In focus - Startseite | MANN+HUMMEL€¦ · Filtration competence for e-mobility For some people...

AUTOMOTIVE newsNo. 2/2018

Digital air cleaner monitorfor predictive maintenance

THE MANN+HUMMEL CUSTOMER MAGAZINE

Cost-effective plastic-aluminum hybriddesign for liquid filter modules

Innovative air cleaner with Flexline technology for Mercedes-Benz

In focusNext generation of filtration

Contents

We are ready for the future. Because with the next gen-eration of filtration products and technical plastic parts MANN+HUMMEL is set to actively shape the mobility of to-morrow. This is what you will see in this issue of Automotive News, which includes products for current challenges as well as future-oriented technologies.

We present new products in the area of alternative drives, digitali-zation and clean mobility. The cathode air cleaner for fuel cell vehicles, the digital air cleaner monitor Senzit or the WAVELOCK spin-on filter concept are just three examples of our extensive development expertise. But as the future always begins with the present, our focus is of course primarily on the current challenges of our customers.

Our strength of being able to recognize these challenges, to find tailor-made solutions and at the same time to think about the further development for future applications is reflected, for example, by our series intake manifold with fully-integrated, in-direct charge air cooler for the BMW Group (page 22). On page 24 you can read about how the further development of the current solution helps engines meet the stricter emission regulations of the Euro 6d standard. A further example is our air cleaner

with Flexline technology for Mercedes-Benz. Thanks to perfect exploitation of the installation space, the filtration surface area and inflow area are enhanced compared to a rectangular filter element fitted in the same space (page 12).

We are also currently facing political and economic challenges. These are reflected in the operating profit of the first six months of the year. Sales revenue is slightly lower than the level of last year. From past experience, however, we know that the second half of the year at MANN+HUMMEL is stronger than the first half. Therefore, we are looking forward to the future with optimism.

We are well prepared to do so: our extensive know-how enables us to come up with solutions across different industries and then to match these down to last detail to the application requirements of our customers. As put clearly in a nutshell by Harald Späth, Vice President Global Sales Heavy Duty & Industrial, in an interview on page 6, the maxim „One size fits all“ doesn‘t apply to us! However, „all in one“ is indeed possible with the whole range of subjects for modern filtration available in a single magazine. Therefore I wish you lots of fun reading.

Your Kai Knickmann

Dear Business Partner,

IMPRINTMANN+HUMMEL Automotive News; [email protected]: MANN+HUMMEL International GmbH & Co. KG, 71636 Ludwigsburg, GermanyResponsible in terms of German press law: Harald Kettenbach; Editor: Birgit Herbst, Lisa BürkleLayout: Ralph Dodel Grafikdesign, 73066 Uhingen, GermanyProduction: Gmähle-Scheel Print-Medien GmbH, 71336 Waiblingen-Hohenacker, Germany

Filtration competence 4 for e-mobility Expansion of the filter media portfolio for alternative drives

‘One size fits all’ 6 does not exist with usHarald Späth talks in an interview about the Heavy Duty & Industrial sector

Senzit – 10 intelligent air cleaner Digital air cleaner monitor for predictive maintenance

High performance 11 centrifuge Extended oil change interval and easy service

Flexibility uses 12 installation spaceInnovative air cleaner with Flexline technology for Mercedes-Benz

New state of the art: 14 water separationEfficient fuel filters with three-stage water separation

Vote of 16 confidence First series order for a cylinder head cover with RobustPlus pressure regulation valve

Double the 17 service lifeHigh performance and durable air cleaner system for CNHTC

Systems competence 18 for commercial vehiclesAir cleaner system offers trucks from Ashok Leyland maximum filtration performance

Perfect 20connectionCost-effective plastic-aluminum hybrid design for liquid filter modules

Fully integrated 22 for maximum efficiencyIntake manifold with fully integrated charge air cooling for the BMW Group

Next generation 24 of intake manifoldsNew concept with numerous integrated functions

One compensation element, 26 many advantagesAgileJoint compensates mounting and thermal tolerances

Active 28 cell protection Cathode air cleaner for use in fuel cells

WAVELOCK - 29 easy to serviceRevolutionary spin-on filter concept simplifies the filter change

Global network, 30 local productionAdditional oil filter module produced locally in India

Cabin air filters 31 for buses and trucksCabin air filter for more protection against allergens, mold and fine dust

Outstanding 32 referencesComplex air cleaner system and charge air ducts for Brilliance

First-class 34 oil separation Innovative SD oil separator finds application by Mercedes-Benz

At a glance 36

2 3AUTOMOTIVE news

Filtration competence for e-mobility

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 friendly. MANN+HUMMEL is open to all options and selectively develops products which support emission-free mobility.

whereby the heat distribution has to be as homogeneous as possible. High, inconstant temperatures lead to a loss of storage capacity and therefore to a reduced range for the vehicle. Ex-treme overheating of the battery pack can even lead to a thermal runaway resulting in the complete destruction of the system.

Heat is also the core issue with fuel cell electric vehicles. In contrast to batteries, fuel cells are not used for energy storage, but for the purpose of conversion. The energy is created through the reaction of hydrogen carried in the fuel cell tank with atmospheric oxygen. Water vapor forms through catalysis. In this process, energy and also heat is generated. It is possible to extract the heat from battery packs and fuel cell packs by means of indirect cooling realized with cooling channels filled with a mixture of water and glycol. However, it is also possible to directly cool individual battery cells using non-conductive media. In this respect, specially developed cooling oils can ensure uniform heat dissipation. For both methods it is essential to make sure that particles in the cooling liquid do not block the fine cooling channels, or contribute to increased wear of the pump.

Designed to reduce differential pressureThe MULTIGRADE eM-CO filter media developed by MANN+HUMMEL especially for use in battery electric vehicles meets the require-ments with regard to lower differential pressure and higher dirt holding capacity. The fully synthetic media offer a high chemical resistance to the low viscosity oils and dielectric fluids used in battery electric vehicles. The mechanical stability of the filter ele-ment is ensured by a drainage grid on the clean side which serves to maintain the ideal distance of the pleats. As a result, the whole filter surface is permanently available for use. This leads also at low temperatures and high flow rates to a low differential pressure. The filter media class MULTIGRADE eM-CO with a separation efficiency of 99.5 percent currently covers particles in the range of 50 to 180 micrometers.

The MULTIGRADE eM-CW filter media class is also efficient when used for the filtration of water-based cooling liquids which find application in the thermal management of fuel cell packs. Due to the fact that flow rates of up to 15,000 liters per hour are required for the purpose of cooling, the filter element has to be stable under pressure and also designed to reduce differential pressure. A stainless steel grid ensures that the filter element is characterized by excellent mechanical stability. The selection of appropriate materials for all components reduces the washing out of ions (dissociation or ion discharge) to a minimum and therefore helps to protect the fuel cell against a loss in performance. The MULTIGRADE eM-CW 180 separates 99 percent of all particles from the size of 180 micrometers.

Challenges and successIn order to bring these new, pioneering filtration solutions to the market, new test benches have to be set up and new test methods have to be developed. Here MANN+HUMMEL can draw on its decades of ex-pertise and quickly create the conditions to already test products during the development stage under conditions which are close to series conditions. In 2017 the first prototypes with MULTIGRADE eM-CW were delivered to customers to enable validation tests on a test bench with virtually field conditions. The filters are currently undergoing vehicle tests for the filtration of cooling oil used to cool battery cells. MANN+HUMMEL has already won series orders for both filtration applications. In addition to the discussed cooling applica-tions the media class MULTIGRADE eM-CO has been successfully tested for its use in e-Axles and is currently in vehicle testing.

