1 million air cleaner systems per year for Ford's global B car platform. MANN+
HUMMEL supplier to first BMW engine build in China. Improved air cleaner for '
Truck of the Year 2013'. In Focus: Global R&D and .... of parts worldwide. .... 2005
. Photo: Ford Motor Company, Jaguar,. Peugeot, Daimler AG, ampnet, Land
Rover ...
1/2013 In Focus: Global R&D and production network
1 million air cleaner systems per year for Ford's global B car platform MANN+HUMMEL supplier to first BMW engine build in China Improved air cleaner for 'Truck of the Year 2013'
Contents 3
Preface
4
Think globally, act locally 1 million air cleaner systems per year for Ford's global B car platform
Preface Dear Business Partner, Charles Kettering (1876-1958) once said: ʻIf you have always done it that way, it is probably wrong.ʼ These wise
5
Global and local interaction
words spoken by the American engineer today sound more
MANN+HUMMEL supplier to first BMW engine build in China
topical than ever. The pace of life today is fast. Economic phenomena and increasing internationalization simul-
6
8
New freedom for sound designers
taneously pose risks and offer potential for growth. This
Sound module conquers small car segment
requires that we all re-examine our own approach and
Global expertise Interview with Markus Kolczyk
11
consider adjustments as suggested by Kettering. Last year positive market developments in North America
Details make the difference
luckily compensated for the weakening European economy.
Intake manifold and cylinder head cover for the Renault Clio do Brasil
The 40% increase in turnover there is a clear signal. The series start of important oil and fuel filters and global air
12
Able to handle biofuels
cleaner systems were further reasons for the overall
Fully synthetic oil filter media for ethanol powered vehicles
positive development. In the production of intake manifolds, products with innovative concepts were successfully
13
Less is more
implemented in series worldwide. Our customers benefit at
Improved air cleaner for ‘Truck of the Year 2013’
an international level from our core expertise in the area of filtration and from the MANN+HUMMEL global R&D and
14
16
Sustainable partnership
production network. We also meet the highest requirements
Air cleaner system for the Ford Fusion as an example
with our know-how in the area of acoustics and air flow
management organization are indispensable. You can read
applications.
more about this in the interview with Markus Kolczyk, our
Sporty sound for the wild cat Dual-flow air cleaner system for the Jaguar F-Type
17
head of R&D for passenger car applications. Over the last decade MANN+HUMMEL has worked hard to
Always the right choice
become a leading global player in the market for filtration
We promote continual further development. You can count
Wide range of materials and production processes
technology. We operate successfully in a globalized world,
on us as a reliable partner for challenging global projects.
in times of continuous change, numerous new challenges
18
At a glance
and frequent crises. It is important to remain open-minded,
MANN+HUMMEL builds new production plant in China
work with new ideas and consider activities outside the
A new intake manifold for the Indian market
established area of business, away from the normal
Air cleaner for the Volkswagen Group
customs and routines. So we are already developing the
MANN+HUMMEL expands production of oil filters in Mexico
solutions for the future! This is precisely why a global R&D
Take us at our word! Your Kai Knickmann
and production network along with an international project
IMPRINT MANN+HUMMEL Automotive News;
[email protected] Publisher: MANN+HUMMEL GMBH, 71631 Ludwigsburg, Germany Responsible in terms of German press law: Harald Kettenbach Editor: Birgit Herbst, Lisa Bürkle Layout, production: Ralph Dodel Grafikdesign, 73066 Uhingen, Germany
2
3
Think globally, act locally
Global and local interaction
1 million air cleaner systems per year for Ford's global B car platform
MANN+HUMMEL supplier to first BMW engine build in China
Special tasks require special solutions. A good example
The local implementation of projects is a fundamental component of the globalization strategy
of this are projects with a large-scale format, such as the
of automobile manufacturers and their system partners. With the localization of the intake
air cleaner system for Ford's global B car platform which includes
manifold for the 2.0 liter 4-cylinder gasoline TwinPower Turbo engine in China, MANN+HUMMEL
applications for the models Fiesta, EcoSport and B-MAX. The solution
accompanies BMW on this course. As supplier of the intake manifold, MANN+HUMMEL with its
from MANN+HUMMEL for demanding projects such as these is globally
global R&D and production network is a part of this strategy.
coordinated project management with local project teams and local production. This means short distances to the customer in the relevant Production in China is guided by the
markets and production locations worldwide.
need to realize the high quality required by international manufacturers in spite of varying conditions con-
MANN+HUMMEL is involved in the B
project teams offers the automobile
cerning suppliers, workforce and
car project around the world at five of
producer a consistently high level of
culture. MANN+HUMMEL can utilize
its more than 50 locations – at Zara-
efficiency, quality and defined costs
its proven network of experienced
goza in Spain, Querétaro in Mexico,
with a concept where everything is
Indaiatuba in Brazil, Tumkur in India
supplied from a single source.
