intake manifold with fully integrated charge air cooler

MANN+HUMMEL produziert das neue Saugrohr mit vollintegriertem indirekten Ladeluftkühler in Shanghai, China.

With the first intake manifold with fully integrated indirect charge air cooling for Jaguar Land Rover, MANN+HUMMEL is delivering an impressive product.

The intake manifold which MANN+HUMMEL developed for Jaguar Land Rover exploits the established full integration of the charge air cooler. In the course of its development the Center of Competence for intake manifolds in Ludwigsburg worked closely together with the R&D colleagues in China. MANN+HUMMEL China was responsible for the design, simulation, project management and production planning as the intake manifold is produced locally in Shanghai. As a result, the sophisticated technology is now available in the largest car market in the world.  

Resistant and robust

The first intake manifold with fully integrated charge air cooler for 3‑cylinder gasoline engines will firstly find application in the new Range Rover Evoque. These engines will form the basis for the electrification of the vehicle with a hybrid drive system. The three main components of the intake manifold are two plastic shells and the cooler made from aluminum. The developers carried out intensive tests and applied modern simulation methods to come up with a robust design which thanks to its complex ribbing and tie rod connections is able to meet all requirements with regard to temperature and pressure stability, vibration resistance as well as sealing characteristics. This was all achieved in a very limited installation space. 

 

The design is also advantageous for the full integration of the charge air cooler as it saves installation space. First and foremost, however, indirect charge air cooling saves CO2 emissions, namely up to three percent. In addition, there are further advantages such as a shorter charge air duct resulting in a reduced charge air volume and therefore improved engine response and a cooling performance which is significantly more constant in comparison to direct cooling.

The fact that the intake manifold is thought out down to the last detail is also evident by the joining process used by MANN+HUMMEL for the plastic components. The particle-free hot gas welding process enables a reduction in weight, an increase in strength and through its narrow weld seam makes a contribution towards efficient exploitation of the installation space. A further advantage of the intake manifold is an easy mounting. This is made possible by sockets pressed into the throttle valve flange and captive screws on the cylinder head flange.

Hot gas welding