Even though more and more European and Asian countries have announced their plans to slowly phase out combustion engines, there remains uncertainty about the alternatives. In addition to the purely battery-powered approach, there are also electric hybrid concepts such as 48 volt hybrids, mild hybrids and full hybrids, which are included in the focus of the development activities of vehicle manufacturers. In purely battery electric vehicles (BEV) the drive energy is derived from the battery cells carried on-board, whereas with fuel cell electric vehicles (FCEV) the drive energy is generated on-board from hydrogen. Both approaches have one thing in common: they require customized solutions for the respective requirements with regard to thermal management and the efficient filtration of cooling circuits. MANN+HUMMEL has now extended its existing range of filter media to include electric mobility (‘eM’) with MULTIGRADE eM-CO and MULTIGRADE eM-CW for the filtration of coolants based on oil and water in battery electric vehicles and fuel cell electric vehicles.

It‘s all about coolingThe requirements for new drive concepts with regard to thermal management are very challenging. The lithium-ion cells used in battery electric vehicles which have a high storage capacity can only be operated within a strictly limited temperature range,

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

Life time +Depth filtration for high dust holding capacity

System security +Filter media without bypass for fast and permanent particle separation

Energy efficiency +Gradient structure and drainage grid for low differential pressure

Structure of the new filter media class MULTIGRADE eM with drainage grid

MULTIGRADE eM-CO filter media portfolio for different customer needs

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MULTIGRADE eM-CO 140MULTIGRADE eM-CO 50

MULTIGRADE eM-CO 180MULTIGRADE eM-CO 100

4 5AUTOMOTIVE news

Mr. Späth, you have already had several management roles at MANN+HUMMEL. What‘s the difference between those previous positions and your current position?

There is tremendous range in the area of Heavy Duty & Indus-trial (HD&I) and that‘s exciting. We have reorganized the original equipment business unit. It comprises the automotive and in-dustrial filtration business. Here we have combined the com-mercial vehicle and industrial business in the so-called HD&I segment. The industrial area is very heterogeneous. In a global market environment, we operate in a wide variety of industries and work with customers who only have local operations as well as customers who are global players. The applications are broadly diversified including railway, marine, machine tools, compressors, industrial engines, and also agricultural and construction machines or even special applications such as dust filters for industrial smoke detectors or garbage trucks for the protection of workers and the environment. However, in the commercial vehicle business the processes are com-parable to the passenger car business and although we have to deal with a lower number of customers, these customers have a global presence. We want to understand all our customers, meet their requirements and hence offer them the best possible service.

‘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, Vice President Global Sales Heavy Duty & Industrial

‘We are currently working intensively

on how we can make our products more

intelligent.’

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

What are the advantages of the restructuring in the HD&I sector?

I can best explain that with an example: In relation to filtration tech-nology, when a vehicle drives on the street, meaning on-road, this is comparable to when a vehicle drives three meters away from the road meaning off-road. In both cases there is a requirement for all kind of air and liquid filtration. Naturally there are differences, for example, in terms of volume demands. In the industrial filter busi-ness these are usually lower. Accordingly, completely developed standard products find application. For our truck customers, on the other hand, we mainly offer customized solutions. But the great thing is that due to interconnections in the new area we are perfectly able to combine viewpoints, market requirements and our experience. This allows us to benefit from synergies and as a result become quicker. That is an important advantage for the customers.

How can this advantage actually be exploited?

There is a very good example. In the automotive area many manu-facturers have been working for some time with so-called platform strategies. These concepts have now found their way to the areas of construction and agricultural machines. Here we can draw on sound expertise and efficiently support customers with their strategies, in the ideal case from early on in the development process.

And how can commercial vehicle customers benefit from industrial know-how?

If we can successfully define our standard products so that they are also suitable for their applications, commercial vehicle manu-facturers will also benefit. We have economies of scale and the products are available at short notice. In the field of commercial vehicles there are also applications which are very suitable for standard products. In particular, a dedicated development process is not economically viable for niche applications. When the tech-nology is comparable, we can ideally exploit synergies because we have integrated the responsibilities in a single team. But one thing is important for me here: despite this, we must not lump every-thing together. There is no ‘One size fits all’ with us and something which works for one customer may be the wrong solution for the other customer.

What competition do we have in the HD&I sector?

We are operating in a highly competitive market environment. There are competitors with a global presence such as ourselves. But there are only a few who are able to serve all the markets and with the kind of wide product range we have at our disposal. Based on our vision of ‘Leadership in Filtration’ we want to offer innovative and competitive filtration solutions with a corresponding added value to our customers.

6 7AUTOMOTIVE news

Where do you see opportunities for growth?

We see clear potential for growth in all areas. This includes on-road, off-road and also industrial applications. There are many varied applications for our products at a global level in all markets and market segments. We currently also take regional drivers of growth into account. China, for example, is currently introducing new emission control legislation, the so-called China 6. This will necessitate the development of new engines and accordingly the requirements for many components will increase. The expectations with regard to filtration will also correspondingly increase. Drawing on our experience and com-parable products from other markets we can efficiently support our customers and grow together with them – in Asia, in America and also in Europe.

What are the challenges dealing with different regions?

Naturally, we cannot implement a global strategy and think that something which is successful in Europe will automatically be successful in America and Asia. Each market has its own challenges. We must always consider the respective competi-tive environment and local legislation and align our strategy to the region or the respective country. To lump everything to-gether in Asia would also be a mistake. This is because India cannot be compared to either Japan or China.

Which general trends do you see in the HD&I sector?

Our customers are very interested in alternative drives. They also have to react to current topics such as the air pollution in cities by considering the use of clean drive technologies. Commercial vehicle manufacturers have started to present vehicles with an electric drive and also the first agricultural machines with an electric drive have been presented. We are developing new pro-ducts to take these trends into account. At the International Motor Show in Hannover in 2018 we will present coolant fluid particle filters, venting units for high-voltage battery systems, and cathode air cleaners for fuel cells.

What role does digitalization have to play?

A very big one! Digitalization in all forms is a trend. For example, let‘s take the area of agricultural machines with autonomous driving and control systems. We are currently working intensively on how we can make our products more intelligent to allow them to communicate with other products in future. With the smart device called Senzit we launched a retrofit solution last year. This digital product measures amongst others the condition of the air cleaner and predicts when the element will have to be replaced. The next step will be to develop smart products such as this for original equipment manufacturers in the HD&I area. Here we will also involve external specialists to consider together how the

filtration product of tomorrow will look like and develop a cor-responding business model. We are currently conducting detailed market research and are engaged in discussions with all our cus-tomers to understand the direction in which they are thinking. This is very exciting because customers are also undecided about how to proceed. There is a lot here which is uncharted territory. And we are confronted with completely new questions such as how to handle the data which is collected.

But you are also prepared to enter uncharted territory with new products such as the fine dust eater …

Absolutely! Fine dust pollution is a big problem and with our fil-tration products we can also make a positive contribution here. In all the areas of on-road, off-road and industrial applications we can offer new solutions to reduce fine dust levels. That also includes our brake dust particle filter. This product has sparked a high level of interest with on-road and also off-road customers. But I am also convinced that we can further develop our existing range of products with intelligent solutions.

Which solutions are you thinking of?

