMMEL plants is damaged. The filter housing made from PP-GF30 was specially AIr cleaner with very high dust holding capacity for CNHTC malfunction of the valve. to serve the North American and Asian markets. developed for CNHTC and is produced by MANN+HUMMEL in China using an injection molding process. Regarding the integration of Playing safe functions, the filtration and plastics specialist also came up with an A number of other components also improve reliability. The water ingenious solution. MANN+HUMMEL designed the housing with discharge valve on the lower side of the housing prevents the numerous ribs and reinforcement elements to ensure maximum accumulation of an excessive amount of water inside the housing. stability. This includes three reinforcement rings located in the area A seal between the service cover and housing also protects against of the two air inlets and the air outlet. Additionally a rod-shaped the intake of warm air, dirt and water. Finally, mounting points Open our video on YouTube. reinforcement made in plastic supports. The rod is fixed between on three sides of the housing enable flexible mounting of the air There you can find details on the function the filter elements to both sides of the housing. A further design cleaner to the vehicle. The development at the Chinese locations of of the RobustPlus membrane. feature of the system is a gathering duct which combines the Changchun and Shanghai and the local production enabled an RobustPlus pressure regulation valve with an almost universal resistance to chemicals cleaned air from the elements and directs it to the air flow meter. excellent cooperation between CNHTC and MANN+HUMMEL. 18 AUTOMOTIVE news 19

Systems competence for commercial vehicles 1

The trucks of Indian commercial vehicle producers have to with- stand a lot, including unsurfaced roads, high dust levels and high humidity. The air cleaner system from MANN+HUMMEL makes sure that they can reliably master these conditions. 5

4 2

Robust air cleaner system for humid and dusty conditions 3 1 Dirty side duct made of plastic and rubber with water separator and drain valve 2 Air cleaner housing with integrated dust pre-separator 3 Dust outlet valve 4 360 degree mounting bracket 5 Clean side duct made of plastic and rubber

In addition, the air cleaner housing was complemented to include filtration performance and an extended service interval. The vehicles driver about the ideal time for a service. The customer is im- a component to fit the customer specific assembly. This is a produced by Indian manufacturers are mainly on the road in countries pressed by the low pressure drop and large dust holding capacity mounting bracket around the housing which enables fitting of with humid and warm climates. Therefore it is essential to protect of the MANN+HUMMEL air cleaner system. Used in commercial the air cleaner in any required position. In order to avoid problems the filter element against humidity especially with a front air intake. vehicles the air cleaner system offers a long service life under caused by high dust levels, a pre-separator has been integrated in A water separator integrated in the dirty air duct of the system extreme conditions – at low costs. The excellent cooperation offers the air cleaner. This separates coarse particles from the air flow provides the necessary protection. The inflowing air is deflected by potential for further common projects. already upstream of the main filter element and therefore extends 90 degree. In this process the water droplets hit the inner wall of its service life. The intelligent integration of the pre-separator in the duct to form a film of water. The water collects in an area with the housing means that no additional installation space is required. reduced flow and is removed from the system via a water drain MANN+HUMMEL air cleaner for Ashok Leyland That saves money as well as components. Metal clamp fasteners valve. As a result, only dry air reaches the filter element and the Advantages at a glance hold the parts of the air cleaner housing and filter element to- maximum filter performance is maintained. The dirty air duct is It is difficult to imagine Indian roads without the buses, vans and gether free of vibration and enable easy servicing. made from plastic and elastomer components. This combination trucks produced by Ashok Leyland. The company is the second of materials and numerous ribs provide the required stability to  Use of many standard components reduces costs largest producer of commercial vehicles in the country. Now for the Environmentally friendly and reliable counter the effects of vibrations.  Mounting bracket allows 360 degree mounting first time, for its high performance trucks, Ashok Leyland will use an The filter element has a cellulose filter media with a high dust hold-  Integrated dust pre-separator in the air cleaner housing air cleaner system from MANN+HUMMEL which the filtration special- ing capacity. The safety element made from a non-woven fabric Flexible and stable  Water separator in dirty air duct to protect ist has developed and produces locally in Bawal. A special point here protects the clean air side during servicing or when the main filter is The engineers also pursued a similar strategy with the clean air the filter elements is that in order to keep costs low the engineers used many standard damaged. Both elements do not require metal elements to make duct. Elastomer parts with numerous ribs compensate engine  Low pressure loss and high dust holding capacity components for the air cleaner. Only the dirty air and clean air ducts recycling easier and protect the environment. The pleats of the movements and simultaneously withstand negative pressure of the complete system are individually adapted to the requirements of the customer. main filter element have an efficient design to enable maximum and high temperatures. A mechanical service display informs the 20 AUTOMOTIVE news 21 Perfect

