MANN-FILTER to present filter solutions for cooling and lubrication of e-axles.
The increasing electrification of commercial fleet vehicles is creating new requirements for maintenance and service in the independent aftermarket. E-axles, consisting of an electric motor, power electronics and transmission, require reliable filtration for cooling and lubrication. Since all components work closely together, the quality of the filters used plays a crucial role in the efficiency and operational safety of the system.
As a premium brand of the global filtration expert MANN+HUMMEL, MANN-FILTER stands for innovative and powerful solutions in the independent aftermarket. This also includes special filters for applications in electric commercial vehicles. MANN+HUMMEL has developed various filters for this purpose, which are already being produced in series for the original equipment. They have recently become available on the independent aftermarket as MANN-FILTER HU 6035 x and HU 7052 x for the filtration of the cooling and lubrication circuits of the e-axle of the new Mercedes-Benz eActros 600 truck.
Various oils are used in the e-axle, which perform several tasks in the system: One oil provides lubrication and cooling of the transmission, another is mainly for cooling the electric motor and power electronics. A high degree of oil purity is required to ensure that these functions are fulfilled reliably over the long term. The filters have been specifically developed to meet this requirement.
Filtration for the electric motor and power electronics
Two HU 7052 x filters are installed in the new eActros 600. They reduce unplanned breakdowns, increase operational reliability and thus offer a clear advantage in the tough everyday life of commercial vehicles. The filters reliably separate particles, abrasion and aging residues from the cooling and lubricating oil of the electric motor and power electronics, thus ensuring the lifetime and efficiency of the e-axle.
Bypass valve ensures lubrication
An integrated bypass valve on the HU 7052 x filter ensures that the oil flow is maintained even in the exceptional case of blockage of the filter element. The valve then opens at the right moment, allowing the oil to bypass the filter element and maintain lubrication and heat transfer. Even during a cold start, when the oil is particularly viscous and has difficulty flowing through the filter medium, the bypass valve opens in time, but only long enough to ensure the supply of the components.
“Unfiltered oil is still better than none at all,” explains Daniela Knodel, Product Portfolio Manager at MANN+HUMMEL. “Our bypass valves work very precisely: they only open when and for as long as necessary. Especially in the commercial vehicle sector, constant flow and reliable lubrication are crucial for the functionality of the e-axle.”
Oil filtration for the transmission
The high forces on the tooth flanks of the gear wheels can cause metallic abrasion in the transmission of the e-axle. These particles must be reliably and permanently removed from the system to minimize abrasion and increase lifetime. As with transmissions for combustion engines, effective particle separation also plays a decisive role here, which requires a high-performance filter.
“This is precisely why we developed our MANN-FILTER HU 6035 x, which is specifically designed to meet the requirements of transmissions in modern e-axles. In addition, it is completely metal-free and can be recycled in a resource-efficient way,” explains Knodel.
Special filter medium for the e-axle
Both the HU 7052 x and the HU 6035 x filters are equipped with the MULTIGRADE O-eM 50 filter medium, which is specially tailored to the operating conditions of oil in e-axles. The fully synthetic medium leads to significantly lower pressure losses compared to conventional cellulose media, particularly at low temperatures. A further advantage is that the considerably reduced differential pressures mean that the bypass valve opens less frequently and for shorter periods, thus allowing more filtered, clean oil to reach the lubrication points. The lower differential pressure also reduces the energy requirement of the overall system and has a positive effect on the range of electric vehicles.
In addition, the fully synthetic filter medium has significantly higher chemical resistance to embrittlement over the entire service life. This makes the filter suitable for long service intervals as specified by the vehicle manufacturer. The medium is also extremely water-resistant – even with water ingress, the structure and function are fully preserved. The filters also achieve a high separation efficiency of 99.5% at a particle size of 50 μm. For comparison, a human hair has a diameter of 50 – 100 μm.
With these new filtration solutions for electric commercial vehicles, MANN-FILTER supports workshops and fleet operators in ensuring the long-term reliability and efficiency of modern e-axles, thus providing a practical response to the increasing electrification in the commercial vehicle sector.