WAVELOCK is such a product. This product has already received an innovation award from John Deere, a leading manufacturer in the area of agricultural machines. For this concept we further developed a spin-on filter which has been in series for many years. Now we no longer attach the filter to the engine block via a thread, but instead use a bayonet lock. The system has a really simple function: Using the bayonet connection, tools are no longer needed to remove and install the filter. Another key feature is that we pre-fill the oil filter with oil so that during the filter change a part of the oil is also changed. This removes the need for an oil change. And it just takes 30 seconds. A second example is the new VarioPleat air cleaner concept. Thanks to production technology which is unique in the world, filter pleats can be produced to different heights to enable the ideal exploitation of the available installation space. These examples impressively illustrate how excellent engineering expertise can be used to introduce new ideas into so-called mature products.

Harald Späth explains the trends in the Heavy Duty & Industrial sector

Harald Späth, Vice President Global Sales Heavy Duty & Industrial

Professional profile

Harald Späth studied mechanical engineering and industrial engineering. He joined MANN+HUMMEL in 1995 and his positions included seven years as Vice President Global Sales and Project Management for the passenger car sector. After his position as Managing Director of MANN+HUMMEL in England he took on responsibility for global sales for the industrial filter business at that time. In September 2017 he was appointed Vice President Global Sales for the restructured area of Heavy Duty & Industrial.

8 9AUTOMOTIVE news

High performance centrifuge

Oil centrifuges separate soot particles from engine oil to reduce engine wear. The system developed by MANN+HUMMEL with a plastic centrifuge can do more. It simplifies servicing, lengthens service intervals and integra-tes further important engine functions.

Soot particles penetrate the lubrication film and increase friction and wear. MANN+HUMMEL has developed a centrifuge for a major Scandinavian commercial vehicle manufacturer which spins a plastic rotor to remove these particles. The rotor is light and can be environmentally disposed of. With a service life of approximately 100,000 kilometers the centrifuge considerably lengthens the interval between oil services.

The centrifuge is fed with high pressure oil from a bypass circuit. When passing through the rotor body the oil escapes through two nozzles on the underside of the rotor. As a result, the rotor is driven at high speed without the need for an external drive. When the oil

passes through the high speed rotor the resulting centrifugal forces ensure that particles are deposited in layers on its interior wall. The cleaned oil then flows back to the oil circuit.

Clean service from belowAnother highlight of the system from MANN+HUMMEL is the plastic cover screwed into the housing from below. Incorporated is an intelligent drain system to prevent oil spillage during service. This allows the rotor to be changed from underneath and enables a clean service. A mounting aid ensures the correct positioning of the new rotor.

Multiple functions offer advantagesThe module includes many additional functions. A connection pipe pressed into the aluminum housing forms the interface for the oil return flow from the turbocharger through the centrifuge housing to the oil sump. An integrated oil reservoir prevents the back flow of de-oiled air into the crankcase ventilation system. In addition, a pressure control valve reliably protects the centrifuge and other engine components against excessive pressure in the oil circuit. The integration of these functions turns the oil centrifuge into a multifunctional engine interface.

Service-friendly centrifuge with plastic rotorSenzit fitted to IQORON VP 25 air cleaner with VarioPleat air filter element

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 smartphone or tablet. This means that information on service-relevant factors such as load status or remaining service life of the filter element is available at any time. Senzit determines this information from numerous sensors which measure vehicle data and the ambient conditions. That simplifies the planning of maintenance times and protects against unplanned machine downtimes. This clever solution changes conventional filters into smart products and enables them to be easily monitored. However, Senzit makes life more difficult for vehicle thieves because with Senzit, as well as knowing where and for how long the vehicle has been in use, users are also able to locate their vehicle if it has been stolen.

Smart product, easy to handleUsing Senzit is absolutely easy. The monitor is installed directly on the service connection of the air cleaner housing and thanks to extensive accessories is easy to fit. Senzit functions on all terrain including under the most extreme conditions. Initially a retro-fit solution will be available. There are already plans for the intro-duction of a product for integration in a telematics system. At the end of 2018 the first samples will be available.

Senzit – intelligent air cleaner

Senzit is a smart air cleaner monitor which measures the status of air cleaners in real time and transfers service-relevant information to users via an app. The optimal planning of maintenance saves time and brings many advantages to the customer.

Senzit application example:Air cleaner IQORON VP 25

Two-stage air cleaner for extremely dusty conditions Excellent performance thanks to innovative VarioPleat technology Short air duct through 45 degree air inlet port Compact design saves up to 15 percent installation space Quick and easy servicing

10 11AUTOMOTIVE news

Sophisticated production technologyThe air filter system for Mercedes-Benz consists of the air filter and the dirty and clean air ducts. For the acoustic damping the en-gineers used an over-molded fleece material for the dirty air duct. The porous structure enables the equalization of local pressure peaks to prevent undesired resonance in the line.

A lot of development expertise also went into the clean air duct of the diesel application. The clean air duct uses an injection molded bellow from high temperature-resistant plastics instead of a bel-low manufactured in a blow molding process. This new innovative feature is a challenge in terms of production engineering, but one which has decisive advantages. Up to now the thinner wall thick-nesses which were necessary for the flexibility of the bellows were not compatible with the required collapse robustness at negative pressure. Apart from that, the noise emissions increased with the reduction in the wall thickness. The injection molded bellow, however, is able to manage the balancing act between the re-quired flexibility and stability and is able to reconcile the opposing requirements with regard to decoupling, acoustics and collapse robustness under high temperatures. MANN+HUMMEL has pro-duced injection molded bellows with a thermoplastic elastomer (TPE) in series for a number of years. The special feature of the new bellow for Mercedes-Benz is the use of high temperature resistant polyamide. This pushes the maximum possible appli-cation temperatures considerably upwards.

Overmolded inserts for higher qualityMANN+HUMMEL also presented a special solution to Mercedes-Benz for the clean air duct of the gasoline application. In order to reduce the number of welded parts, the engineers designed a bracket in the form of an overmolded insert part. The challenge here was the connection of the hard material of the bracket to the

soft base material of the blow molded part. The engineers solved this problem by improving the wall thickness at the corresponding positions and created new geometries which enable a better connection between the components. The removal of the need for a welding process means that customers benefit from two ad-vantages: higher quality and lower costs.

The requirements for cars are increasing, also demanding comfort functions for small and compact cars, low emission values, and maxi-mum performance. And as a result the number of components competing for space under the hood is going up. Consequently, in-stallation space is valuable and MANN+HUMMEL with Flexline now exploits the available installation space more efficiently. In contrast to conventional air filter elements, which mostly either have a trapezium shape, are rectangular or have a polygon shape and usually have straight sides, the rounded edges of Flexline filter elements allow excellent design flexibility. This enables completely new shapes. It is therefore possible to efficiently match the filters to the inter-ference contours in the engine compartment and perfectly exploit the available installation space, even when this is very complex.

Increase performance, reduce noiseThe innovative air filter system from MANN+HUMMEL is now going into series production for Mercedes-Benz. The vehicle manufactureris using Flexline for its MFA2 platform (modular front architecture). The air filter system celebrates its premiere in the new A-Class and scores points on several fronts. The filtration surface area and the inflow area are enhanced thanks to perfect exploitation of the installation space. The result is a service life which is increased by approximately 20 percent and also an improved filtration performance. Apart from that, the increase in volume is also advantageous for the acoustics. The damping is improved by roughly 20 percent.

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

Flexibility uses installation spaceWhen 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.

Air cleaner system with innovative Flexline solution for the 4-cylinder diesel engines of the Mercedes-Benz A-Class

Compact air cleaner system for the 4-cylinder gasoline engines of the Mercedes-Benz A-Class

13AUTOMOTIVE news12

The automotive industry certainly agrees on one point: The diesel will also be an important component in the drive mix of the future. This is also the view of MANN+HUMMEL, which is further expanding its competences for diesel fuel filters. The experts at MANN+HUMMEL have developed a range of fuel filters for the new generation of Ford vehicles with a diesel engine which meets the high requirements necessary for the use of modern diesel fuel. It effi-ciently protects the injection system against particles and water.