Costs which pay off The new concept was validated through direct comparison with a fuel filter module for a 13.0 liter commercial vehicle engine. For this connection purpose samples in aluminum and also in the new plastic- aluminum hybrid design were tested on the test bench. The results were impressive. In particular in tests seen as very critical such as with high temperatures and alternating pressure loads or burst pressure strength the hybrid component achieved the same or better values than the aluminum housing. Experts involved in the development of basic concepts, processes and series pro- jects at MANN+HUMMEL have successfully developed and tested an innovative The plastic-aluminum hybrid design can be seen as a real alter- native to conventional aluminum solutions. In order to achieve a plastic-aluminum hybrid design for liquid filter modules used in trucks. cost advantage, a number of conditions have to be met, for example, with regard to volume, design suitability for plastic and Designs for hydraulic connections with a quick connector molded on the module or distribution channel the necessity for machining. The additional tool required for the insert leads to higher costs. With higher volumes these costs are In component areas where there is a high stress load such as better distributed and as a result the hybrid concept can be de- flange joints or cover threads the metal absorbs and distributes scribed as economic. In addition, the maintenance of component the high local mechanical forces. This enables the component cleanliness with aluminum housings is more cost intensive than to withstand the respective load at these points. The housing with the hybrid module. If the insert and plastic remain unpro- envelope in plastic allows the easy integration of functions. cessed, this enables a reduction in costs.

Complex design The long-standing experience in the design of complex, highly- The design of the component with this hybrid concept turned out stressed plastic components over many years and expertise in the to be complex. The aluminum framework, the so-called insert, has conception of injection molding tools enables the specialists at to absorb any forces which arise and transfer these through the MANN+HUMMEL to draw up a robust hybrid component which is interlocking of the plastic and aluminum. In this process stress able to meet the high requirements for commercial vehicles and peaks are to be avoided which could lead to a damage of the is also economic. The first definite projects are currently being material. At the same time the insert has to be designed for the developed. subsequent overmolding process and has to be able to be reliably fixed in the injection molding tool so that the overmolding process Concept of the hybrid fuel filter module for a commercial vehicle application does not result in any deformation. Preliminary tests showed that given the different thermal expansion coefficients of the materials Plastic has proven itself over many years as a versatile material it is not possible to achieve a permanently sealed connection suitable for use in a wide range of applications in commercial between the aluminum and plastic. In the contact area a tight vehicles and motor cars. There are limits, however, to the appli- ‘We are always connection between the aluminum and plastic cannot be ensured cation of plastic in areas where components are subject to high working to inspire permanently. Therefore the developers designed all of the areas thermal or mechanical stress since the relevant plastics can only with contact to the media in plastic. achieve a certain strength and rigidity. Whereas MANN+HUMMEL our customers introduced the world‘s first plastic oil filter module for cars in 2003, The polyamide used for the plastic envelope has a number of for reasons of stability filter modules in aluminum continue to be with cost-effective advantages with regard to flexibility. Although a die-cast process used in commercial vehicles. The specialists at MANN+HUMMEL and innovative with multi-part tools can be used to achieve complex geometries, looked for an alternative and developed a solution which also has the production of a functional liquid filter module requires the the robustness required for these applications. solutions.’ subsequent machining of threads, sealing surfaces and hydraulic connections. This involves additional machining processes and Best of both worlds high costs to be able to ensure the required degree of component The aim of the developers was to combine the mechanical strength Dr. Pius Trautmann, cleanliness. The injection molding of a plastic part on the other of aluminum with the design flexibility of plastic. The solution is Director Engineering Liquid Filter Systems hand enables the creation of all of the required connections and an aluminum framework which is enclosed by a plastic envelope. Heavy Duty & Industrial threads directly in the mold. Sample of a hybrid fuel filter module produced in transparent plastic 22 AUTOMOTIVE news 23

Fully integrated for maximum efficiency

For its new generation of 4- and 6-cylinder gasoline engines with indirect charge air cooling, the BMW Group has opted for intake manifolds from MANN+HUMMEL with a fully integrated cooler.

