MAHLE flexible ECU

A powerful and fully flexible control unit for a wide variety of engine management and vehicle tasks.

Our Approach

The MAHLE Flexible ECU (MFE) is a robust, open architecture controller based on the proven AFT PROtroniC platform. It has the capability to control any powertrain application utilising MAHLE's highly optimised functional software. The Flexible ECU overcomes traditional prototype controller development issues and provides a cost-effective solution that is representative of a series production unit.

• Complete flexibility
  
• Controls all engine functions
  
• Fully configurable/modular software
  
• Covers current and future engine technologies
  
• Torque based structure
• Simple to use
• Matlab/Simulink compatible
• Intellectual Property Rights (IPR) protection
• Comprehensive documentation
  

Our Tools, Facilities and Services

Using the MAHLE Flexible ECU, MAHLE Powertrain can support development and calibration activities for gasoline and diesel products in the following areas:

• Full integration with existing vehicle systems, ideal for producing 'close to production level' demonstration vehicles for new hardware concepts

• Software, control algorithms, and system development
• Benchmarking
• Research and development programmes
• Demonstration of new engine hardware concepts
  

Customer Benefits

• Controls any powertrain application
• Protects intellectual property (customer and MAHLE)
• Quick and easy implementation of new strategies
• Fast and cost effective solution
• Access to MAHLE's extension function library
• Modular software with 'plug-in' functionality
• Rapid and cost effective implementation into demonstrator/prototype vehicles

Project Examples

1.4I downsized turbocharged production engine modified to accept various MAHLE technologies for power/FE investigations.
Special feature controls:

• MAHLE DC motor actuator for turbo wastegate
• Inlet and exhaust MAHLE Torque Boost CamInCam control
• Full-load EGR with EGR temperature control, regulated intake depression
• VTG or wastegate boost control

MAHLE 3 Cylinder Downsize Technology Demonstrator,
Special features include:

• Twin turbochargers with DC motor wastegate and compressor bypass, closed-loop turbo speed control
  
• Variable oil pump with closed-loop pressure temperature control

2L Common Rail Diesel investigation into high and low pressure EGR concepts.
Special control features:

• MAHLE rotating EGR valves controlled from ECU via CAN messages
• EGR rate sensing via intake and exhaust O2 sensors
• MAHLE CamInCam
• Combustion pressure analysis

Single cylinder research engine for fuel investigations.
Special control features:

• Direct and port injection
• boost control via external compressed air supply valve, backpressure control for turbocharger turbine simulation
• Control of EGR pump system for driving EGR with unfavourable delta-P from exhaust to inlet

Golf 1.4 TFSi demonstrator vehicle using the MAHLE Flexible ECU to replace the standard production ECU.

• Rapid and cost effective development of demonstrator/prototype vehicles for feasibility assessment/management appraisals etc.,