For the variety of new vehicle models of an US-American car manufacturer customized solutions were developed to meet the individual requirements. In all the variants the innovative three-stage water separation is used. In addition, MANN+HUMMEL established a common-part strategy to reduce complexity and costs in the production process and therefore ensures economic production.

Individually equippedThe numerous model variants and respective associated require-ments presented a challenge to the engineers at MANN+HUMMEL. The varying amount of installation space in the models and the access to the components for servicing required different housing designs. Besides, it was necessary to come up with suitable con-cepts for the water discharge and to integrate additional functions Fuel filter with metal bracket for vans

Compact fuel filter for passenger cars

Openable fuel filter with a plastic bracket for SUVs and pick-ups

like fuel heating. As a result, a non-openable fuel filter is used in one variant with a flanged sheet metal design. The fuel filter for 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 a plastic bracket. Despite all the differences, the filter types are designed to enable them to be manufactured on the same final assembly line in the Czech production plant in Okrisky.

Uniformly efficientThe basic design of the fuel filter elements for the separation of particles and water is the same for all filter variants. All of the named types are fitted with the particle filter media MULTIGRADE F-MB 25 and are thus able to combine excellent filtration per-formance with a high dirt holding capacity. Depending on the size of the used filter element, the fuel filter variants achieve a service interval of 60,000 to 80,000 kilometers. All the designs also have an electric heating system integrated in the housing cover. This prevents a clogging of the filter media at cold temperatures.

Just as previously, MANN+HUMMEL has equipped all of the new fuel filter types with high efficient three-stage water separation. This enables the separation of even the smallest water droplets down to a size of 10 micrometers and a separation efficiency which is considerably over 90 percent – even with a fully loaded filter element until the service interval is reached.

Sensors detect when the water collection bowl beneath the filter element is full and the water has to be professionally discharged from the fuel circuit. Depending on the installation space situation and accessibility for servicing, the water discharge for the respec-tive variant has a different design. Designs with access from above are fitted with a water discharge pipe. Variants where the water

discharge is possible from below are fitted with a water drain plug. These solutions simplify servicing and reliably protect the injection systems for the entire service life of the filter element.

New and pioneeringAn 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 the filter element and seals to the housing and the housing cover. Its special design with an elliptical geometry combines a radial and 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-duced fitting and removal forces make it easier to replace the filter element and on the other hand the service technician does not have to insert an additional seal. The design also elim-inates the risk of fitting the filter element without a ring seal.

With the common part strategy, the efficient and flexible fuel filters from MANN+HUMMEL can be integrated into a number of models in order to continue to achieve economic advantages in the future.

New state of the art:water separation

MANN+HUMMEL further expands its range of fuel filters. In the new genera-tion of diesel engines the car manufacturers are extensively using fuel filters with excellent three-stage water separation from MANN+HUMMEL.

Openable fuel filter with half-moon seal for numerous passenger car models


Up to now pressure regulation valves have been a weak point for the crankcase ventilation systems used in gasoline engines. The limited chemical resistance of their membranes mostly made from fluorosilicone rubber in connection with the aggressive chemical substances produced in the combustion process leads to ageing. In particular in markets with poor oil and fuel quality this can in the worst case lead to the formation of cracks and ultimately the malfunction of the valve.

The development of the RobustPlus regulation valve by MANN+HUMMEL represents a pioneering breakthrough. The membrane made from a new fully fluorinated polymer convinces with an almost universal resistance to chemicals and therefore solves the problem the automotive industry has been faced with up to now. The pressure regulation valve is resistant to aggressive acids present in combustion residues and has achieved excellent results with regard to control behavior, tightness and burst pressure during tests.

These are convincing facts for a large North American customer. Just one year after the introduction of the product, a large series order has been won. From 2021 MANN+HUMMEL will annually produce 600,000 cylinder head covers with an integrated SD oil separator and RobustPlus pressure regulation valve for fitting to a 1.5 liter turbocharged gasoline engine for a period of five years. The components will be produced in two MANN+HUMMEL plants to serve the North American and Asian markets.

Cylinder head cover with integrated fine oil separator and RobustPlus pressure regulation valve

RobustPlus pressure regulation valve with an almost universal resistance to chemicals

Open our video on YouTube.There you can find details on the function of the RobustPlus membrane.

The requirements from the China National Heavy Duty Truck Group (CNHTC) for the air cleaner system to be used in its heavy duty trucks were a low pressure drop, excellent dust holding capacity and a long service interval. A high air flow rate of 36.7 m³/min is the reason why these requirements are necessary. The vehicles are also used in mines with extremely high dust levels. This was no easy task, but MANN+HUMMEL developed a system with two separate air filter elements and in this way fulfilled all of the requirements of the customer.

Maximum stabilityThanks to the used cellulose filter media the filter elements achieve a high dust holding capacity of nine kilograms of coarse dust. With two cyclones fitted upstream the dust pre-separation is significantly increased and in combination with the two filter elements the service life is more than doubled even under extremely dusty conditions. Furthermore, the two safety elements protect the clean air side against dirt particles during servicing or when a main filter element is damaged. The filter housing made from PP-GF30 was specially developed for CNHTC and is produced by MANN+HUMMEL in China using an injection molding process. Regarding the integration of functions, the filtration and plastics specialist also came up with an ingenious solution. MANN+HUMMEL designed the housing with numerous ribs and reinforcement elements to ensure maximum stability. This includes three reinforcement rings located in the area of the two air inlets and the air outlet. Additionally a rod-shaped reinforcement made in plastic supports. The rod is fixed between the filter elements to both sides of the housing. A further design feature of the system is a gathering duct which combines the cleaned air from the elements and directs it to the air flow meter.

Playing safeA number of other components also improve reliability. The water discharge valve on the lower side of the housing prevents the accumulation of an excessive amount of water inside the housing. A seal between the service cover and housing also protects against the intake of warm air, dirt and water. Finally, mounting points on three sides of the housing enable flexible mounting of the air cleaner to the vehicle. The development at the Chinese locations of Changchun and Shanghai and the local production enabled an excellent cooperation between CNHTC and MANN+HUMMEL.

AIr cleaner with very high dust holding capacity for CNHTC

Double theservice life CNHTC, the leading Chinese manufacturer of heavy duty trucks, required a stable, high performance and durable air cleaner system. MANN+HUMMEL developed a customized solution which impresses with maximum performance.

Vote of confidence

RobustPlus is an innovative membrane material developed by MANN+HUMMEL for pressure regulation valves which sets new standards with regard to its chemical resistance. Just one year after its market introduction, a large series order from an US-American manufacturer confirms the success of the solution.


Use of many standard components reduces costs Mounting bracket allows 360 degree mounting Integrated dust pre-separator in the air cleaner housing Water separator in dirty air duct to protect the filter elements Low pressure loss and high dust holding capacity of the complete system

Advantages at a glance

Systems competencefor commercial vehicles

In addition, the air cleaner housing was complemented to include a component to fit the customer specific assembly. This is a mounting bracket around the housing which enables fitting of the air cleaner in any required position. In order to avoid problems caused by high dust levels, a pre-separator has been integrated in the air cleaner. This separates coarse particles from the air flow already upstream of the main filter element and therefore extends its service life. The intelligent integration of the pre-separator in the housing means that no additional installation space is required. That saves money as well as components. Metal clamp fasteners hold the parts of the air cleaner housing and filter element to-gether free of vibration and enable easy servicing.