Fully integrated indirect charge air cooling – firmly enclosed by the plastic half shells by means of hot gas welding

The indirect charge air cooling offers a number of advantages. Its With a temperature difference of less than three Kelvin over four re- function is more constant and effective than direct charge air spectively six cylinders, the system also enables an excellent uniform cooling and reduces CO2 emissions by up to three percent. In temperature distribution. It is also remarkable that the whole system addition, the working principle enables a reduced charge air has to withstand high temperature differences of up to 150 Kelvin volume and therefore a faster buildup of boost pressure which between the air inlet and outlet. Absolute manifold pressures of up improves the responsiveness of the engine. to three bar and the large areas of the plastic shells required by the cooler lead to a high load on the intake manifold. With the aid of The MANN+HUMMEL solution fully exploits these advantages. simulations, internally produced prototypes and intensive testing, The indirect charge air cooling is integrated in the intake manifold the specialists at MANN+HUMMEL perfectly designed the com- and goes one step further. In contrast to conventional screw-in ponents. Special cambering and selective ribbing ensure the MANN+HUMMEL intake manifold for the 3.0 liter solutions the cooler is completely encapsulated by the shells of highest stability and also reduce weight at the same time. inline 6-cylinder turbo gasoline engine of the BMW Group the intake manifold which allows the whole system to impress with MANN+HUMMEL intake manifold for the 2.0 liter its high stability without the need for external sealing surfaces. 4-cylinder turbo gasoline engine of the BMW Group The design also focused on an ideal air flow. The consistent filling of the cylinders is maintained by a plenum design improved by High requirements computational fluid dynamics which also leads to a lower pressure Advantages at a glance The BMW Group was looking for a solution for its 4- and 6-cylinder the cooler and intake manifold shells to meet the requirements loss. The joining of the components using hot gas welding enables gasoline engines which is able to withstand the high system loads with regard to chemical resistance and low leakage values. The narrower and stronger weld seams. The advantages of the com-  Minimum number of components with regard to boost pressure and temperature differences in the double lip seal made from ethylene acrylate elastomer is able plete solution supplied by MANN+HUMMEL with its customized  No external cooler sealing component. The engineers at MANN+HUMMEL managed this to compensate high tolerances while simultaneously remaining design impressed the BMW Group. The vehicle manufacturer uses  High mechanical stiffness of the system challenge with the aid of modern simulation technology, expertise dimensionally stable. The cooler and intake manifold positively the new solution in its 4- and 6-cylinder gasoline engines with  Excellent uniform temperature distribution and know-how. The engineers used a special bypass seal between lock in order to firmly and securely join them together. longitudinal installation. 24 AUTOMOTIVE news 25

Next generation of 5 intake manifolds 6

4 7 The engines of today have to generate lower emissions and offer higher performance. MANN+HUMMEL supports its customers here with a new intake manifold which integrates numerous functions. 3

1 2 The requirements which modern engines have to fulfill are extremely also serve to generate controlled turbulence of the air when it demanding. They should generate fewer emissions under real driving flows into the cylinders. Both measures are designed to improve conditions and at the same time have a higher performance. There- the combustion process in the engine and reduce fuel consumption Sectional view of the active intake manifold with dual integrated fore it‘s a good thing that the specialists at MANN+HUMMEL have and therefore also CO2 emissions by up to three percent. A self- intercooler and water injection system developed a suitable solution. An active intake manifold which in- regulating bypass flap with two charge air ducts between turbo- cludes the complete intake section from the turbocharger to the charger and electric booster compressor also improve low-end cylinder head with a two-stage, indirect charge air cooling and a torque, i.e. providing of torque in the low rpm range. The complete 1 Charge air duct (hot side) with AgileJoint element for tolerance compensation water injection. This contributes to ensuring that engines also system also includes the charge air ducts from the turbocharger to 2 Stand-alone indirect charge air cooler as pre-cooler meet future emission regulations such as the Euro 6d standard. the pre-cooler and from there to the intake manifold with main 3 Charge air duct (cold side) with AgileJoint element for tolerance compensation Apart from that, the flexible arrangement of the components in cooler. They are equipped with AgileJoint connections which 4 Self-regulation bypass flap with two ducts to the electric compressor or second turbo charger the system offers considerable design flexibility. enable the required tolerance compensation. On the hot side the 5 Self-containing indirect charge air cooler as main cooler (connected to low temperature cooling circuit) duct can also be fitted with an optional broadband silencer to 6 Water injection system with plastic water rail and inline water filter (optional) Next development stage eliminate undesired noise. 7 Intake manifold module including tumble flap system with electric plug-in actuator In 2015 MANN+HUMMEL presented an active intake manifold with fully integrated charge air cooling. This concept forms the basis Water injection as an option for the new system. In the new concept the pre-cooler and main The use of an optional water injection system can be used to cooler are designed to be self-containing. Crimping to the reduce raw emissions, to protect components at full load and to Market success adjacent plastic components ensures the required stability. As a increase efficiency. Which of these benefits is in the foreground The new system and its components have attracted a great deal of Advantages at a glance result, costs were reduced as there is no need for a bypass seal, can be determined individually by the engine development interest on the market. MANN+HUMMEL has already been nomi- tension anchors and a welding process. The compact design also department. With this variant a water filter, water rail and injectors nated to develop an intake manifold with self-containing, indirect  Concept to achieve the future CO2 emission targets requires less installation space and reduces weight. are also integrated in the intake manifold. MANN+HUMMEL has charge air cooler and also a stand-alone, indirect charge air cooler.  Increase engine efficiency by using an transferred its experience over many decades in the area of liquid First applications for the 4-cylinder diesel and gasoline engines of integrated charge air cooler Constant cooling filtration to this new application. The multi-layer, fully synthetic European engine producers are set to enter series production from  Enhanced low-end torque with an The engineers integrated two indirect charge air coolers in the in- MULTIGRADE filter media for water injection meets all require- 2019. Customers benefit from a high performance solution with self-regulating bypass flap take system. This makes the system more compact, reduces the ments with regard to particle separation efficiency, dirt holding integrated functions as well as a reliable partner with a global de-  Optimized control of the turbulence in the cylinder charge air volume and improves engine response. In comparison capacity, chemical resistance and mechanical stability. If required, velopment and production network. MANN+HUMMEL has already by tumble flap system to a direct charge air cooling, the main advantage of the indirect an additional electric heater can be integrated into the filter planned the next development steps. Design improvements to  Higher performance thanks to water injection charge air cooling is a more constant cooling performance over housing to support the system during the defrosting process. This the arrangement of the coolers will further reduce the number the dynamic range. Robust tumble flaps in the intake manifold enables water injection to be used even at low temperatures. of interfaces. 26 AUTOMOTIVE news 27

