Performance Calibration and Controls
The development and optimisation of modern powertrain systems is a highly complex task. Extensive knowledge and experience is necessary for the successful delivery of vehicle programmes.
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