Environmentally friendly and reliable The filter element has a cellulose filter media with a high dust hold-ing capacity. The safety element made from a non-woven fabric protects the clean air side during servicing or when the main filter is damaged. Both elements do not require metal elements to make recycling easier and protect the environment. The pleats of the main filter element have an efficient design to enable maximum

filtration performance and an extended service interval. The vehicles produced by Indian manufacturers are mainly on the road in countries with humid and warm climates. Therefore it is essential to protect the filter element against humidity especially with a front air intake. A water separator integrated in the dirty air duct of the system provides the necessary protection. The inflowing air is deflected by 90 degree. In this process the water droplets hit the inner wall of the duct to form a film of water. The water collects in an area with reduced flow and is removed from the system via a water drain valve. As a result, only dry air reaches the filter element and the maximum filter performance is maintained. The dirty air duct is made from plastic and elastomer components. This combination of materials and numerous ribs provide the required stability to counter the effects of vibrations.

Flexible and stableThe engineers also pursued a similar strategy with the clean air duct. Elastomer parts with numerous ribs compensate engine movements and simultaneously withstand negative pressure and high temperatures. A mechanical service display informs the

driver about the ideal time for a service. The customer is im-pressed by the low pressure drop and large dust holding capacity of the MANN+HUMMEL air cleaner system. Used in commercial vehicles the air cleaner system offers a long service life under extreme conditions – at low costs. The excellent cooperation offers potential for further common projects.

It is difficult to imagine Indian roads without the buses, vans and trucks produced by Ashok Leyland. The company is the second largest producer of commercial vehicles in the country. Now for the first time, for its high performance trucks, Ashok Leyland will use an air cleaner system from MANN+HUMMEL which the filtration special-ist has developed and produces locally in Bawal. A special point here is that in order to keep costs low the engineers used many standard components for the air cleaner. Only the dirty air and clean air ducts are individually adapted to the requirements of the customer.

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 thatthey can reliably master these conditions.

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MANN+HUMMEL air cleaner for Ashok Leyland

Robust air cleaner system for humid and dusty conditions

1 Dirty side duct made of plastic and rubber with water separator and drain valve2 Air cleaner housing with integrated dust pre-separator 3 Dust outlet valve4 360 degree mounting bracket5 Clean side duct made of plastic and rubber


Plastic has proven itself over many years as a versatile material suitable for use in a wide range of applications in commercial vehicles and motor cars. There are limits, however, to the appli-cation of plastic in areas where components are subject to high thermal or mechanical stress since the relevant plastics can only achieve a certain strength and rigidity. Whereas MANN+HUMMEL introduced the world‘s first plastic oil filter module for cars in 2003, for reasons of stability filter modules in aluminum continue to be used in commercial vehicles. The specialists at MANN+HUMMEL looked for an alternative and developed a solution which also has the robustness required for these applications.

Best of both worldsThe aim of the developers was to combine the mechanical strength of aluminum with the design flexibility of plastic. The solution is an aluminum framework which is enclosed by a plastic envelope.

In component areas where there is a high stress load such as flange joints or cover threads the metal absorbs and distributes the high local mechanical forces. This enables the component to withstand the respective load at these points. The housing envelope in plastic allows the easy integration of functions.

Complex designThe design of the component with this hybrid concept turned out to be complex. The aluminum framework, the so-called insert, has to absorb any forces which arise and transfer these through the interlocking of the plastic and aluminum. In this process stress peaks are to be avoided which could lead to a damage of the material. At the same time the insert has to be designed for the subsequent overmolding process and has to be able to be reliably fixed in the injection molding tool so that the overmolding process does not result in any deformation. Preliminary tests showed that given the different thermal expansion coefficients of the materials it is not possible to achieve a permanently sealed connection between the aluminum and plastic. In the contact area a tight connection between the aluminum and plastic cannot be ensured permanently. Therefore the developers designed all of the areas with contact to the media in plastic.

The polyamide used for the plastic envelope has a number of advantages with regard to flexibility. Although a die-cast process with multi-part tools can be used to achieve complex geometries, the production of a functional liquid filter module requires the subsequent machining of threads, sealing surfaces and hydraulic connections. This involves additional machining processes and high costs to be able to ensure the required degree of component cleanliness. The injection molding of a plastic part on the other hand enables the creation of all of the required connections and threads directly in the mold.

Costs which pay offThe new concept was validated through direct comparison with a fuel filter module for a 13.0 liter commercial vehicle engine. For this 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.

The plastic-aluminum hybrid design can be seen as a real alter-native to conventional aluminum solutions. In order to achieve a cost advantage, a number of conditions have to be met, for example, with regard to volume, design suitability for plastic and the necessity for machining. The additional tool required for the insert leads to higher costs. With higher volumes these costs are better distributed and as a result the hybrid concept can be de-scribed as economic. In addition, the maintenance of component cleanliness with aluminum housings is more cost intensive than with the hybrid module. If the insert and plastic remain unpro-cessed, this enables a reduction in costs.

The long-standing experience in the design of complex, highly-stressed plastic components over many years and expertise in the conception of injection molding tools enables the specialists at MANN+HUMMEL to draw up a robust hybrid component which is able to meet the high requirements for commercial vehicles and is also economic. The first definite projects are currently being developed.

Perfect connection Experts involved in the development of basic concepts, processes and series pro-jects at MANN+HUMMEL have successfully developed and tested an innovative plastic-aluminum hybrid design for liquid filter modules used in trucks.

Concept of the hybrid fuel filter module for a commercial vehicle application

Designs for hydraulic connections with a quick connector molded on the module or distribution channel

Sample of a hybrid fuel filter module produced in transparent plastic

Dr. Pius Trautmann, Director Engineering Liquid Filter Systems Heavy Duty & Industrial

‘We are always working to inspire

our customers with cost-effective

and innovative solutions.’


The indirect charge air cooling offers a number of advantages. Its function is more constant and effective than direct charge air cooling and reduces CO2 emissions by up to three percent. In addition, the working principle enables a reduced charge air volume and therefore a faster buildup of boost pressure which improves the responsiveness of the engine.

The MANN+HUMMEL solution fully exploits these advantages. The indirect charge air cooling is integrated in the intake manifold and goes one step further. In contrast to conventional screw-in solutions the cooler is completely encapsulated by the shells of the intake manifold which allows the whole system to impress with its high stability without the need for external sealing surfaces.

High requirementsThe BMW Group was looking for a solution for its 4- and 6-cylinder gasoline engines which is able to withstand the high system loads with regard to boost pressure and temperature differences in the component. The engineers at MANN+HUMMEL managed this challenge with the aid of modern simulation technology, expertise and know-how. The engineers used a special bypass seal between

the cooler and intake manifold shells to meet the requirements with regard to chemical resistance and low leakage values. The double lip seal made from ethylene acrylate elastomer is able to compensate high tolerances while simultaneously remaining dimensionally stable. The cooler and intake manifold positively lock in order to firmly and securely join them together.

With a temperature difference of less than three Kelvin over four re-spectively six cylinders, the system also enables an excellent uniform temperature distribution. It is also remarkable that the whole system has to withstand high temperature differences of up to 150 Kelvin between the air inlet and outlet. Absolute manifold pressures of up 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 simulations, internally produced prototypes and intensive testing, the specialists at MANN+HUMMEL perfectly designed the com-ponents. Special cambering and selective ribbing ensure the highest stability and also reduce weight at the same time.

