Industry

COOLING SYSTEMS
FOR INDUSTRIAL ENGINES
A STAPLE WITH POTENTIAL FOR GROWTH
Wherever there is a need for efficient and safe cooling in mobile and stationary applications, MAHLE Behr Industry is
synonymous with maximum reliability. As the leading manufacturer of thermal management systems, we are engaged
in many industries and demonstrate our expertise time after time. We are thus ready for a wide variety of projects—
as your reliable partner and proven supplier of high-performance cooling systems—for safe, reliable, comfortable, and
economical mobility.

Innovation as a principle of success
As a member of the MAHLE Group, our focus at MAHLE Behr In-
dustry is on the development and production of cooling and air
conditioning systems for a wide range of applications. These
include industrial engines, ships, buses and special chassis,
construction and agricultural machines, railways, special vehicles,
gensets, power electronics, and aircraft.
In collaboration with our customers, experienced engineers
develop the best technical solution for each application, which is
then subjected to thorough and severe testing to ensure long-term
functionality in operation. An extensive range of equipment and test
benches is available for this purpose at the development and test
center. State-of-the-art programs are used for calculating the
strength (FEM), pressure, temperature, and flow curves (CFD), as
well as the thermodynamics.
Our areas of expertise
Certification according to DIN EN ISO 9001:2000 and TS16949
guarantees optimal functionality and consistently high quality of our
products. The success of MAHLE Behr Industry, however, is based
Overview 3
not only on quality, but also on the close, constructive cooperation
with our customers, beginning in the early stages of the project.
Our experienced specialists are at your side from start to finish
of a project and provide active on-site support, such as for
commissioning, validation, maintenance, and overhaul of cooling
and air conditioning systems.
Our products for every application
ƒƒ Charge air coolers, direct and indirect
ƒƒ Mixed gas coolers
ƒƒ Exhaust gas heat exchangers, direct and indirect
ƒƒ Oil coolers, engine/hydraulics/transmission
ƒƒ Fuel coolers
4 Technology and innovations
Technology and innovations
for your benefit
We develop tomorrow’s innovations today
High-performance, reliable cooling systems and components such
as exhaust gas coolers and indirect charge air coolers provide the
preconditions for meeting the tightened emissions standards today
and in the future.
Our staff—highly experienced in project planning and thermodynamic
design—will be pleased to offer you detailed and factual advice during
the project planning phase. Using in-house thermal management
simulation tools at MAHLE Behr Industry, heat exchangers can be
precisely designed and calculated, and complete cooling systems
can be simulated.
Our expert development team is at your service
Our project managers work hand in hand with experienced and
goal-oriented developers on behalf of your project. Technical stan-
dards, available to all members of staff through a company-internal
knowledge database, ensure detailed design at the highest level.
Coolers and fans undergo precise measurements
on special test benches
All tests required for product validation are carried out in our own
durability laboratory: thermal performance measurements, pressure
and thermal cycle tests, as well as performance measurements for
complete cooling systems and comprehensive vehicle tests.
 
FEM and CFD simulations ensure our developments are
reliable and compliant with specifications
Product Validation, a group within our Development department,
simulates strength-critical components parallel to the design. CFD
calculations are used to determine the air and heat flows, pressure
and temperature distributions for components and overall systems,
even before the first part is produced. Finite element simulations help
to optimize the strength and service life of our products right from the
initial design stages.
 Cooling systems 5

OUR COOLING SYSTEMS—

AS INNOVATIVE AS THEY COME
Gas and diesel engines provide enormous performance—and are Optimal functionality under the toughest conditions, in a small
subject to equally enormous loads at the same time. They perform package: these are the constraints within which our engineers
extremely reliably at continuous operation, however. The failure rate implement just the right application-specific cooling concept—
is exceedingly low. again and again. We are flexible with regard to the material
selection and produce coolers in aluminum, copper alloy, and
The same applies to our cooling systems. Based upon proven and steel—depending on the requirements.
consistently innovative cooling concepts, they support the perfor-
mance of engines and transmissions, always contributing significantly
to the reliability of the overall system. Because our tried and tested
cooling concepts are simply unrivaled.
6 Cooling systems

Charge air cooler aluminum bar and plate design

In applications where coolants with anticorrosive additives are

available, direct charge air coolers in bar and plate design
are the best choice for the recooling of compressed charge air.
They combine high power density with low weight and cost. Due
to the great flexibility given during the design phase, the charge
air coolers can be customized to match just about any space
conditions in an engine.

Special fin and profile geometries as well as reinforced side

parts provide compression strength and vibration resistance. For
especially powerful engines with high charge air temperatures (up to
over 250°C), MAHLE Behr Industry produces high-temperature
charge air coolers with cooled side parts and special high-tempera-
ture fins. This reduces the thermal strain inside the cooler and
Charge air cooler, bar and plate design
prevents damage to the cooler and engine.

“CF charge air cooler”—indirect charge air cooler

stacked-plate design

CF stands for Counter Flow and describes the flow of charge air
and coolant with this heat exchanger in stacked-plate design. The
counter-flow media guide is the most effective way of designing
heat exchangers. This design results in significant advantages
in comparison with conventionally designed charge air coolers
in terms of installation space and weight characteristics, while
maintaining equal performance. Here an example: a CF charge
air cooler made of aluminum is 70% lighter and 50% smaller than
a charge air cooler made in aluminum bar and plate—and
delivers the same performance.

The circumferential coolant channel eliminates the need for complex

heat protection of the component. SOLASII (external component tem-
perature <200°C) is achieved without additional parts. CF charge air
CF-charge air cooler coolers are produced in combinations of aluminum and stainless steel.