3 4

One compensation element, many advantages

The AgileJoint compensation element facilitates the fitting of ducts for indirect charge air cooling. MANN+HUMMEL has now further improved this clever solution for the BMW Group. 1 2

One instead of two The plastic specialists from MANN+HUMMEL Bad Harzburg further improved the AgileJoint for the second big series application for the BMW Group. In the first variant, the male coupling consisted of two components, the actual duct and a connection piece which was welded on. In the new variant, this part is now formed directly in the plastic duct. This is made possible by a blow molding pro- cess as this process can also be used to manufacture complex duct geometries.

The use of this process, however, is a challenge. In contrast to injec- tion molding, the internal geometry is not determined by the tool. As a result, wall thicknesses can vary and lead to higher tolerances. In addition, in the blow molding process the glass fibers are mainly orientated in the direction of the extruded hose. The result is a lower mechanical load-bearing capacity in circumferential direction. Apart from that, in the area of the male connector where the parts have to withstand high forces there is a thinner wall due to the process.

Little helper 5 6 The solution is the integration of a support ring to generate the required stability. This is not just pushed in, but is pressed from the inside to the outside with the blow molded part using a crimp 1 Joint Connector: forms the female part of the AgileJoint Intelligent thermal management, maximum power and low emissions process with a segmented tool. The process takes the dimension together with the crown ring are the current requirements for modern engines. Especially in the situation of each individual component into account and in this 2 Crown ring: is pre-assembled to the male part and high-end area, the trend is away from direct over to indirect charge way reduces its oval shape and ensures a stable connection which joins a snap-fit with the female coupling air cooling. MANN+HUMMEL applies the innovative AgileJoint can also withstand the highest pull-off forces. 3 Connection piece: injection molded male part of the compensation element to charge air ducts used in indirect charge AgileJoint, welded to the actual duct air cooling. AgileJoint effortlessly compensates fitting tolerances After the successful use of the first AgileJoint variant and the 4 Charge air duct: blow molded with welding interface to or dimensional changes due to thermal expansion. In addition, it nomination for the ’Supplier Innovation Award‘, BMW Group will connection piece replaces expensive elastomer hoses which were previously used now fit the new charge air duct to its 3.0 liter inline 6-cylinder 5 Charge air duct: with connection piece blow molded for decoupling. That cuts costs and provides a weight advantage gasoline engines for the 3, 5 and 7 Series as well as X3 and X5. directly to the duct without interface

Charge air duct with AgileJoint compensation elements to manage of up to 30 percent. The solution also convinces through its easy The BMW Group again benefits from excellent fitting charac- 6 Support ring: gives mechanical strength to the mounting and thermal tolerances fitting. teristics, reduced costs and lower weight. connection and reduces ovality 28 29 Active cell WAVELOCK – protection easy to service

Fuel cell technology has enormous potential. In order to realize this poten- MANN+HUMMEL has developed a new revolutionary spin-on filter concept tial, the sensitive cells have to be reliably protected. MANN+HUMMEL has with bayonet lock. It simplifies servicing and is available as a modular now developed a cathode air cleaner to do just that. system.

