At the 2024 IAA Transportation trade fair, scheduled for September 17–22 in Hanover, Mahle will introduce a world first: a bionic high-performance fan that dramatically reduces noise levels in commercial vehicles.
The fan was designed for fuel cell and battery electric vehicles that have specific requirements. The Mahle engineers were inspired by an owl’s wings when they optimized their ventilation blades using AI: The owl is one of the world’s quietest birds, and its feathers muffle noise. The truck’s fan noise can be cut by up to 4 dB(A) with the bionic fan blades, which is more than half the output. This substantial reduction addresses another issue with e-mobility: strong fan noise, which can be annoying when the vehicle is fully loaded or charging at night in residential areas or while it is stopping at a service station.
Because of its 10% improved performance and 10% lighter design, the fan is also much more efficient than traditional models. Additionally, MAHLE permits its revolutionary bionic fan to be used in passenger cars. At the IAA Transportation, the company is introducing the product to the general public for the first time. The commercial vehicle trade fair is scheduled for September 17–22, 2024, in Hanover, Germany.
“Nature teaches us many things and inspires us in numerous ways! Our bionic battery cooling plate, a technique that greatly aided us in fan optimization, has already shown results. We examined the distinguishing qualities of swordfish, bats, and numerous other natural inspirations with the aid of artificial intelligence. Ultimately, we decided to use the owl—the silent hunter—as the primary model for our new fan,” said Uli Christian Blessing, Head of Development Thermal Management at Mahle.
The fan blades’ design was inspired by the wings and feathers of owls. By doing this, the fan becomes considerably quieter and more efficient while also minimizing noise turbulence. “It is possible to compare our fan’s ability to reduce noise to that of shutting off a stereo speaker,” Blessing said.
The new bionic high-performance fan excels in noisy environments in particular. For instance, lower noise levels during vehicle rapid charging improve comfort for both locals and drivers. Mahle provides a wide range of power options for the fan, ranging from 300 watts to 35 kW. This makes it possible to employ it in big, especially temperature-sensitive fuel cell trucks, as well as tiny electric passenger cars. Manufacturers of commercial vehicles and passenger cars are currently testing the initial prototypes.
Mahle also created the fan cover and carrier using bionic concepts in order to reduce weight even further. Both components have improved structural integrity and are more than 10% lighter as a result.
Thermal management, or heating and cooling, and electrification are closely related concepts. Effective thermal management is a prerequisite for effective electrification. Mahle is one of the few international suppliers working in both industries, utilizing its superior knowledge to create technical solutions for all drives.
This September, attendees at the IAA Transportation in Hannover can get a closer look at the fan. It is a component of an exhibit ensemble that illustrates the fuel cell truck’s systematic Mahle method. It includes a heavy-duty electric axle, thermal management (fan and battery cooling), and fuel cell peripherals in addition to a fully operational fuel cell. Within the e-axle, a demonstrator, MAHLE has incorporated two of their SCT electric motors (with a combined power of 520 kW) and a full liquid management system in a compact manner. After development and testing, each of these products is prepared for mass manufacturing.