The design also focused on an ideal air flow. The consistent filling of the cylinders is maintained by a plenum design improved by computational fluid dynamics which also leads to a lower pressure loss. The joining of the components using hot gas welding enables narrower and stronger weld seams. The advantages of the com-plete solution supplied by MANN+HUMMEL with its customized design impressed the BMW Group. The vehicle manufacturer uses the new solution in its 4- and 6-cylinder gasoline engines with longitudinal installation.

Fully integratedfor 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.

Minimum number of components No external cooler sealing High mechanical stiffness of the system Excellent uniform temperature distribution


MANN+HUMMEL intake manifold for the 2.0 liter 4-cylinder turbo gasoline engine of the BMW Group

MANN+HUMMEL intake manifold for the 3.0 liter inline 6-cylinder turbo gasoline engine of the BMW Group

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


Next generation of intake manifolds

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.

also serve to generate controlled turbulence of the air when it flows into the cylinders. Both measures are designed to improve the combustion process in the engine and reduce fuel consumption and therefore also CO2 emissions by up to three percent. A self-regulating bypass flap with two charge air ducts between turbo-charger and electric booster compressor also improve low-end torque, i.e. providing of torque in the low rpm range. The complete system also includes the charge air ducts from the turbocharger to the pre-cooler and from there to the intake manifold with main cooler. They are equipped with AgileJoint connections which enable the required tolerance compensation. On the hot side the duct can also be fitted with an optional broadband silencer to eliminate undesired noise.

Water injection as an optionThe use of an optional water injection system can be used to reduce raw emissions, to protect components at full load and to increase efficiency. Which of these benefits is in the foreground can be determined individually by the engine development department. With this variant a water filter, water rail and injectors are also integrated in the intake manifold. MANN+HUMMEL has transferred its experience over many decades in the area of liquid filtration to this new application. The multi-layer, fully synthetic MULTIGRADE filter media for water injection meets all require-ments with regard to particle separation efficiency, dirt holding capacity, chemical resistance and mechanical stability. If required, an additional electric heater can be integrated into the filter housing to support the system during the defrosting process. This enables water injection to be used even at low temperatures.

Market successThe new system and its components have attracted a great deal of interest on the market. MANN+HUMMEL has already been nomi-nated to develop an intake manifold with self-containing, indirect charge air cooler and also a stand-alone, indirect charge air cooler. First applications for the 4-cylinder diesel and gasoline engines of European engine producers are set to enter series production from 2019. Customers benefit from a high performance solution with integrated functions as well as a reliable partner with a global de-velopment and production network. MANN+HUMMEL has already planned the next development steps. Design improvements to the arrangement of the coolers will further reduce the number of interfaces.

The requirements which modern engines have to fulfill are extremely demanding. They should generate fewer emissions under real driving conditions and at the same time have a higher performance. There-fore it‘s a good thing that the specialists at MANN+HUMMEL have developed a suitable solution. An active intake manifold which in-cludes the complete intake section from the turbocharger to the cylinder head with a two-stage, indirect charge air cooling and a water injection. This contributes to ensuring that engines also meet future emission regulations such as the Euro 6d standard. Apart from that, the flexible arrangement of the components in the system offers considerable design flexibility.

Next development stageIn 2015 MANN+HUMMEL presented an active intake manifold with fully integrated charge air cooling. This concept forms the basis for the new system. In the new concept the pre-cooler and main cooler are designed to be self-containing. Crimping to the adjacent plastic components ensures the required stability. As a result, costs were reduced as there is no need for a bypass seal, tension anchors and a welding process. The compact design also requires less installation space and reduces weight.

Constant coolingThe engineers integrated two indirect charge air coolers in the in-take system. This makes the system more compact, reduces the charge air volume and improves engine response. In comparison to a direct charge air cooling, the main advantage of the indirect charge air cooling is a more constant cooling performance over the dynamic range. Robust tumble flaps in the intake manifold

Concept to achieve the future CO2 emission targets Increase engine efficiency by using an integrated charge air cooler Enhanced low-end torque with an self-regulating bypass flap Optimized control of the turbulence in the cylinder by tumble flap system Higher performance thanks to water injection


1 Charge air duct (hot side) with AgileJoint element for tolerance compensation2 Stand-alone indirect charge air cooler as pre-cooler3 Charge air duct (cold side) with AgileJoint element for tolerance compensation4 Self-regulation bypass flap with two ducts to the electric compressor or second turbo charger5 Self-containing indirect charge air cooler as main cooler (connected to low temperature cooling circuit) 6 Water injection system with plastic water rail and inline water filter (optional)7 Intake manifold module including tumble flap system with electric plug-in actuator

Sectional view of the active intake manifold with dual integrated intercooler and water injection system

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1 Joint Connector: forms the female part of the AgileJoint together with the crown ring2 Crown ring: is pre-assembled to the male part and joins a snap-fit with the female coupling 3 Connection piece: injection molded male part of the AgileJoint, welded to the actual duct4 Charge air duct: blow molded with welding interface to connection piece5 Charge air duct: with connection piece blow molded directly to the duct without interface6 Support ring: gives mechanical strength to the connection and reduces ovality

Intelligent thermal management, maximum power and low emissions are the current requirements for modern engines. Especially in the high-end area, the trend is away from direct over to indirect charge air cooling. MANN+HUMMEL applies the innovative AgileJoint compensation element to charge air ducts used in indirect charge air cooling. AgileJoint effortlessly compensates fitting tolerances or dimensional changes due to thermal expansion. In addition, it replaces expensive elastomer hoses which were previously used for decoupling. That cuts costs and provides a weight advantage of up to 30 percent. The solution also convinces through its easy fitting.

One instead of twoThe 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 helperThe 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 process with a segmented tool. The process takes the dimension situation of each individual component into account and in this way reduces its oval shape and ensures a stable connection which can also withstand the highest pull-off forces.

After the successful use of the first AgileJoint variant and the nomination for the ’Supplier Innovation Award‘, BMW Group will now fit the new charge air duct to its 3.0 liter inline 6-cylinder gasoline engines for the 3, 5 and 7 Series as well as X3 and X5. The BMW Group again benefits from excellent fitting charac-teristics, reduced costs and lower weight.

Charge air duct with AgileJoint compensation elements to manage mounting and thermal tolerances

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.


WAVELOCK –easy to service MANN+HUMMEL has developed a new revolutionary spin-on filter concept with bayonet lock. It simplifies servicing and is available as a modular 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.

Clean solutionA further advantage is the improved component cleanliness. With conventional systems the thread is milled into the aluminum head. In this process minute residual particles of dirt can stick to the component and cause substantial damage on the clean side of the filter. With the WAVELOCK solution there is no danger of this happening. This is firstly because the connecting piece is not manufactured in a machining process, but is pressed. This means that shavings are not possible. Secondly, it is fitted on the dirty side and is not part of the flow circuit. This protects the system against contaminants. In addition, for the purpose of reliability, the Poka-Yoke principle is applied during servicing to ensure that only the right product can be fitted.

Products used in modern combustion engines and compressors are subject to high requirements with regard to the pressure stability of the filter components. As a result, they have to be able to reliably withstand pressures of more than six bar. That is not a problem for the new WAVELOCK filter concept. A high resistance to vibration is also a must. The transportation protection cap on the spin-on filter fulfills two functions. Before installation it pro-tects the connection geometry against damage. During instal-

lation the mechanic removes the middle part along a perforated line. After that a ring remains around the edge of the component. During fitting this serves as a seal and prevents splash water from penetrating the area between the filter head and the service part. Modular system with growth potentialMANN+HUMMEL will in future offer its range of WAVELOCK spin-on filters as a modular system. The modular will consist of the two main assembly groups of filter head and spin-on filter. A number of different variants are planned in the same way as practiced with existing modular systems which have a traditional spin-on filter concept. Possibilities exist to produce an oil filter head, a fuel filter head with and without manual pump as well as a kit for engine-mounted components. It is possible to combine these variants with numerous filter media, anti-drain membranes and bypass valves. The spin-on filters are currently available in size 9 and an extension of the modular system is planned to enable further sizes. The revolutionary filter concept has already been in operation since the beginning of the year for a garden tractor of an US-American manufacturer. There are ongoing tests for further appli-cation areas for on- and off-road applications.