The innovative WAVELOCK spin-on filter concept enables easy, quick and clean servicing. MANN+HUMMEL has, for the time being, developed the system for use in off-road applications and offers a product variant mounted to the engine and also a product variant mounted to the chassis. A key element of the design is a bayonet lock which securely joins the filter head to the spin-on filter and simultaneously simplifies servicing. When a filter change is due, the filter can be removed and refitted with an easy rotation movement and completely without the need for tools. At the same time the system can only be fitted in one way and therefore jamming is excluded. New spin-on filter concept for an easy, fast and clean service

Clean solution A further advantage is the improved component cleanliness. With lation the mechanic removes the middle part along a perforated This allows the air cleaner to separate particles and also adsorb conventional systems the thread is milled into the aluminum head. line. After that a ring remains around the edge of the component. harmful gases in order to provide the best protection for the fuel In this process minute residual particles of dirt can stick to the During fitting this serves as a seal and prevents splash water from cell. In comparison to conventional air cleaners, the media in the component and cause substantial damage on the clean side of penetrating the area between the filter head and the service part. cathode air filter element is wound around a supporting grid the filter. With the WAVELOCK solution there is no danger of this ENTARON HD 4 with cathode air filter element instead of being pleated as before. This creates space for con- happening. This is firstly because the connecting piece is not Modular system with growth potential siderably more media in the same installation area and therefore manufactured in a machining process, but is pressed. This means MANN+HUMMEL will in future offer its range of WAVELOCK spin- Cell protection helps to prevent ageing and is essential where cells increases the dust holding capacity and filtration performance. that shavings are not possible. Secondly, it is fitted on the dirty on filters as a modular system. The modular will consist of the two are exposed to extreme loads. This is true for biology and also true In addition to the standard component, the structure of the side and is not part of the flow circuit. This protects the system main assembly groups of filter head and spin-on filter. A number of on our roads. Fuel cells work in a field where if they were unpro- element can also be customized to specific customer require- against contaminants. In addition, for the purpose of reliability, the different variants are planned in the same way as practiced with tected they would soon age. Gases such as sulfur oxides (SO2), ments. A pleated activated carbon element is therefore also Poka-Yoke principle is applied during servicing to ensure that only existing modular systems which have a traditional spin-on filter hydrogen sulfide (H2S) and ammonia (NH3) are able to damage possible. the right product can be fitted. concept. Possibilities exist to produce an oil filter head, a fuel filter the low-temperature proton exchange membrane of the fuel cell. head with and without manual pump as well as a kit for engine- Without protection irreversible damage can occur. A further advantage is the quick availability resulting from the Products used in modern combustion engines and compressors mounted components. It is possible to combine these variants further development of a proven air cleaner system. The housing are subject to high requirements with regard to the pressure with numerous filter media, anti-drain membranes and bypass Custom development of proven solution remains unchanged. The air cleaner is available as a single- or stability of the filter components. As a result, they have to be able valves. The spin-on filters are currently available in size 9 and an MANN+HUMMEL knows about the sensitivity of the fuel cell and two-stage air cleaner and depending on the customer require- to reliably withstand pressures of more than six bar. That is not a extension of the modular system is planned to enable further sizes. has further developed an air cleaner from the ENTARON series ments can be fitted within a 360 degree range. For even greater problem for the new WAVELOCK filter concept. A high resistance The revolutionary filter concept has already been in operation especially for use in fuel cells. The catalog component which is cell protection an optional safety element made from a non-woven to vibration is also a must. The transportation protection cap on since the beginning of the year for a garden tractor of an US- usually equipped with a conventional filter element with a cellu- fabric is also available which ensures that the air on the clean side the spin-on filter fulfills two functions. Before installation it pro- American manufacturer. There are ongoing tests for further appli- lose media is now fitted with a new activated carbon filter element. remains clean during service. tects the connection geometry against damage. During instal- cation areas for on- and off-road applications. 30 AUTOMOTIVE news 31

Global network, Cabin air filters local production for buses and trucks

MANN+HUMMEL continues to expand its local production capabilities According to the World Health Organization, allergic diseases are among and has started production of an additional oil filter module for an US- the most common chronic diseases in the world. Biofunctional cabin air American car manufacturer's new 4-cylinder diesel engine at the Indian filters from MANN+HUMMEL ensure that the affected professional drivers location in Tumkur. can breathe in freely when they are behind the wheel.

