German automotive parts maker Mahle has introduced a bionic radial blower for automotive air conditioning (AC) systems to enhance efficiency.
Inspired by the aerodynamics of penguin fins, this blower allows the fan to operate 60% quieter, at a reduction of four decibels, compared to conventional models.
Additionally, the bionic fan boasts a 15% increase in efficiency due to the motor's reduced energy requirements.
Particularly suited for vehicles with limited installation space, the bionic radial blower can be fitted to various classes of passenger cars as well as light and heavy-duty commercial vehicles
Mahle Thermal and Fluid Systems R&D vice-president Dr Uli Christian Blessing said: “Evolution has equipped the penguin with fins that allow it to glide through the water with minimal resistance and, therefore, ultrahigh efficiency. The fin shape served as a model in the optimisation process of the impeller of our radial blower.”
A key element in the rapid development of the bionic radial blower was Mahle’s AI tool, which enabled engineers to optimise the fan blade shape and positioning, facilitating swift prototyping, Mahle said.
Positioned strategically in front of the evaporator, the bionic radial blower contributes to a symmetrical and compact design for the air conditioning system.
This design choice enhances the aesthetic while optimising the available space within the vehicle, allowing for additional components to be accommodated more easily.
This space-saving feature is particularly beneficial in battery electric vehicles, where efficient use of space is paramount.
Blessing added: “The application of artificial intelligence has been enormously useful in the optimisation of the bionic radial blower. Our engineers guided the AI and provided it with data and information, enabling it to create more than 30 million virtual designs in a very short time. Internally, we are referring to this as ‘superhuman engineering’.”
Mahle is showcasing this technology at Auto Shanghai, which is scheduled from 23 April to 2 May 2025 at the National Exhibition and Convention Center in Shanghai, China.
At the event, Mahle will also display other bionic solutions such as the high-performance fan for demanding fuel cell and battery electric vehicles, and the bionic battery cooling plate for electrified vehicles.