New spin-on filter concept for an easy, fast and clean service

ENTARON HD 4 with cathode air filter element

Active cell protectionFuel cell technology has enormous potential. In order to realize this poten-tial, the sensitive cells have to be reliably protected. MANN+HUMMEL has now developed a cathode air cleaner to do just that.

This allows the air cleaner to separate particles and also adsorb harmful gases in order to provide the best protection for the fuel cell. In comparison to conventional air cleaners, the media in the cathode air filter element is wound around a supporting grid instead of being pleated as before. This creates space for con-siderably more media in the same installation area and therefore increases the dust holding capacity and filtration performance. In addition to the standard component, the structure of the element can also be customized to specific customer require-ments. A pleated activated carbon element is therefore also possible.

A further advantage is the quick availability resulting from the further development of a proven air cleaner system. The housing remains unchanged. The air cleaner is available as a single- or two-stage air cleaner and depending on the customer require-ments can be fitted within a 360 degree range. For even greater cell protection an optional safety element made from a non-woven fabric is also available which ensures that the air on the clean side remains clean during service.

Cell protection helps to prevent ageing and is essential where cells are exposed to extreme loads. This is true for biology and also true on our roads. Fuel cells work in a field where if they were unpro-tected they would soon age. Gases such as sulfur oxides (SO2), hydrogen sulfide (H2S) and ammonia (NH3) are able to damage the low-temperature proton exchange membrane of the fuel cell. Without protection irreversible damage can occur.

Custom development of proven solution MANN+HUMMEL knows about the sensitivity of the fuel cell and has further developed an air cleaner from the ENTARON series especially for use in fuel cells. The catalog component which is usually equipped with a conventional filter element with a cellu-lose media is now fitted with a new activated carbon filter element.

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Oil filter module for the 2.0 liter diesel engine for off-road vehicles

Proximity to the customer is an important factor for success with global projects. In 2016 the first oil filter module for an US-Ameri-can car manufacturer rolled off the production line for the first time at the Indian MANN+HUMMEL location in Tumkur. A second module now follows on the same production line. In addition to supplying the customer plant in India, the new oil filter will also be delivered to South Africa and Argentina.

Proven technologyThe robust die-cast aluminum housing of the oil filter module inte-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, a filter bypass and an anti-drain valve as well as a patented oil drain system ensure efficient oil management. In comparison to the pre-vious module, the engineers managed to decrease the pressure drop by a third and therefore also reduce the power required to run the pump in the oil circuit. Due to the tight installation space, the oil/water heat exchanger was developed with a pentagonal geometry and enables an increase in cooling capacity by more than 30 percent. It cools the lubricating oil at high temperatures and simultaneously protects the engine against overheating. With a high oil viscosity or blocked filter element the filter bypass valve integrated in the center tube ensures that the engine re-ceives sufficient lubricating oil. The anti-drain valve pressed into the housing also provides protection against wear. It prevents

the oil filter from emptying when the engine is switched off and after the engine is restarted ensures that the oil pressure is high enough. The patented anti-drain valve enables a clean and easy oil change. In total the system impresses with its high per-formance while being environmentally friendly. Completely free of metal, the fully incinerable filter element can be disposed of after use in an environmentally compatible way. The series start for the oil filter module in India is a further proof of the successful cooperation in the global development and production network of MANN+HUMMEL.

Biofunctional cabin air filter protects professional drivers

The special innovative biofunctional coating has both an anti-allergenic and antimicrobial effect. The anti-allergenic function is enabled by the third layer which has a natural polyphenol coating. Polyphenols occur naturally in many plants such as green tea, apples, grapes and citrus fruits and are able to bind allergens, rendering them harmless. An additional biostatic coating has also been shown to prevent the growth of microorganisms such as molds or bacteria on the filter. This gives drivers excellent pro-tection against allergens, bacteria and mould fungi.

In Europe around 60 million people suffer from allergies and this number is set to rise. For sensitive drivers of commercial vehicles there is an increased risk of an allergic reaction due to pollen, bacteria and mould fungi. Anti-allergenic cabin air filters from MANN+HUMMEL now also protect the affected drivers in trucks and buses. They bind allergenic substances and prevent the growth of bacteria and mould fungi on the filter by more than 98 percent. The new cabin air filter is already available in the independent aftermarket in original equipment matching quality for millions of trucks in Europe and selective bus applications.

Good air quality at the driver‘s workplace is important to stay fit, reduce the effects of tiredness and maintain concentration and awareness so that the risk of an accident is decreased. For this purpose anti-allergenic cabin air filters with their multi-layer struc-ture offer a solution. The particle filter layer separates coarse par-ticles such as dust and particles from tire abrasion and also filters nearly 100 percent of harmful fine dust particles with an aero-dynamic diameter of less than 2.5 micrometers (PM

2.5). These small particles are approximately 40 times smaller than a human hair. They can penetrate the lungs or even enter the bloodstream via the pulmonary alveoli to cause cardiovascular diseases. The second layer contains activated carbon, which is derived from coconut shell. This adsorbs almost all unpleasant odors and harmful gases such as nitrogen oxide, sulfur dioxide and ozone from the airflow.

Global network,local production

MANN+HUMMEL continues to expand its local production capabilities and has started production of an additional oil filter module for an US-American car manufacturer's new 4-cylinder diesel engine at the Indian location in Tumkur.

Cabin air filters for buses and trucks

According to the World Health Organization, allergic diseases are among the most common chronic diseases in the world. Biofunctional cabin air filters from MANN+HUMMEL ensure that the affected professional drivers can breathe in freely when they are behind the wheel.


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

facturer had a very good experience with that project. A further positive point is that also in China closeness to the customer literally is a factor for success. The priorities of Brilliance are local competence from contact partners, quick and reliable supply chains and uniform quality standards. These are precisely the advantages offered by MANN+HUMMEL with its location at Changchun in China.

Common goalThe 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-cess, for example, Product Coaches from the respective Center of Competence support local functions and teams. The successful approach was also efficiently applied in this project.

Local MANN+HUMMEL experts developed an air cleaner system andcharge air ducts for the Chinese car manufacturer. The air cleaner sys-tem is produced using injection molding and blow molding tech-nology. The air filter element offers excellent filtration performance with a separation efficiency of up to 99.5 percent. In addition, the Poka-Yoke design of the filter ensures that during a service the new filter is fitted in the right position. The engineers intensively used flow simulations to reduce the pressure loss in the system in order to maximize engine performance. Additionally, they paid special attention to the acoustics and integrated broadband silencers, Helmholtz resonators and lambda quarter tubes in the injection molded section of the dirty air duct. As a result, it was possible to considerably reduce the intake noise and improve drive comfort.

Filter change with a single actionA special feature is the design of the dirty air duct which has a patent pending. It can be easily removed using a clip connection to change the oil filter which is located underneath and facilitate the fitting of the air cleaner system. Here one section of the blow molded duct is not inserted axially into its counterpart as is usually the case, but is clipped on using a semi-circular fixture. When changing the oil filter element the duct section can be removed with a swivel movement to allow direct access to the filter. After the replacement of the filter, the duct can be easily inserted and clipped on again. The complex air cleaner project for Brilliance is the biggest project so far in this product area at the MANN+HUMMEL location in Changchun.