Air cleaner system for the Fiesta ST 1.6 liter EcoBoost
teams at locations in Germany and China to manage these issues.
and Shanghai in China. The annual
Lessons learned – improving the process
of the systems is possible at all loca-
For the BMW project the series sup-
systems covers the demand for the
tions according to the same drawings
plier set up a special global project
current Fiesta for nearly 100% of its
MANN+HUMMEL provides the right
and requirements. The lessons learned
team on the basis of a ‘buddy sys-
variations around the world.
conditions to realize challenging pro-
from previous developments and se-
tem’ where all functional areas are
ries projects serve as an input for the
assigned to all involved customer in-
next and current series and this re-
terfaces with contact partners in
sults in process improvements.
Germany and China. In addition, a
output of almost one million air cleaner
position was created to provide Ludwigsburg, DE
Zaragoza, ES Shanghai, CN Santiago de Querétaro, MX
Tumkur, IN
Indaiatuba, BR
The international project network
Intake manifold for the 2.0 liter 4-cylinder gasoline TwinPower Turbo engine with mounted cooling plate for the control unit
Depending on the variation, the air
coordination and support for central
cleaner system, consisting of a hous-
functions such as quality, production
ing, filter element as well as clean air
planning and project management
wards maintaining the high quality
sits perfectly in position on the intake
and dirty air ducts, has an integrated
and to serve as a link between the
standard.
manifold. At the same time the
air flow meter inserted in the clean air
local functions.
port and special holes on the rear
MANN+HUMMEL engineers designed A special technical feature of the two-
the intake manifold to enable it to
side of the blow-molded part to main-
In the area of production technology,
shell, vibration-welded intake mani-
handle high mechanical stress re-
tain the acoustic characteristics at a
MANN+HUMMEL decided to build up
fold is a cooling plate for the control
sulting from the pressure pulsations
high level. In order to avoid mix-ups
the injection molding tools in Ger-
unit which removes heat from the air
of the turbocharged engine.
between the often similar variations,
many and then to transfer to the Far
flowing past through openings in the
the designers came up with some
East. The assembly line was built in
upper shell of the manifold. Close
The excellent communication and
clever details specific to the respec-
China, with the support of the central
contact between the cooling plate and
coordination enabled a smooth start
tive variation, e.g. ribs and pins. The
production planning. Extensive train-
the control unit is necessary to achieve
to the production in China – thanks to the ‘buddies’.
The combination of central coordina-
jects such as the standardized design
result is that only the right part can be
ing sessions enabled our Chinese
the required cooling efficiency. This
tion and control in the area of project
of parts worldwide. Despite varying
fitted, in line with the ‘Poka Yoke’
colleagues to become familiar with
solution placed great demands on the
management and engineering in Lud-
technological standards in the markets
principle of achieving top quality by
the new equipment and this consti-
accuracy of the plastic flange to en-
wigsburg with local interdisciplinary
and different suppliers, manufacture
avoiding errors.
tuted an important contribution to-
sure that after fitting the cooling plate
4
5
New freedom for sound designers
The first continuously switchable symposer in the Ford
enters the passenger compartment via the cable duct and
Focus ST produced in cooperation with Ford, its long-term
has a sound quality equal to sound pipes with a larger
development partner, allows MANN+HUMMEL to demon-
cross-section. MANN+HUMMEL is currently producing a further application for the symposer for the US variation of the Ford Fusion and the Mondeo. The symposer produced in Querétaro (Mexico) is equipped with a modified paddle to transfer pulses to ensure the sound meets market
Sound modules such as the symposer have been a specialty for powerful sports cars such as
strate its extensive expertise in the area of acoustics and
the Ford Focus ST for some time. In the slipstream of engine downsizing, the compact sound
sound design. In the new application the symposer is not
creator is now conquering more models and for the first time includes the Ford Fiesta in the small car segment. In the new Focus ST the MANN+HUMMEL acoustic experts have also introduced the first continuously switchable symposer in series.
