Performance, Calibration and Controls

Our Value Add

• Extensive experience in supporting range of customer mainstream and R&D development activities
• Flexible approach to development program from multi-phase production project to single system focus
• Collaborative approach to project delivery
• Utilisation of MAHLE Flexible ECU (MFE) for rapid concept development
• Experience of different EMS suppliers on test bed to support customer requirements
• Global footprint – teams in UK, USA, Germany and China

Our Tools, Facilities and Services

Base Engine Hardware Selection and Layout

• Combustion System Development
• Powertrain Hardware Selection
  • Airpath layout
  • Boosting system layout
  • Charge Air Cooler sizing
  • Base engine layout (Compression Ratio, Valvetrain, Injection System, etc.)
  • After-treatment system
• Port Flow and Charge Motion Optimisation
  • Concept design intake and exhaust port
  • Benchmarking port and system and flow characteristics
  • Extensive benchmarking database
  • Concept appraisal via CFD
  • Early assessment of design with rapid prototype flowbox or cylinder head modification
  • Steady state flow testing to validate cylinder head

Engine and System Optimisation

• Base Engine Emissions and Performance Optimisation
  • Characterisation of engine performance over a range of standard MAHLE or customer defined tests
  • Early system/component validation testing
  • Propulsion System Testing
• Advanced Engine Modelling and Optimisation
  • DoE methodology used to improve test efficiency
  • Gaussian Process Modelling to characterise key engine responses
  • Whole area map optimisation
  • PN optimisation over drive cycles/RDE
  • Catalyst heating optimisation
  • Transient load step optimisation
  • Complex valvetrain system modelling
• Experience of optical measurement techniques
• Concerns resolution

Application of State of the Art Technologies

• Advanced Downsizing and Boosting Technologies
  • Research and Customer projects assessing advanced boost system technology
  • eBoosting, eTurbo, Multiple stage, VTG
• Boosting and EGR Technologies
• Downsizing
• Lambda 1 optimisation and hardware system selection

Industry Databases and Competitor Benchmarking

• Understand industry and wider market trends
• Understand performance and emissions attributes to support target setting
• Wide range of general performance and specific attribute databases available
• Experience of combined engine/vehicle competitor benchmarking projects
• Demonstrator vehicle projects with application of novel technology (Charge Air Subcooling, combined HP/LP gasoline EGR)

Our Value Add

• Extensive knowledge base
• Calibration for gasoline and alternative fuel products from concept to production
• Highly experienced in emissions measurement for all markets including RDE, On Board Diagnostics (OBD), driveability and fleet running
• CalLogiq philosophy applied to the whole calibration process to increase efficiency
• Lead / follow approach on projects with multiple derivatives (multiple engine, gearbox and platform combinations)
• Validation run in parallel with calibration
• Targets/measures of success integrated into calibration process
• Efficient resource utilization
• Continuous monitoring of quality targets
• Advanced data management and analysis
  

Our Tools, Facilities and Services

Powertrain Calibration Methods and Tools

• Concept demonstration including rapid development of prototype vehicles
• Software development using MAHLE Powertrain's Flexible ECU platform (MFE)
• Exhaust aftertreatment specification and emissions calibration
• Engine and vehicle validation using ProLogiq™ and MApps™
• Certification, master proving and Production Vehicle Evaluation (PVE) testing

In Use Compliance

• Certified vehicle rolling road & emissions testing capability
• Flexible fleet support capabilities
• MAHLE’s in-house drivestyle assessment tools: In Use Monitor Performance Ratio (IUMPR) / In Use Performance Ratio (IUPR)
• ProLogiq™ - MAHLE’s fleet robustness data processing tool

On Board Diagnostic Applications

• Flexible, Matlab based, toolset for calibration that can be quickly and easily adapted to different EMS or new software functionality
• Large database of fleet drive data from USA and Europe
• Offline software development, evaluation and calibration
• OBD calibration to latest US and European standards including In Use Monitor Performance Ratio (IUMPR) / IUPR requirements
• Catalyst ageing, limit hardware generation and fault simulation
• OBD demonstration testing (master proving) and Production Vehicle Evaluation (PVE) testing
• Certification testing and support

CalLogiq Toolset

• Integrated data management and analysis service for engine and vehicle validation
• Automatic processing and reporting of data
• Improved efficiency through reduced development timescales
• Enhanced reliability and product robustness
• ProLogiq™ processes all test data and automates repetitive tasks
• Independent of control system type
• Simplified reporting tailored to analysis requirements

Customer Benefits

• Flexibility allows for small concept programs through to full system calibration
• Enhanced product quality
• Reduced costs and improved project timescales
• Experience with a broad range of EMS, engine configurations and vehicle platforms
• Improved calibration robustness through CalLogiq and ProLogiq™
• Optimization of data logging setup and data analysis
• Reduced warranty claims due to early concern identification
• Efficient resource utilization
• Optimized fleet size

Our Value Add

• Extensive systems, software and functional safety experience
• Flexible support for customers:
• Powertrain, battery, electric motor, hybrid controls & more 
• From rapid prototype control projects to volume production
• Systems engineering
• Full testing and validation support
• Partner/supplier management
• Teams in UK, Germany, USA & China

Our Tools, Facilities and Services

Systems Engineering

• Concept and production systems & architecture development
• Benchmarking, trade-off studies & target setting
• Support for sensors, actuators and wiring harnesses
• System integration & optimization
• Safety analysis

Software

• Model based function design in Simulink and TargetLink
• Simulation and validation of models using HIL and SIL methods

Vehicle Systems

• Hybrid vehicle system controllers
• Intelligent gateway modules
• Battery management systems
• In-vehicle displays and data logging options 

Powertrain Controls

• Powertrain function development, modelling & implementation
• Access to extensive function library, including:
• • Full torque structure for early vehicle integration
  • Alternative fuels (CNG, LPG, hydrogen and biofuels)
  • Closed loop combustion control
  • Electronic throttle control

Hardware 

• Range ofMAHLE Flexible ECU rapid prototype and production solutions
• Low and high volume applications
• Bespoke control hardware design and manufacturing options