Good experiences get around: for the air cleaner system for a new drive based on the Prince engine developed by PSA and the BMW Group, the Chinese car manufacturer Brilliance decided to use MANN+HUMMEL as its supplier. Brilliance and the BMW Group are joint venture partners. MANN+HUMMEL was already respon-sible for the development and series production of the intake system for the European Prince engine. The European car manu-

Zhonghua V7 from Brilliance (Photo: Brilliance)

Air cleaner system for the 1.6 liter and 1.8 liter turbo gasoline engines of Brilliance

Charge air ducts for the 1.6 liter and 1.8 liter turbo gasoline engines: hot side right, cold side left

1 Dirty air duct - injection molded section2 Dirty air duct - blow molded section3 Air filter element4 Air cleaner housing 5 Clean side duct

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In combustion engines gases are generated during combustion which, for example, can be pressed past the piston rings into the crankcase. The oil particles contained in this blowby can deposit themselves on the turbocharger, the intercooler and the inlet valves and as a result cause damage. The separation of oil droplets from the blowby returned to the intake air is therefore important and also relevant for the reduction of oil consumption. Effective oil separation is a condition to meet the emission standards of modern engines and is also necessary for the protection of the components of the intake system.

Clever designThe SD oil separator (structured deflection) which MANN+HUMMEL presented in 2013 was and remains pioneering in terms of efficiency and its compact design. In 2015 the product went into series for the first time with an Indian car manufacturer. Since then the solu-tion has established itself on the market. Now the component will also find application in a 2.0 liter 4-cylinder gasoline engine from Mercedes-Benz, mounted longitudinally for models with rear wheel drive and transversely for vehicles with front wheel drive. The ambitious aim of the customer here was to achieve a con-siderably greater oil separation in a smaller installation space with less interfaces.

settling chamber becomes a coarse separator. In the follow-up this pre-cleaned blowby is directed through a number of nozzles bores in the SD oil separator. The narrowing of the cross section in this process causes the gas to accelerate again and it impacts the deflector plate with a high amount of kinetic energy. There the air/oil mix is radically deflected by the special pyramid-shaped structure of the plate which causes even the smallest particles to coalesce, i.e. to come together to form an oil film, which then flows back to the oil circuit. The pyramid structure of the SD deflector plate significantly increases the efficiency of the oil separator.

Robust, reliable and variableAlso this new variant of the oil separator from MANN+HUMMEL convinces with its robust component concept which can find application in very small installation spaces. According to the California Air Resources Board (CARB), crankcase ventilation is relevant for exhaust emissions. The laser-welded pressure control valve cannot be opened without damage and therefore meets the requirements of the OBD II on-board diagnostics standard.

Numerous control and safety valves ensure that the crankcase ventilation works perfectly in all situations. Two non-return valves, one for the full-load and one for the part-load ventilation, ensure

Firstly coarse, then fineThe blowby which escapes from the crankcase contains oil par-ticles with varied sizes. It includes visible droplets as well as droplets which are substantially smaller than one micrometer. The challenge here is to separate all the sizes with a high level of efficiency. The MANN+HUMMEL experts solved this task by fitting the pressure control valve with the SD oil separator on the crank-case such that the cylinder head is closed by the component like a cover. This type of mounting creates a settling chamber between the cylinder head and SD fine separator where the blowby loses kinetic energy. Consequently, large and heavy oil particles are released from the gas and can be efficiently separated. The

that the cleaned air reaches the fresh air path against the pre-vailing pressure gradient. A ball-type non-return oil valve prevents the bypass of blowby and the drawing in of oil from the sump. If it is technically necessary the oil separator can, however, be bypassed using a bypass valve.

The new crankcase ventilation system for Mercedes-Benz is the latest series product of the MANN+HUMMEL SD oil separator family. MANN+HUMMEL experts are currently working on approximately ten development projects for oil separation with international car manufacturers. As a result, many new products will enter series production in the coming months and years.

First-classoil separationThe 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.

Crankcase ventilation system for longitudinally mounted engines

Crankcase ventilation system for transversely mounted engines

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MANN+HUMMEL received the ‘Regional Quality Award’ from Nissan in Asia

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MANN+HUMMEL was awarded a prize by the Society of Plastics Engineers Central-Europe (SPE), the International Society for Plastics Technology, at the 18th Automotive Award in Düssel-dorf-Neuss. In the category ’Powertrain’ the worldwide first intake manifold with fully integrated charge air cooler was ranked the third place.

The awards are presented in various categories for outstanding developments of plastic parts for the automotive and supplier in-dustry. The criteria are the level of innovation, the quality as well as the design’s compatibility with regards to material and speci-fication. Numerous MANN+HUMMEL products have already re-ceived awards in previous years. ‘The development was a big challenge, which could only be handled thanks to an excellent cooperation across all functions internally and at our customer.’ Heinz Bühl, Vice President Intake Manifold Systems, honored the team‘s success.

Award for outstanding developments

‘Supplier of the Year Award’ from General Motors

General Motors awarded the recognition ‘Supplier of the Year’ for the 26th time in April 2018. MANN+HUMMEL belongs to the winners and received the award for the 23rd time. The award specifically recognized MANN+HUMMEL’s air induction systems. In total 132 suppliers from 17 countries were honored. All of them have consistently exceeded the expectations of General Motors, created outstanding value, or brought inno-vations to the company.

The 2017 Supplier of the Year Award was received by Kai Knickmann, General Manager Automotive Original Equipment and Industrial Filtration at MANN+HUMMEL, in Orlando. ‘Our teams are incredibly proud of this and see it as validation of the way in which we work’, says Knickmann. ‘During our long decades of partnership with GM, we have never failed to im-press with our innovative technology and the unwavering premium quality of our products.’

MANN+HUMMEL Thailand was selected as the winner of the ‘Regional Quality Award’ by Nissan in the category ‘Engine & Drive’. With this award, Nissan values the excellent quality performance of the plant over the last years as well as the strong engagement of the management team and all em-ployees of MANN+HUMMEL Thailand. The manufacturing plant is located in the WHA Industrial Estate of the Rayong provinces and started production of air cleaner systems and intake manifolds in 2014. We at MANN+HUMMEL attach importance to a high quality of our products that means to have a daily focus on our target to deliver perfect parts in order to avoid customer complaints. As a result, MANN+HUMMEL belongs to the top suppliers of Nissan in Asia. This award confirms our approach and is a motivation to main-tain our high quality standards.

‘Regional Quality Award’ for MANN+HUMMEL Thailand Now fully synthetic

The continuous development and improvement of the existing products is necessary in order to meet the increasing market demands. A clear example is the oil filter of the Audi 3.0 liter V6 TDI diesel engine. With the change of the filter media, the sustainability specifications are satisfied, having a great positive impact on the product. Before this innovation, the oil filter was already in mass production in Ludwigsburg, Germany.

Compared to its predecessor, this new product uses the fully synthetic filter media called MULTIGRADE O-S 16.1, which makes it more resistant to ageing. The fully synthetic media offers further advantages: The increased mechanical stability by a drainage grid reduces the differential pressure, especially during cold start of the engine. Besides, it is insensitive to water ingress into the oil and in-creases the element’s resistance. Therefore, premature or frequent opening of the filter bypass is prevented. As a result, the reliability of the oil filtration increases and achieves a maximum wear protection.

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 offers various filtration solutions to reduce fine dust emissions.

Finedusteater.com


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