MAHLE has developed HeatX Range+, an innovative heat recovery system designed to improve cabin heating efficiency in electric vehicles, especially in cold weather conditions where heating significantly impacts driving range.
Compared to conventional exhaust air systems, the MAHLE HeatX Range+ reduces the energy demand of the electric vehicle’s air conditioning system by approximately 20 percent, enabling drivers to achieve longer driving ranges per battery charge while maintaining high interior air quality.
Commenting on the development, Martin Wellhofer, Member of the MAHLE Group Management Board and Head of Thermal and Fluid Systems, said, “Our HeatX range + heat recovery concept enhances the everyday usability of electric vehicles in winter and makes a meaningful contribution to increasing the attractiveness of electric mobility.”
Thanks to its modular design, the HeatX Range+ can be easily and cost-effectively integrated into existing vehicle architectures. In tests conducted on a typical medium-sized electric vehicle at an ambient temperature of -7 °C and a cabin temperature of 20 °C, the system delivered a range extension of approximately 10 kilometres.
Apart from improved efficiency, the continuous supply of oxygenated fresh air enhances cabin air quality and significantly reduces the risk of window fogging, further improving comfort and safety for EV passengers.
The new heat recovery system uses the air conditioning evaporator to extract and use heat energy from the exhaust air of the vehicle cabin. As the outward-directed air passes through the evaporator, it heats the refrigerant as it leaves the cabin. The refrigerant transfers stored energy to the fresh air intake before it enters the vehicle interior. It efficiently preheats fresh air and reduces heating power demand at winter temperatures compared to conventional exhaust air systems.
The new heat recovery system has no adverse effect on the airflow performance or acoustic behavior of the vehicle air conditioning system. In implementing this innovative energy recovery technology, MAHLE used its extensive experience in the development and manufacturing of vehicle climate control systems. Dr. Uli Christian Blessing, Vice President of R&D Thermal and Fluid Systems at MAHLE, said, “In the early 1990s, MAHLE introduced the first cabin heat recovery system concept “Economizer” for passenger and commercial vehicles, starting today’s trend toward efficient cabin climate control. The current heat recovery layout is designed for the refrigerant R1234yf and can be adapted to all alternative refrigerants with only minor modifications. Can be adapted for.