requirements.
located behind the throttle body as usual but is flanged directly to the intake manifold. The design engineers gave the symposer a separate switching flap to replace the load pulses from the throttle body. The fully variable flap is controlled by the engine control unit
What makes the symposer so interesting is its ability to get
More and more applications
via a pulse width modulation signal. The flap angle depends
back the lost sporty sound. A feature of charged engines is
Since the world premiere of the first symposer in the Ford
on a set of defined engine characteristics including the
that they lose their characteristic sound as the charging
Focus ST, MANN+HUMMEL has introduced more than ten
engine speed, load and gear. The advantage is greater
pressure damps the pulsations of the engine. Charged
other sound systems in series.
freedom for the sound design and improved differentiation for the sound feedback to take customer requirements
engines are also generally better insulated to suppress undesired noises such as the high frequency tones of the
The symposer has really stepped on the gas since 2012
better into account. As it functions independently of the
turbocharger.
with the first continuously switchable variation worldwide in
throttle body, the system is also ideal for diesel applications.
the Focus ST 2.0 liter EcoBoost and also applications in the This is where the symposer comes in. It picks up the engine
Mondeo. The current year will see the inclusion of the small
Sound module conquers small car segment
pulsations near to the throttle body and directs these to the
segment with the Ford Fiesta ST 1.6 liter EcoBoost as well
The first symposer in a small car, in the Fiesta ST 1.6 liter
passenger compartment. The driver then receives an
as the Jaguar sportscar F-Type. A number of applications
EcoBoost, also has a special technical feature. The orifice
acoustic feedback which corresponds to a sporty vehicle
for 2013 and 2014 with other customers will come into
of the sound pipe is no longer located behind the bulkhead
without exceeding the noise limit for accelerated passing.
series shortly.
partition between the engine and cabin, but is situated in the passenger compartment. MANN+HUMMEL developed a very slim two-part sound pipe for this application which
2005
Worldwide first Symposer in series production
6
Jaguar XK, XF, Range Rover Sport V8 5.0 liter
Ford Focus RS 2.5 liter
Ford Focus 1.6 liter EcoBoost
2009
2008
Symposer with vacuum actuator to shut-off in part load and overrun condition
Peugeot 308 1.6 liter Turbo
Adaption of Focus ST Symposer with additional sound enhancement
Injection-molded two-shell charge air duct with integrated Symposer
Ford Mondeo 2.0 liter EcoBoost (Europa)
2010
Symposer not only limited to special editions like Focus ST any more
First Symposer in Mondeo application
Mercedes Benz SLK 1.8 liter/2.0 liter gasoline engine
Ford Focus ST 2.0 liter EcoBoost
2011
Symposer directly integrated at the throttle body connection flange
Ford Fusion 2.0 liter EcoBoost (USA)
Jaguar XFR-S 5.0 liter V8
2012
Worldwide first continuously switchable Symposer application
Adaption of existing system to US-market
Jaguar F-Type and Range Rover Sport
Ford Fiesta ST 1.6 liter EcoBoost
2013
Special edition for rally application Jaguar XFR-S
First Symposer in small car application
Symposer with vacuum actuator to shut-off in part load and overrun condition
Photo: Ford Motor Company, Jaguar, Peugeot, Daimler AG, ampnet, Land Rover
Ford Focus ST 2.5 liter
Worldwide first continuously switchable Symposer application for the Ford Focus ST 2.0 liter EcoBoost
7
Mr. Kolczyk, what are your con-
tinents simultaneously. I am con-
allows us to process the different
cerns as head of global R&D for
vinced that this distinguishes us from
requirements for filtration, acoustics
passenger car applications at
many of our competitors. There are
and pressure loss in a complete pack-
MANN+HUMMEL?
many local competitors in individual
age. Further core expertise includes
markets but there are few competitors
our ability to innovate together with
Every day I think about what our
with a global organization like ours
the global R&D expertise already
customers need, about very high
who are able to manage global R&D
mentioned.
quality products which exactly meet
projects.
the requirements of our customers
How does MANN+HUMMEL manage
and which fulfil cost targets, about
What are your strategic objec-
to meet the customer demand for
innovations customers would like to
tives?
