e-Waste Heat Recovery System for Commercial Vehicles - MAHLE

Innovative Waste Heat Recovery System in a red box for fuel savings of up to 5%! Boost Box for commercial vehicles.

30% of the energy is lost via the exhaust system. MAHLE harvests this energy using a compact waste heat recovery system in one box.

With its e-Waste Heat Recovery (eWHR) system, MAHLE offers a true enabler for economically efficient hybrid technology in long-distance hauling and distribution transport. And it comes packed into the compact MAHLE Boost Box. The eWHR system in a box extracts heat from the exhaust flow.

It is then converted into electrical energy that can be used in a 48-volt electrical system to supply electrified auxiliary consumers or be fed directly into the powertrain via an electric motor. Fuel savings of up to 5 percent can thus be achieved. But at MAHLE, we’re always thinking one step ahead.

To reach maximum efficiency, it’s possible to add a Mild Hybrid component to the eWHR system. Using a Mild Hybrid, the electrical energy obtained in the eWHR system can be transferred to the powertrain in the form of mechanical energy and the energy released during braking can be recovered.

Features:

- Quick installation
- Plug-in system
- Easy integration
- Retrofit solution
- Fully integrated hybrid system
- Tested under all conditions
- Maximum heat waste recovery
- E-power increased by 13 kW (18 horsepower increase that is transmitted to the powertrain)
- Up to 6000 kg CO2 savings per year (equals planting 500 trees)
- 150 kg compact light weight design
- Make the most of your energy

MAHLE has chosen to feature conventional combustion engines, hybrid drives, and fuel cell drives—all on an equal footing—at this year’s IAA.

The e-Waste Heat Recovery System is presented at the IAA 2018 in Hannover (IAA Nutzfahrzeuge) as well.

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MAHLE is a leading international development partner and supplier to the automotive industry as well as a pioneer for the mobility of the future. The MAHLE Group is committed to making transportation more efficient, more environmentally friendly, and more comfortable by continuously optimizing the combustion engine, driving forward the use of alternative fuels, and laying the foundation for the worldwide introduction of e-mobility.

The group’s product portfolio addresses all the crucial issues relating to the powertrain and air conditioning technology—both for drives with combustion engines and for e-mobility. MAHLE products are fitted in at least every second vehicle worldwide. Components and systems from MAHLE are also used off the road—in stationary applications, for mobile machinery, rail transport, as well as marine applications.

Our videos include the following subjects: Automobile, Cars, Motorsport, Piston, Valve, Compressor, Engine, Connecting Rod, Turbocharger & Filter.

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[karlswanson]

So you are using WHR to generate electricity and then have an electric motor assist the main motor. I am not a mechanic but is there room in most semi truck engine compartments to add this feature. I live in the United States and we have a Peterbilt 579 and a Freightliner Cascadia 126, could be adapted for these?

Maybe it would be cheaper to offload the Engine draw from alternator, pumps etc to simplify things and still get good improvements.

Are you using an Organic Rankine Cycle which has a low conversion efficiency? Could a Brayton Cycle with supercritical CO2 (sCO2) be used with a radial outflow turbine instead? My guess is that temperature and pressure may make it difficult if at all possible.

If you had a large surplus of electricity maybe it would be possible to increase oxygen % in combustion by 10% and get more improvement that way (Urea will help with electrolysis).

With an extra 20kw of power I think you could provide most of the power for a dual zone reefer while going down the road at speed.

[karlswanson]

I never considered direct electric motor assist on existing motor. Thank you

[ericlotze]

Can these ever be systems like this for consumer vehicles (large cars, trucks, and vans), or can those only support coolant heat exchangers?