At the IAA Transportation 2024 in Hanover, MAHLE introduced a groundbreaking bionic high-performance fan designed to make commercial vehicles significantly quieter, particularly those with fuel cell and battery electric systems. Inspired by the noise-reducing wings of owls, one of nature’s quietest birds, the fan’s blades were optimized using AI to cut fan noise by up to 4 dB(A), effectively halving sound output. This innovation addresses the challenge of loud fan noise in e-mobility, particularly during nighttime charging in noise-sensitive areas. The fan also boasts enhanced efficiency, with a 10% improvement in performance and a 10% reduction in weight compared to conventional designs. MAHLE’s bionic fan is not limited to commercial vehicles; it is also adaptable for passenger cars, marking its public debut at the IAA Transportation. The company is already testing prototypes with various manufacturers.
MAHLE’s innovative approach extends beyond the fan to other vehicle components, all designed with bionic principles for optimal efficiency and reduced weight. The fan cover and carrier, for example, are over 10% lighter while offering increased structural integrity. MAHLE’s exhibit at the IAA highlights its systemic approach to fuel cell trucks, featuring a fully functional fuel cell, thermal management systems, and a heavy-duty electric axle. Additionally, MAHLE is showcasing a new evaporative cooling system for fuel cell vehicles, which improves cooling capacity by up to 50 kW, reducing hydrogen consumption by up to 1.5%. Through these advancements, MAHLE continues to lead in the electrification of mobility, integrating thermal management and electrification to create innovative solutions ready for mass production.
