Electrification Technologies

MAHLE Powertrain has proven capabilities and facilities to support our clients in developing fully optimised mild-hybrid, plug-in hybrid, range extended, battery and fuel cell electric vehicles.

  • Battery module & pack design and modelling
  • Battery assembly and testing
  • Cell selection and characterisation
  • Electro-thermal simulation
  • eMotor design & development
  • Control hardware (prototype & production)
  • Control strategy development & calibration
  • Whole vehicle system integration
  • Powertrain & component testing
  • Vehicle build & testing
  • Real world validation

Project examples:

  • M3x High Performance Battery Module [PDF; 3548 KB]- An in-house designed battery module concept with advanced thermal management technology for sustained high performance.
  • MAHLE Modular Hybrid Powertrain- A fully integrated modular solution combining high efficiency IC engine, traction motor, generator, power electronics and transmission. Scalable for a wide range of vehicle applications.
  • MAHLE Flexible ECU (MFE) [PDF; 1128 KB]- A range of powerful, open platform ECUs with in-house developed software for controlling EV and hybrid vehicle systems, including battery charging and battery management.
  • 48V Battery Pack - A high power, high charge rate 48V battery pack for a range of mild hybrid applications.
  • Integration & control of electric turbo chargers for a PHEV application.
  • Full vehicle integration of performance hybrid with MGU-K and MGU-H.
  • Through the Road Parallel Hybrid - A Performance Hybrid AWD demonstrator employing high output wheel motors to provide three alternative drive modes.
  • Range Extender demo car - Series hybrid with full integration of clean sheet range extender engine. Conversion of a vehicle to full electric operation.
  • Advanced Downsizing demo car - 48V MHEV vehicle conversion including BSG, eSupercharger and control system.

Electrification Build & Test [PDF; 1785 KB]

Electrification Design & Development [PDF; 1228 KB]

Power Electronics