The Hengst incentive: pioneering leading-edge technology
Innovative filtration solutions are an integral part of pioneering vehicle and engine technology. At IAA Commercial Vehicles from September 20 - 27, 2018 the Münster-based specialist Hengst SE – at Booth C28 in Hall 13 – will not only present its latest products and developments, but will also be celebrating the company’s 60th anniversary. 60 years of Hengst also mean 60 years of expertise in filtration and fluid management, as well as long-standing close cooperation with the commercial vehicle and engine industry.
Blue.maxx: A new level of diesel filtration
Modern diesel engines put high requirements on the purity of diesel fuel. Differences in fuel qualities around the world necessitate efficient cleaning with modern fuel filtration concepts. That is why Hengst developed Blue.maxx – an innovative fuel filtration system in which the pre-filter and main filter are no longer considered separately. Instead, they form a well-coordinated overall system that combines single components on the basis of customer requirements. Up to five filtration stages achieve significantly better performance with respect to particle filtration, water separation and differential pressure combined with an optimal filter life, while also reducing the space needed for installation.
Customized Blue.maxx solution for MAN
For its customer MAN Truck & Bus, Hengst used the Blue.maxx modular system for diesel filtration as the basis for development of a custom solution: the Fuel Service Center (FSC).
The “new” FSC is a five-stage filtration system with lifetime water separation, in which the single stages are optimally integrated in a pre-filter and main filter. The special feature of this custom application is the mixing valve. At cold temperatures (during winter operation) warm diesel fuel from the return flow of the common rail system is mixed with cold diesel from the fuel tank. This prevents blockage of the filter insert by paraffin crystals. The system also ensures reliable operation during the transition period from summer to winter. This makes it possible to eliminate the electric heater in the pre-filter for normal use. The FSC will first be installed in MAN’s new D15 engine series.
Multi-functional module with hybrid design for Weichai
Hengst developed a fluid management module for the Chinese engine manufacturer Weichai that is used in all engines of the WP9H and WP10H series. These engines are installed for example in the models of the Shaanxi Automobile Group and the FAW Group Qingdao.
The new module from the Münster-based specialist combines numerous functions. In addition to the oil filter and oil cooler there is also an oil pressure control valve. In this new design, the valve is located downstream of the oil filter and therefore controls the pressure of the filtered oil, regardless of the differential pressure of the filter insert or other components. In addition, an oil filter service valve, a filter bypass valve, a check valve, and the heat exchanger bypass valve are integrated in the module. It is available with or without a lubricating oil centrifuge. The centrifuge removes the soot from the oil to prevent excessive wear of the bearings as a result of high soot content. An important element of the system is the central oil return channel. The oil flowing from the optional centrifuge, the service valve and the oil pressure control valve are fed back to the oil pan through a central return flow channel made of plastic. The hybrid aluminum-plastic design reduces the weight by 7 % in comparison with a version constructed using only aluminum. Other components integrated in the module are the coolant feeder, including a coolant filter and a service valve. The service interval is 60,000 km.
CO2 reduction through use of multi-functional modules
Hengst continuously conducts R&D activities in lightweight construction, integrated thermal management and differential pressure reduction to develop filtration solutions that reduce CO2 emissions. While individual measures already achieve fuel savings of 0.5 %, the combination of different measures can save about 1.7 % in comparison to previous solutions.
Lightweight construction: Heavy-duty plastic also in commercial vehicles
In the area of lightweight construction, customers of Hengst benefit from the use of thin-walled aluminum components in combination with high-strength plastics to achieve a hybrid solution. In the interest of reducing weight, Hengst is increasing the amount of strong plastics that are resistant to oil, chemicals and hydrolysis. Within two generations, continuous research and development in this area has increased the strength of plastic components by more than 40 % with respect to burst pressure and 60 % for dynamic pressure pulsation load. These high load capacities allow the increased use of plastics especially in commercial vehicles, which operate in harsh conditions. As a result, the partial use of plastics helps to reduce the weight of oil/coolant modules.
Integrated thermal management: Precise operating point saves fuel
In the area of integrated thermal management Hengst strives for designs with compact installation space by integrating different functions – such as efficient filters, heat exchangers, sensors, and control valves – in one commercial vehicle oil/coolant module. In the most current modules, oil and water thermostats are implemented in a space-saving design. The latest developments from Hengst enable lower system costs, larger opening strokes, and expanded free flow cross sections and therefore less reduction of performance in the fluid circuits. Fast response and control characteristics allow precise control of an operating point at higher temperatures, which reduces friction as a result of lower viscosity and prevents unnecessary harm to the oil.
Differential pressure: High potential due to new production process
A special focus of the Hengst engineers is on reduction of the differential pressure. For example, interdisciplinary teams use CFD (flow simulation) and new filter media and processing techniques to develop new potentials. The goal is to achieve high dust holding capacities and filter efficiency in combination with low differential pressures. An example of the use of new production methods is the optimal shape of a media-conducting channel. The Hengst engineers are researching ways to manufacture casted parts by utilizing lost cores or by optimizing joining techniques to make them suitable for series production. This allows the implementation of cost-efficient shapes that reduce the differential pressure by up to 70 % compared to standard components, with the same installation space and cross section.
Custom-tailored filtration solutions from Hengst
There are no standard solutions for oil filtration under the hood. Countless influences and requirements necessitate a separate solution for virtually every individual case. But they all have one thing in common: Hengst provides its customers with the optimal combination of filtration efficiency, cost-effectiveness and reliable operation over an extended period.
Fully synthetic filters for improved water resistance
During the combustion process in gas engines, high quantities of water can occur in the oil. This effect is intensified by the ambient conditions, the use of start-stop systems, and water injection. Conventional cellulose filters would be softened by the water, causing the differential pressure to rise and the filter bypass valve to open sooner, so that more unfiltered oil reaches the filtered side. This can be prevented by using a fully synthetic filter from Hengst.
Stack filters for high loads and differential pressures
The operation of motor vehicles in countries where extremely low temperatures prevail results in engine oil with a very thick and highly viscous consistency. When it impacts the filter, this highly viscous oil generates an enormous differential pressure, resulting in high strain on the filter. Although the filter bypass valve opens, this is delayed. The solution developed by Hengst is the stack filter. Special intermediate plates embedded in the filter cartridge shorten the pleats, giving a significant boost to stability. At the same time, these plates keep the pleats open, thus keeping differential pressure and filtration performance at optimum levels.
Multi-layer filters: The ideal solution for use in dusty environments
Hengst also has the ideal solution for construction machines, which are used for example in gravel pits in the Arizona Desert. The problem consists of large quantities of very fine dust, which also gets into the engine and contaminates the oil. If a fine filter is used, it becomes clogged very quickly. A coarse filter does not clog as easily, but the filtration capacity is also less than optimal. As a solution to this trade-off Hengst offers multi-layer filters that can be adapted exactly to the prevailing conditions to achieve the ideal combination of long service life and high filtration efficiency.
Download Picture material Blue.maxx
Download Picture material MAN KSC mainfilter
Download Picture material MAN KSC prefilter
Download Picture material Weichai
Download Picture material Synthetik filter
Download Picture material Synthetik filter chart
Download Picture material Stack filter
Download Picture material Multi-layer filter chart