worldwide uniform standards?
opment service we offer our inter-
Our company strategy clearly fore-
We work with a clearly standardized
national customers.
sees further growth in the expanding
R&D landscape. A special network
markets of Asia and America. Today
group for all locations worldwide
How have you organized your glob-
in those markets we already have
serves to ensure that all systems and
ally oriented R&D service?
substantial R&D operations and in
tools are the same, that we work at all
future we plan to strengthen our pre-
locations with the same CAD pro-
Today MANN+HUMMEL has more
sence in the regions where our custo-
grams, and that a central database is
than 15 R&D locations worldwide with
mers are active. A further important
used as a basis for data. We also use
more than 1,000 employees. But the
aspect is the acceleration of the in-
this network to coordinate the test
more important point – and here we
novation. The automotive industry is
benches at our locations. We check,
have in their cars and the devel-
« Every day I think about what our customers need» Markus Kolczyk
Markus Kolczyk, head of R&D for passenger car applications for the original equipment automotive business at MANN+HUMMEL
Global expertise Interview with Markus Kolczyk
are leading – is that our locations are
one of the most innovative fields in
calibrate and match them so that a
closely integrated in a global R&D
the world and therefore we as a sup-
measurement in Brazil leads to the
network. All the establishments work
plier are working intensively on the
same result in China. Apart from that,
to the same standards, the same
development of new technologies.
independent, neutral and strict audits
databases and CAD systems, with
This means we constantly have to
are carried out to check that these
the same test equipment and the
improve our products and come up
standards are maintained. Further-
same project management system.
with innovative solutions for existing
more, the network group reports to
So we have managed to establish a
systems but also create completely
our central R&D committee to ensure
common working platform with
new solutions.
the network is comprehensive and standardized.
common rules and processes. What expertise is required for that? How does this affect specific projects?
How do you realize to develop your Regarding filter systems, intake mani-
solutions economically in the face
folds and technical plastic parts, we
of such high requirements?
In the last ten years the R&D landscape in the automotive industry has undergone a dynamic
These uniform tools allow the imple-
do not only have the know-how to
change. Car producers today demand a presence and R&D expertise from their system
mentation of R&D work for customers
construct components but we are also
We are constantly working on our
on a global basis involving different
able to design a complete system.
processes to become more efficient.
partners all over the world. We talked to Markus Kolczyk, head of R&D for passenger car
locations. For example, if a customer
For example, with an air cleaner sys-
It's all about ensuring the required
applications for the original equipment automotive business, about how the filtration specialist
wishes to manufacture a product with
tem our system expertise ranges from
quality and keeping to the agreed
MANN+HUMMEL has positioned itself.
us locally in China, Europe and North
the air intake up to the delivery point
schedule. But it's also about the more
America and is involved in R&D ac-
at the cylinder head and includes dirty
intensive use of standard tools and
tivities at two locations, we are able to
air ducts, the filter system, clean air
methods such as simulation. For
work on a single project on three con-
ducts and all acoustic measures. This
example, constant improvements to
8
9
Details make the difference Sometimes it only takes small details to make a good product even better. And these matter. This proved to be the case with a project involving MANN+HUMMEL Brazil in cooperation with MANN+HUMMEL France. The challenge was to improve the cylinder head cover and intake manifold for the Renault Clio do Brasil. Through detailed technical solutions and the systematic integration of functions, the design engineers were able to further improve the existing product design and simultaneously reduce costs.
MANN+HUMMEL was also able to refine the solution for the integration of bushings in the cylinder head cover and intake manifold. Previously the bushings were pressed in afterwards in a separate process. The integration of the bushings in the molding process now removes the need for the separate process. This has led to a reduction in costs. The MANN+HUMMEL engineering team has also successfully improved the cylinder head cover. The team integrated the formerly complex oil filler neck and the blow-by
Markus Kolczyk explains how his department meets today’s requirements
connection of the existing design without an additional hardware and software help to clarify
which meet the highest requirements
development to be able to continually
welding process in the molded part. A baffle plate is fitted in
the product characteristics in ad-
for fuel purity and water separation. In
offer our customers new and im-
the cylinder head cover to separate oil from the blow-by gas.
