Mahle is set to debut a groundbreaking innovation at the 2024 IAA Transportation trade fair in Hanover, Germany, from September 17-22. The company is introducing a high-performance, noise-reducing fan designed specifically for electric and fuel cell vehicles, inspired by the quiet flight of owls.
The fan, a first-of-its-kind development, promises to make commercial vehicles significantly quieter by reducing fan noise by up to 4 dB(A)—equivalent to more than halving the perceived sound. This innovation addresses a key issue in e-mobility, where loud fan noise during vehicle operation or charging, particularly in residential areas or service stations at night, can be disruptive.
Mahle’s engineers turned to nature for inspiration, using artificial intelligence to study the noise-reducing characteristics of owl wings. Owls, known as some of the quietest birds in the world, have special plumage that minimizes noise turbulence. By mimicking these features, the new bionic fan blades not only reduce noise but also improve efficiency. The fan boasts a 10 percent performance boost and is 10 percent lighter than traditional designs.
This innovation isn’t limited to commercial vehicles. Mahle plans to make the new bionic fan available for passenger cars as well, offering a wide power range from 300 watts to 35 kW, making it suitable for small electric vehicles to large, temperature-sensitive fuel cell trucks. The fan is already in the prototype stage, with various manufacturers testing it for potential inclusion in future models.
Dr. Uli Christian Blessing, Mahle’s Head of Development Thermal Management, emphasized the role of nature in this breakthrough. “Nature is a great teacher. Our bionic battery cooling plate already showed us the potential of nature-inspired designs, and now we’ve applied that knowledge to our fan, drawing inspiration from the owl, a master of silent flight,” he said. The owl-inspired design minimizes noise turbulence, much like turning off one of the speakers on a stereo system, making the fan quieter and more efficient.
Mahle also extended its bionic principles to the fan’s cover and carrier, making them over 10 percent lighter while increasing their structural strength. This weight reduction further enhances the efficiency and performance of the fan, particularly in noise-sensitive areas.
The new fan is part of Mahle’s broader strategy to integrate advanced electrification and thermal management technologies, critical for the efficient operation of electric vehicles. Mahle, a global leader in both fields, is showcasing this fan as part of a comprehensive exhibit at the IAA Transportation fair. The exhibit will feature a complete fuel cell truck system, including a fully functional fuel cell, thermal management components, and a heavy-duty electric axle.
The e-axle demonstrator integrates two of Mahle’s SCT electric motors with a combined output of 520 kW, alongside a complete liquid management system—all of which are ready for mass production. Visitors to the IAA Transportation fair will have the opportunity to see the fan and other innovations firsthand, highlighting Mahle’s commitment to advancing the future of e-mobility through cutting-edge technology.