Proximity to the customer is an important factor for success with In Europe around 60 million people suffer from allergies and this global projects. In 2016 the first oil filter module for an US-Ameri- number is set to rise. For sensitive drivers of commercial vehicles can car manufacturer rolled off the production line for the first there is an increased risk of an allergic reaction due to pollen, time at the Indian MANN+HUMMEL location in Tumkur. A second bacteria and mould fungi. Anti-allergenic cabin air filters from module now follows on the same production line. In addition to MANN+HUMMEL now also protect the affected drivers in trucks supplying the customer plant in India, the new oil filter will also be and buses. They bind allergenic substances and prevent the growth delivered to South Africa and Argentina. of bacteria and mould fungi on the filter by more than 98 percent. The new cabin air filter is already available in the independent Proven technology aftermarket in original equipment matching quality for millions of The robust die-cast aluminum housing of the oil filter module inte- trucks in Europe and selective bus applications. grates a number of essential functions for the 2.0 liter 4-cylinder diesel engine of the midsize pick-up. An oil/water heat exchanger, Good air quality at the driver‘s workplace is important to stay fit, a filter bypass and an anti-drain valve as well as a patented oil drain reduce the effects of tiredness and maintain concentration and system ensure efficient oil management. In comparison to the pre- Oil filter module for the 2.0 liter diesel engine for off-road vehicles awareness so that the risk of an accident is decreased. For this vious module, the engineers managed to decrease the pressure purpose anti-allergenic cabin air filters with their multi-layer struc- Biofunctional cabin air filter protects professional drivers drop by a third and therefore also reduce the power required to the oil filter from emptying when the engine is switched off and ture offer a solution. The particle filter layer separates coarse par- run the pump in the oil circuit. Due to the tight installation space, after the engine is restarted ensures that the oil pressure is high ticles such as dust and particles from tire abrasion and also filters The special innovative biofunctional coating has both an anti- the oil/water heat exchanger was developed with a pentagonal enough. The patented anti-drain valve enables a clean and easy nearly 100 percent of harmful fine dust particles with an aero- allergenic and antimicrobial effect. The anti-allergenic function is geometry and enables an increase in cooling capacity by more oil change. In total the system impresses with its high per- dynamic diameter of less than 2.5 micrometers (PM2.5). These small enabled by the third layer which has a natural polyphenol coating. than 30 percent. It cools the lubricating oil at high temperatures formance while being environmentally friendly. Completely free particles are approximately 40 times smaller than a human hair. Polyphenols occur naturally in many plants such as green tea, and simultaneously protects the engine against overheating. of metal, the fully incinerable filter element can be disposed of They can penetrate the lungs or even enter the bloodstream via the apples, grapes and citrus fruits and are able to bind allergens, With a high oil viscosity or blocked filter element the filter bypass after use in an environmentally compatible way. The series start pulmonary alveoli to cause cardiovascular diseases. The second rendering them harmless. An additional biostatic coating has also valve integrated in the center tube ensures that the engine re- for the oil filter module in India is a further proof of the successful layer contains activated carbon, which is derived from coconut been shown to prevent the growth of microorganisms such as ceives sufficient lubricating oil. The anti-drain valve pressed into cooperation in the global development and production network shell. This adsorbs almost all unpleasant odors and harmful gases molds or bacteria on the filter. This gives drivers excellent pro- the housing also provides protection against wear. It prevents of MANN+HUMMEL. such as nitrogen oxide, sulfur dioxide and ozone from the airflow. tection against allergens, bacteria and mould fungi. 32 AUTOMOTIVE news 33 Outstanding references

Brilliance uses the systems competence of MANN+HUMMEL in its new vehicle Zhonghua V7. The filtration specialist supplies air cleaner systems and charge air ducts.

Zhonghua V7 from Brilliance (Photo: Brilliance)

5

1 Common goal The worldwide presence of MANN+HUMMEL is an important part of its company profile. All of the steps from the development to the finished product for series production are made in the com- pany‘s global development and production network. In this pro- 4 3 2 cess, for example, Product Coaches from the respective Center of Competence support local functions and teams. The successful Charge air ducts for the 1.6 liter and 1.8 liter turbo gasoline engines: Air cleaner system for the 1.6 liter and 1.8 liter turbo gasoline engines of Brilliance approach was also efficiently applied in this project. hot side right, cold side left