vance. In the ideal case this can take
the field of filtration, this is all suppor-
proved products which support our
Also here the intelligent integration of the oil return flow
place in just one night whereas pre-
ted by highly efficient media which we
customersʼ objectives, in particular
removes the need for additional steps. The integrated clips,
viously a loop involving samples and
are constantly matching to meet the
weight reduction and lower CO2 emis-
which function as cable holders in positions where parts are
tests might have taken months. The
cur-rent requirements. We are active
sions.
fact that we develop our products at
in the market with an intake manifold
local costs in the markets of our cus-
which has an integrated charge air
tomers is an important aspect to
cooler and also with our active ther-
The close cooperation of MANN+HUMMEL France
make sure we remain competitive.
momanagement valve which is a
and MANN+HUMMEL Brazil within the global
highly innovative system to improve
R&D network and efficient exploitation of
the heating circuit of the engine.
common CAE tools identified substantial
Which new innovations has MANN+
What key challenges does the
cluded the fixing points which hold the
future hold?
intake manifold to the 1.0 liter 4-cy-
Photo: Renault
linder flex fuel engine of the Clio.
In the area of air filtration, the radial sealing concept is a top innovation we
We will follow the dynamic markets
Ingenious modifications to the pro-
have successfully brought to series
and further expand our R&D expertise
duct design were successfully able
which makes the system simpler and
in these regions. We will organize
to considerably increase the per-
more economic and is also easy to
ourselves more efficiently and at the
missible load on the fixing points
handle during servicing. Moreover, we
same time grow. A further challenge
enabling their number to be re-
are the technological leader with our
is clearly to constantly develop new
duced from eight to five. The result
new generation of diesel fuel filters
products and push the technical
is less weight and lower costs.
10
welded on, represent a modern solution.
potential for improvement. This in-
HUMMEL realized recently or is about to realize?
Intake manifold and cylinder head cover for the Renault Clio do Brasil
Intake manifold and cylinder head cover for the Renault Clio do Brasil
11
Less is more
Fully synthetic oil filter media for ethanol powered vehicles
Improved air cleaner for 'Truck of the Year 2013'
Ethanol fuels are gaining in importance worldwide. The alcohol produced from biomass has
Production is starting of the new air cleaner gen-
the potential to reduce the carbon dioxide emissions of cars running on ethanol (E85) and of
eration for the Iveco Euro 6 truck Stralis developed
flex fuel cars common in Brazil (up to E100). However, high ethanol levels in fuel can increase
by MANN+HUMMEL which has a number of
the water content in the engine oil and cause problems with the cellulose used in conventional
improved details. The air cleaner system with
oil filter media. MANN+HUMMEL has now introduced a modified fully synthetic oil filter media
integrated clean air duct stands out with its
suitable for use with fuels containing ethanol.
very compact design, reduced number of inter-
Photo: © IVECO
Able to handle biofuels
faces and lower flow losses achieved through shorter distances. Servicing and filter change During an engine cold start, water is
creased by up to 15% at the end of a
is made easier by good air cleaner accessibility
more likely to enter the oil circuit. In
cold start phase, before decreasing
on the 'Truck of the Year 2013'.
this phase, small amounts of water
during the hot phase.
and fuel condense on the cold cylin-
‘Truck of the Year 2013’ with MANN+HUMMEL air cleaner system
der linings and intake system and
The oil filtration concept must there-
then penetrate the engine oil via
fore be suitably designed for these
blow-by gas. Higher ethanol content
harsh operating conditions. With con-
channel slides securely onto the air cleaner fitted to the
in the fuel causes the water content of
ventional cellulose filter media, in-
chassis when the driver's cab is tilted back after the
the oil to increase because unlike
creased water content in the engine
servicing work is completed. The seal attached to the
conventional fuels ethanol mixes with
oil leads to negative effects. The filter
insertion basket prevents ingress of water via the interface
water and this enters the engine oil.
media swells and softens, which re-
between the channel and the air cleaner.