CF-charge air cooler

 Cooling systems 7

Charge air/mixed gas cooler

nonferrous-metal round-tube design

Round-tube charge air/mixed gas coolers made from nonferrous

materials are used “when the going gets tough.” High resistance
to mechanical and thermal loads and corrosion are the
defining characteristics of this cooling system. The design can be
customized to allow the use of seawater or poorly maintained
coolants as cooling agents.

Mixed gas cooler The mixed gas coolers can be used for natural gas, biogas, as well
as for landfill gas engines.

Targeted material selection allows us to offer a solution that

guarantees high operational safety and long maintenance
intervals for various requirements in all areas of application.

The ongoing development of cooling systems, especially of air fins,

enables an increase in cooler performance, which in turn results in
a reduction of installation space and weight and in the protection
of resources.

Modern round-tube charge air/mixed gas coolers from MAHLE

Behr Industry are exclusively assembled by mechanical means,
eliminating the need for brazing. The systems are easy to clean
and maintain due to the screw connections in the coolant and
charge air boxes.

Charge air cooler

Slide-in charge air cooler Charge air cooler

seawater-cooled
8 Cooling systems

Aluminum low-pressure charge air cooler stacked-plate design

Aluminum charge air coolers in stacked-plate design stand out due

to their very compact construction and are superbly suitable for low-
pressure applications with engines of up to 600 kW power output.
The vacuum-brazed and therefore flux-free coolers can be varied
with regard to plate quantity and selection of the air-side fin.

Using a cast housing, this type of cooler can be integrated into the
charge air line. This reduces the installation space requirement and
the charge air volume in the intake section, leading to an improved
responsiveness of the engine.

Charge air cooler stacked-plate design

Aluminum charge air cooler tube and fin design

For engines with up to 600 kW power output, indirect aluminum

charge air coolers in fin-and-tube design are the preferred choice
for medium to high quantities. Compared to coolers in bar and
plate design, they are distinguished by lower weight and cost while
achieving equal performance. Due to the counter-flow media guide,
the coolers are highly efficient. This is particularly beneficial when
implemented as a charge air cooler in the context of two-stage
turbocharging.

Various tubes and air-side fins are available in order to be able to

adapt the coolers to the installation space, performance, and
pressure loss requirements of the respective application.
Charge air cooler
tube and fin design
 Cooling systems 9

Oil coolers

The cooling of highly thermally stressed oils (engine, transmission,

power steering) through oil coolers provides significant advantages.
Oil change intervals are extended and the service life of various
components is increased. Depending on the requirements, the oil
cooler is located at the oil filter module or directly on the engine block.

Aluminum stacked-plate Stacked-plate oil coolers from MAHLE Behr Industry are customer-
oil cooler
specific products, developed and configured in accordance with the
respective requirements profile.

Liquid-cooled oil coolers are connected to the coolant circuit of the

engine and offer optimal temperature regulation.

ƒƒ Various disk geometries from 64 mm x 95 mm up to

400 mm x 615 mm are available for oil cooling of industrial
engines within the performance range of 20 to 4,000 kW
ƒƒ Vacuum-brazed oil coolers
ƒƒ Stacked-plate oil coolers are available with and without turbulators
ƒƒ Performance and pressure loss optimization through selection of
respective disk sizes and quantity
ƒƒ High compression and vibration resistance
ƒƒ High efficiency due to counter flow of media
ƒƒ Mounting on engine possible without additional housing
ƒƒ Application possible as oil/coolant, oil/oil, and fuel/oil cooler
ƒƒ Available in aluminum or stainless steel

Stainless steel
stacked-plate oil cooler
10 References

CONCLUSIVELY INTERNATIONAL:
OUR REFERENCES
ƒƒ 2 G ƒƒ Isotta Fraschini

ƒƒ AGCO SISU Power ƒƒ Liebherr

ƒƒ Caterpillar ƒƒ MAN AG

ƒƒ Deutz AG ƒƒ MAN DIESEL SE

ƒƒ GE Energy ƒƒ MTU

ƒƒ GE Transportation ƒƒ MWM

ƒƒ Hatz ƒƒ Same Deutz Fahr

ƒƒ Hyundai Heavy Industries Co., Ltd. ƒƒ Wärtsilä

COMPANY HEADQUARTERS
MAHLE Behr Industry GmbH & Co. KG
Heilbronner Strasse 380
70469 Stuttgart
GERMANY
Phone: + 49 711 501- 42100
Fax: + 49 711 501- 42396
SUBSIDIARIES
USA
MAHLE Behr Industry America LP
5858 Safety Drive, NE – Suite F
Belmont, MI 49306
USA
Phone: + 1 616 647-3490
Fax: + 1 616 647-3491
FRANCE
MAHLE Behr Industry GmbH & Co. KG
18, rue de l‘Esterel, SILIC
94563 RUNGIS
FRANCE
Phone: + 33 145 121293
Fax: + 33 146 875868
Great Britain
MAHLE Behr Industry GmbH & Co. KG
214 Jockey Road
Sutton Coldfield B73 5XP
GREAT BRITAIN
Phone: + 44 121 355- 5546
Fax: + 44 121 355- 5546
CHINA
MAHLE Behr Industry Cooling Equipment (Tianjin) Co., Ltd.
Workshop D5-1, XEDA International Industrial City
300385 Tianjin, Xiqing Economic Development Area
P.R. CHINA
Phone: + 86 22-23828358
Fax: + 86 22-23828368
KOREA
MAHLE Behr Industry GmbH & Co. KG
Hyein B/D #301, MAHLE Sales office
67 Yangjae-dong, Secho-gu
137-889 Seoul
KOREA
Phone: + 82 (0)2 2088 3457
Fax: + 82 (0)2 2088 3939
www.mahle-behr-industry.com

00007673EN0.5.08/12