1 Dirty air duct - injection molded section Local MANN+HUMMEL experts developed an air cleaner system and Filter change with a single action 2 Dirty air duct - blow molded section charge air ducts for the Chinese car manufacturer. The air cleaner sys- A special feature is the design of the dirty air duct which has a 3 Air filter element tem is produced using injection molding and blow molding tech- patent pending. It can be easily removed using a clip connection 4 Air cleaner housing nology. The air filter element offers excellent filtration performance to change the oil filter which is located underneath and facilitate 5 Clean side duct with a separation efficiency of up to 99.5 percent. In addition, the the fitting of the air cleaner system. Here one section of the Poka-Yoke design of the filter ensures that during a service the new blow molded duct is not inserted axially into its counterpart as is Good experiences get around: for the air cleaner system for a facturer had a very good experience with that project. A further filter is fitted in the right position. The engineers intensively used usually the case, but is clipped on using a semi-circular fixture. new drive based on the Prince engine developed by PSA and the positive point is that also in China closeness to the customer flow simulations to reduce the pressure loss in the system in order When changing the oil filter element the duct section can be BMW Group, the Chinese car manufacturer Brilliance decided to literally is a factor for success. The priorities of Brilliance are local to maximize engine performance. Additionally, they paid special removed with a swivel movement to allow direct access to the use MANN+HUMMEL as its supplier. Brilliance and the BMW Group competence from contact partners, quick and reliable supply attention to the acoustics and integrated broadband silencers, filter. After the replacement of the filter, the duct can be easily are joint venture partners. MANN+HUMMEL was already respon- chains and uniform quality standards. These are precisely the Helmholtz resonators and lambda quarter tubes in the injection inserted and clipped on again. The complex air cleaner project sible for the development and series production of the intake advantages offered by MANN+HUMMEL with its location at molded section of the dirty air duct. As a result, it was possible to for Brilliance is the biggest project so far in this product area at system for the European Prince engine. The European car manu- Changchun in China. considerably reduce the intake noise and improve drive comfort. the MANN+HUMMEL location in Changchun. 34 AUTOMOTIVE news 35 First-class oil separation

The success story of the innovative SD oil separator from MANN+HUMMEL continues. The product now finds application in a highly integrated module for crankcase ventilation with Mercedes-Benz.

Mercedes-Benz E-Class Coupé with SD oil separator from MANN+HUMMEL (Photo: Daimler AG)

settling chamber becomes a coarse separator. In the follow-up this that the cleaned air reaches the fresh air path against the pre- In combustion engines gases are generated during combustion pre-cleaned blowby is directed through a number of nozzles bores vailing pressure gradient. A ball-type non-return oil valve prevents which, for example, can be pressed past the piston rings into the in the SD oil separator. The narrowing of the cross section in this the bypass of blowby and the drawing in of oil from the sump. crankcase. The oil particles contained in this blowby can deposit process causes the gas to accelerate again and it impacts the If it is technically necessary the oil separator can, however, be themselves on the turbocharger, the intercooler and the inlet deflector plate with a high amount of kinetic energy. There the bypassed using a bypass valve. valves and as a result cause damage. The separation of oil droplets air/oil mix is radically deflected by the special pyramid-shaped from the blowby returned to the intake air is therefore important structure of the plate which causes even the smallest particles and also relevant for the reduction of oil consumption. Effective to coalesce, i.e. to come together to form an oil film, which then oil separation is a condition to meet the emission standards of flows back to the oil circuit. The pyramid structure of the SD modern engines and is also necessary for the protection of the deflector plate significantly increases the efficiency of the oil components of the intake system. Crankcase ventilation system for longitudinally mounted engines separator.

Clever design Firstly coarse, then fine Robust, reliable and variable The SD oil separator (structured deflection) which MANN+HUMMEL The blowby which escapes from the crankcase contains oil par- Also this new variant of the oil separator from MANN+HUMMEL presented in 2013 was and remains pioneering in terms of efficiency ticles with varied sizes. It includes visible droplets as well as convinces with its robust component concept which can find and its compact design. In 2015 the product went into series for droplets which are substantially smaller than one micrometer. The application in very small installation spaces. According to the the first time with an Indian car manufacturer. Since then the solu- challenge here is to separate all the sizes with a high level of California Air Resources Board (CARB), crankcase ventilation is Crankcase ventilation system for transversely mounted engines tion has established itself on the market. Now the component will efficiency. The MANN+HUMMEL experts solved this task by fitting relevant for exhaust emissions. The laser-welded pressure control also find application in a 2.0 liter 4-cylinder gasoline engine from the pressure control valve with the SD oil separator on the crank- valve cannot be opened without damage and therefore meets the The new crankcase ventilation system for Mercedes-Benz is the Mercedes-Benz, mounted longitudinally for models with rear case such that the cylinder head is closed by the component like a requirements of the OBD II on-board diagnostics standard. latest series product of the MANN+HUMMEL SD oil separator family. wheel drive and transversely for vehicles with front wheel drive. cover. This type of mounting creates a settling chamber between MANN+HUMMEL experts are currently working on approximately The ambitious aim of the customer here was to achieve a con- the cylinder head and SD fine separator where the blowby loses Numerous control and safety valves ensure that the crankcase ten development projects for oil separation with international car siderably greater oil separation in a smaller installation space kinetic energy. Consequently, large and heavy oil particles are ventilation works perfectly in all situations. Two non-return valves, manufacturers. As a result, many new products will enter series with less interfaces. released from the gas and can be efficiently separated. The one for the full-load and one for the part-load ventilation, ensure production in the coming months and years. 36 AUTOMOTIVE news 37

