Mahle outlines e-compressor innovations
Vehicle technology provider Mahle has explained the workings behind the latest innovations in its work with electric air conditioning (AC) compressors, which are primarily used in electric vehicles.
“The e-compressor is used to not only cool the vehicle cabin, but also the battery,” explained Jonathan Walker, managing director of Mahle Aftermarket Ltd.
“This highlights the importance of a functional AC system in electric and hybrid vehicles of today and the future – if the AC system were to fail, the vehicle would not operate due to the safety risk posed by the battery overheating.”
The compressor plays a crucial role in battery thermal management, says Jonathan, extending range, maintaining battery service life, and allowing for shorter charging times.
“Mahle views the revolutionary potential of the e-compressor at a similar level to the introduction of their aluminium piston nearly 100 years ago,” he continued.
“The impact of this technology on electric vehicles and hybrid mobility is significant, but the engineering required spans multiple areas.
“Mahle Electric Drives in Slovenia provide the heart of the compressor, in the form of an advanced electric motor. Mahle Electronics in Spain provide the brain – the power electronics circuitry. The e-compressor itself is manufactured at Mahle Compressors in Hungary.”
The e-compressor represents a key component of Mahle’s Integrated Thermal System (ITS), which the company says is at the forefront of OEM electric vehicle projects.
“In cold weather, most electric vehicles currently use electrically powered heating solutions to warm the cabin and battery,” said Jonathan.
“However, the ITS uses a vehicle’s refrigerant system to transfer thermal energy into coolant, which can then be used elsewhere in the vehicle. This can improve EV cruising range by between seven and 20 per cent.”
The introduction of this new technology poses a challenge to many workshops, he explains, who will require extra training in order to work on vehicles with e-compressors.
“This is because the units run off high voltage systems that are much more dangerous to work on, and much more complex than standard thermal management systems.
“A direct-current voltage of over 200 volts is used to generate the right amount of torque to drive the electric compressor, which is a very high voltage for this sector.
“Mahle is encouraging training where possible to ensure workshops and technicians do not get left behind and can stay ahead of the curve, futureproofing themselves and their businesses.”