In tests carried out by the German
sults in a considerable increase in the
Research Association for Combustion
differential pressure over the filter ele-
Engines (FVV), the fuel and water
ment. In addition the cellulose filter
pleats of the filter element. All the pleats of the filter element
content in the oil of E85 engines in-
media tends to embrittle more quickly.
are held firmly together by the glue strip and kept in
Filter element with modified fully synthetic oil filter media of MANN+HUMMEL
MANN+HUMMEL uses glue strip technology to stabilize the
The advanced fully synthetic oil filter
position. This prevents possible damage of the filter
media from MANN+HUMMEL is the
element during fitting or through ingress of moisture.
solution to the problem. In contrast to oil filters based on cellulose, the
Differential pressure [bar]
3,5
Cellulose filter media without water content Fully synthetic filter media without water content Cellulose filter media with 5% water content Fully synthetic filter media with 5% water content
3,0
Test conditions: 40°C with 0W30 engine oil
1,5 1,0 0,5 0,0 0%
10%
20%
30%
40%
50%
60%
70%
80%
Volume flow Significantly lower differential pressure when using the fully synthetic oil filter media
12
90%
100%
The integration of the blow-molded clean air duct in the housing is a further plus for the air cleaner. The hotplate-
media, also used for the first time in a
2,5 2,0
Compact air cleaner system with integrated clean air duct
spin-on filter, successfully filters oil
The servicing personnel clearly benefit from the new air
welded connection removes the need for the otherwise
with a high water content with hardly
cleaner. After the air cleaner had to give up its previous
used rubber part and clips and therefore makes a
any negative influence on differential
position on the front left wheel to the Euro 6 aftertreatment
contribution to the reduction of interfaces and costs. Fitting
pressure (see diagram below). The
system, it is now positioned in a service-friendly position
is also simpler. The clean air duct together with the air
fully synthetic filter media also per-
above the frame behind the driver's cab. In the previous
cleaner can be screwed to the chassis. The flat surfaces of
forms well with high oil viscosities
position it was only possible to change the filter element
the filter housing have honeycomb ribs to improve the filter
during a cold start with a differential
from underneath, whereas now the servicing personnel can
acoustics.
pressure which is considerably lower
easily pull out the filter element horizontally at chest height.
than that observed with common cel-
An overmolded anti-rotation lock helps to ensure the proper
The scope of equipment also includes an electrical service
lulose media. Even with lower quality
and secure fitting of the air cleaner housing cover.
switch and a flange to fit a humidity sensor. The air cleaner is prepared for the fitting of a secondary filter element for
oils, the tests indicated significantly greater resistance to ageing.
The integrated insertion basket also assists the servicing
use with applications on construction sites or dusty con-
personnel. The insertion basket ensures that the intake
ditions.
13
Sustainable partnership Air cleaner system for the Ford Fusion as an example
4
The Aligned Business Framework (ABF) is the name of the magic formula for automotive suppliers to the Ford group. In fact, the ABF is Ford's strategy designed to build up a network of selected suppliers who particularly stand out due to their innovation, competitiveness and
3
global footprint. For the last two years MANN+HUMMEL has been part of this select circle of ABF suppliers and therefore has a good chance of continuing the close development and production partnership with the world's fifth largest automobile producer. Photo: © Ford Motor Company
2
1
MANN+HUMMEL air cleaner system for the new Ford Fusion and Ford Mondeo
Ford Fusion with the new air cleaner system of MANN+HUMMEL
Global R&D and production expertise and many years of
(China). As a result, thanks to the MANN+HUMMEL global
excellent business relations with Ford enabled the
R&D and production network, the air cleaner system is
MANN+HUMMEL teams to qualify for the highly revered
globally available.
1
Two-component dirty air duct
3
HC adsorber element (variation)
2
Filter element
4
Injection-molded TPC bellows
The system mainly consists of a two-component dirty air
The special technical features of the product also include
duct with an overmolded seal and buffers, air cleaner
injection-molded bellows for the clean air duct. Instead of
housing, an plug-in air flow meter integrated in the clean air
the usual elastomer bellows, in the Fusion air cleaner
port and a multi-part clean air duct. For the US market, a
system MANN+HUMMEL uses bellows manufactured in a
hydrocarbon (HC) adsorber is integrated in the upper part of
thermoplastic elastomer (TPC) injection molding process.
the housing. The injection-molded parts are made from up
This solution fully meets the high quality requirements of the
to 20% recompounded material.
customer and costs less than the elastomer bellows previously used.