At a glance At a glance

‘Supplier of the Year Award’ ‘Regional Quality Award’ for Now fully synthetic Award for outstanding MANN+HUMMEL Thailand developments from General Motors

MANN+HUMMEL received the ‘Regional Quality Award’ from Nissan in Asia Oil filter module with fully synthetic filter media for Audi V6 diesel engines First intake manifold with fully integrated charge air cooler made by MANN+HUMMEL Presentation of the ‘Supplier of the Year Award’

MANN+HUMMEL Thailand was selected as the winner of the The continuous development and improvement of the existing MANN+HUMMEL was awarded a prize by the Society of Plastics General Motors awarded the recognition ‘Supplier of the Year’ ‘Regional Quality Award’ by Nissan in the category ‘Engine & products is necessary in order to meet the increasing market Engineers Central-Europe (SPE), the International Society for for the 26th time in April 2018. MANN+HUMMEL belongs to Drive’. With this award, Nissan values the excellent quality demands. A clear example is the oil filter of the Audi 3.0 liter V6 Plastics Technology, at the 18th Automotive Award in Düssel- the winners and received the award for the 23rd time. The performance of the plant over the last years as well as the TDI diesel engine. With the change of the filter media, the dorf-Neuss. In the category ’Powertrain’ the worldwide first intake award specifically recognized MANN+HUMMEL’s air induction strong engagement of the management team and all em- sustainability specifications are satisfied, having a great positive manifold with fully integrated charge air cooler was ranked the systems. In total 132 suppliers from 17 countries were honored. ployees of MANN+HUMMEL Thailand. The manufacturing plant impact on the product. Before this innovation, the oil filter was third place. All of them have consistently exceeded the expectations of is located in the WHA Industrial Estate of the Rayong provinces already in mass production in Ludwigsburg, Germany. General Motors, created outstanding value, or brought inno- and started production of air cleaner systems and intake The awards are presented in various categories for outstanding vations to the company. manifolds in 2014. Compared to its predecessor, this new product uses the fully developments of plastic parts for the automotive and supplier in- synthetic filter media called MULTIGRADE O-S 16.1, which makes it dustry. The criteria are the level of innovation, the quality as well The 2017 Supplier of the Year Award was received by Kai We at MANN+HUMMEL attach importance to a high quality of our more resistant to ageing. The fully synthetic media offers further as the design’s compatibility with regards to material and speci- Knickmann, General Manager Automotive Original Equipment products that means to have a daily focus on our target to deliver advantages: The increased mechanical stability by a drainage grid fication. Numerous MANN+HUMMEL products have already re- and Industrial Filtration at MANN+HUMMEL, in Orlando. ‘Our perfect parts in order to avoid customer complaints. As a result, reduces the differential pressure, especially during cold start of the ceived awards in previous years. ‘The development was a big teams are incredibly proud of this and see it as validation of MANN+HUMMEL belongs to the top suppliers of Nissan in Asia. engine. Besides, it is insensitive to water ingress into the oil and in- challenge, which could only be handled thanks to an excellent the way in which we work’, says Knickmann. ‘During our long This award confirms our approach and is a motivation to main- creases the element’s resistance. Therefore, premature or frequent cooperation across all functions internally and at our customer.’ decades of partnership with GM, we have never failed to im- tain our high quality standards. opening of the filter bypass is prevented. As a result, the reliability of Heinz Bühl, Vice President Intake Manifold Systems, honored press with our innovative technology and the unwavering the oil filtration increases and achieves a maximum wear protection. the team‘s success. premium quality of our products.’

MANN+HUMMEL offers various filtration solutions to reduce fine dust emissions. Finedusteater.com Globally successful Pioneering filtration

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