Electric heaters and sensors

MAHLE electric heaters are used in diesel and ethanol engines in passenger cars and commercial vehicles for cold starting and operation at low ambient temperatures. In diesel engines, they ensure that flowability is maintained and prevent coagulation of fuel components that could lead to clogging of the filter. In ethanol engines, MAHLE heaters significantly improve the critical cold start.

When designing the heaters, MAHLE drew upon the company’s broad knowledge base in the area of fuel systems, thus achieving a high level of integration in the fuel filter module. Other salient features of the heaters include low pressure loss during high heat transfer to the medium, a robust design with separate chambers for the electronics and heating element, a low energy requirement, and a high power output (600 W). The heater is controlled by the integrated electronics or the engine management system. The heating element is based on modern resistance technology with a positive temperature coefficient (PTC), and the integrated overheating protection ensures maximum safety. With its modular design, MAHLE’s electric heaters can be flexibly adapted to the specific requirements of passenger car and commercial vehicle manufacturers.

MAHLE blow-by heaters are used in air and blow-by lines in order to prevent icing.

MAHLE heaters use PTC technology and are available in modular variants, such as bar heaters, plug-in heaters (stand-alone), and solutions that can be integrated into the filter housing. The power range is 200–600 W, and the maximum flow rate is 200 L/h. Various control concepts such as thermoswitches, electronic switches, and independent controls using pressure and temperature are all possible. The advantages of MAHLE heaters are the optimized heating function and the potential for a high level of integration in the engine periphery.

MAHLE water level sensors

MAHLE water level sensors for fuel filter modules determine whether too much fluid has collected in the module during operation, thus ensuring reliable filter operation throughout the vehicle’s service life. With MAHLE’s innovative, patented technology, the sensor elements are made of conductive plastic instead of metal, preventing electrolysis problems from occurring. This, combined with a gasket concept based on two-component injection molding, adds to the robustness of the design.

Their broad 9–36 V operating voltage range makes the sensors suitable for a broad array of applications in passenger cars and commercial vehicles. Thanks to MAHLE’s extensive expertise in fuel filter systems, it was possible to achieve a high level of systems integration in developing the sensors. Yet the sensor platform can still be tailored flexibly to the requirements of different passenger car and commercial vehicle applications through adaptations in sensor element length and connection contacts, for example. Available in analog or digital format, the electronic sensor control system offers numerous add-on functions such as diagnostic options.