Two-component technology expertise
The plastic closing clips developed by Ford are another
worldwide presence has now produced the third air cleaner
It is expected that the volume of air cleaner systems to be
In the manufacturing process, MANN+HUMMEL is able to
detail worthy of note. They join the upper and lower part of
for the Mondeo / Fusion platform in succession.
produced in these plants add up to many hundreds of
exploit its extensive expertise in the area of two-component
the air cleaner housing on the side opposite the two hinges.
thousands. As well as in the Fusion, the part also finds
technology to eliminate individual production steps, shorten
MANN+HUMMEL's extensive expertise over many years as
Globally available products
application in the Ford Mondeo for Europe. In total, ten
efforts and therefore reduce costs. With the two-component
a plastics specialist enables the manufacture of the clips –
MANN+HUMMEL's first project as an ABF supplier involves
different diesel and gasoline engine variations in Europe,
technology it is possible to eliminate post-processing steps
usually produced in metal – for the first time in series in
the MANN+HUMMEL production locations in Portage (US),
the NAFTA region and the Asia-Pacific area are equipped
like assembly or welding, for example, it is not necessary to
plastic, which is a contribution towards the reduction of
Querétaro (Mexico), Zaragoza (Spain) and Shanghai
with the air cleaner system.
fit rubber buffers afterwards.
costs and weight.
ABF status. This explains why MANN+HUMMEL with its
14
15
Sporty sound for the wild cat
Always the right choice
A wild cat needs a lot of exercise and a lot of fresh air for a sense of well-being. These principles
Single- or two-component technology, hard or soft materials, injection molding, 2D or 3D blow
not only hold true for the animal world – they are also valid for none less than the Jaguar F-Type,
molding – in the area of plastics processing MANN+HUMMEL is able to call all the shots. The sys-
the first two-seater produced by the high quality British marque since the end of the produc-
tem supplier has a wide range of expertise encompassing a variety of production processes
tion of the legendary E-Type in 1974. The dual-flow air cleaner system developed by Jaguar
which provides an excellent basis to decide on the right material and production process for the
Land Rover meets the high requirements for the V6 and V8 supercharged engines used in the
customer.
Wide range of materials and production processes
F-Type. MANN+HUMMEL supported the design maturation and mass-produces the system. The ability to choose from a wide range of materials and
Low-cost single-component technology
five-sided filter element consisting of two trapezoidal bellows
production processes is extremely beneficial. Depending on
In this case the design engineers opted for a low-cost
allows it to perfectly exploit the existing installation space to
the application requirements, implementation of the right
solution. Instead of a two-component part with quick
maximize service life. The filter element is just one of many
solution for each component part is possible. The current
connector, they realized an fully-plastic duct made from just
special designs necessary to fully exploit the increasingly tight
project to produce charge air ducts for the Focus, C-MAX
one material, thermoplastic polyester elastomer (TPC).
installation space in the engine compartments nowadays.
and Mondeo for Ford is a good example. With selective use
MANN+HUMMEL's decision to change from a two-com-
Due to the low fitting position of around 200 mm above the
of materials and design improvements MANN+HUMMEL
ponent process to a single-component process led to
ground, the filter change is made from below. Hinges on the
has been able to provide a high quality, economic solution.
considerably lower process costs. In order to compensate
air cleaner housing make it easy to service and reduce the Fully-plastic charge air ducts are often manufactured as
comparison to the hard component in the connection area,
hard-soft parts in a two-component process or consist of
MANN+HUMMEL developed a stable connection with a
Another special technical feature of the dual-flow system is
different components of hard and soft materials welded
hose clip and rubber insulator which even functions without
the broadband silencer integrated in the clean air duct. It
together. In both cases the connection area is made in the
the usual metal supporting rings.
eliminates undesired high frequency noise components of
hard component. This area then has the required rigidity to
the compressor from the intake noise. A Symposer system,
meet the high requirements with regard to charging pres-
A further special feature of the charge air
made by MANN+HUMMEL, contributes to the pleasant
sure, temperatures and tightness.
duct located between the intercooler and
number of screws.
Dual-flow air cleaner system for the Jaguar F-Type
for the lower material strength of TPC, especially in
sporty sound of the car.
the throttle are the flexible monoaxial bellows which compensate for move-
The work of the MANN+HUMMEL R&D engineers in Wolverhampton in the UK to integrate a high performance air cleaner
MANN+HUMMEL was able to selectively utilize synergy
system in the engine compartment of the new Jaguar roadster
effects for this project from its proven global R&D and
was made easier by being close to the customer, sharing the
production network. The clean air ducts are supplied from
same language, short distances and an established relation-
MANN+HUMMEL Laval, France to Wolverhampton and pre-
ship to Jaguar.
assembled to the air cleaner housing. Wolverhampton then
ment between the engine and bodywork.
is tier-one supplier for the air cleaner assembly to Jaguar Land Rover and Laval supplies the dirty air ducts also as a
The compact air cleaner system designed for the available
tier-one supplier. The full-flow hydrocarbon adsorber
installation space is fitted in a low position respectively left
element for the US version comes from the German
and right behind the headlights. The special shape of the
MANN+HUMMEL locations in Gefrees and Marklkofen.
Photo: Jaguar
Compact dual-flow system
Jaguar F-Type with compact air cleaner system of MANN+HUMMEL
MANN+HUMMEL charge air ducts for the Ford models Focus, C-MAX and Mondeo
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Photo: Volkswagen
At a glance
MANN+HUMMEL builds new production plant in China In the meantime MANN+HUMMEL has five production loNew Golf 7 – another vehicle with a MANN+HUMMEL air cleaner system
cations in China. The Changchun plant located in the northeast of China in an economic and technological develop-
Air cleaner for the Volkswagen Group
ment zone has been so successful that the production area is no longer large enough to accommodate the planned production capacity. Therefore in July 2012 work began on building a new plant. The relocation to the new plant is scheduled to start at the
MANN+HUMMEL supplies the Volkswagen group with
The filter also offers high performance for areas with above
different air cleaner variations for the MQB A platform from
average rainfall. An insert to separate water prevents in-
its plant in Wolverhampton in the UK
gress of water into the engine.
Modern production plant in Changchun
end of June 2013 and be completed by September. After
The various air cleaners are used in the 1.6 liter and 2.0
the official opening of the plant, customers will be supplied
The production plant in Changchun has belonged to the
liter diesel engines and 1.8 liter and 2.0 liter gasoline
from the modern production plant in Changchun from Octo-
group since 2003. MANN+HUMMEL produces a wide range
engines which find use in the VW Golf 7, Audi A3, Seat
ber onwards.
of products there for the automotive industry, for industrial
Leon and Skoda Octavia.
customers and for the aftermarket business. Different technical variations cover the requirements of the various markets. For example, a variation with a warm air flap is offered for cold countries. This regulates the inflow of
A new intake manifold for the Indian market
warm air to reliably protect the filter against blocking due to
Photo: ampnet
snow. A thermostat element regulates the flap according to plant in Tumkur located in the state of Karnataka. The
the outside temperature.
MANN+HUMMEL air cleaner system for the MQB A platform
customer plant in Biadi is also located in the state of Karnataka, right next to the capital city of Bangalore and less than 90 minutes away from the MANN+HUMMEL plant. The injection-molded and subsequently vibration-welded intake manifold is characterized by its compact design and
MANN+HUMMEL expands production of oil filters in Mexico
meets the high quality requirements of the Japanese car producer.
After the successful start of series production in the Czech plant of Okrisky, production of the screw-in oil filter unit for the Audi 1.8 liter and 2.0 liter TFSI engines has now also commenced at the Mexican location of Querétaro. The Mexican location will meet customer demands for the new engine plant at Silao. A decisive advantage for both sides is
New Toyota Etios Liva with MANN+HUMMEL intake manifold from India
closeness to the customer as both plants are located only around 150 km from each other.
A further intake manifold produced by MANN+HUMMEL sees the light of day in India.
The Mexican production location has many years of knowhow in the production of oil filters. As early as 2004 plastic
MANN+HUMMEL has three production locations in India. The intake manifold for the 1.2 liter gasoline engine of the new Toyota Etios Liva is produced at the MANN+HUMMEL
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Compact intake manifold for the 1.2 liter gasoline engine of the Toyota Etios Liva
modules were produced there for the 2.5 liter TFSI engines of the Volkswagen Group.
MANN+HUMMEL plant in Querétaro
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Center of competence
Low-pressure EGR systems from MANN+HUMMEL: modular design fitting into the smallest space For regulating and mixing air-exhaust flows, removing condensate or protecting the turbocharger through filtration. Our leading know-how offers you customized solutions for the sustainable mobility concepts of the future. As a long-term development partner and system supplier to the international automotive industry we have been providing optimum solutions for our customers and the environment for more than 70 years. Our core competence is filtration. We combine systems and plastics expertise with the ability to manage projects and manufacture products professionally and reliably to uniform standards worldwide.
www.mann-hummel.com
