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 of ICE, Hybrid and BEV powertrains
• Highly experienced in calibration for all markets including C02 optimisation, Real Driving Emissions (RDE), On Board Diagnostics (OBD), driveability and fleet robustness
• Flexibility - small concept programs through to full system calibration
• Efficient resource utilisation through highly integrated test progress
• Advanced automated data management and analysis with MApps MAHLE Applications (MApps) [PDF; 596 KB]
• Global footprint - teams in UK, Germany, USA and China

Our Tools, Facilities and Services

Powertrain Calibration Methods and Tools

• Concept demonstration with rapid developed prototype vehicles Prototype Assembly [PDF; 935 KB]
• Software development using MAHLE Flexible ECU (MFE) MAHLE Powertrain's Flexible ECU platform (MFE)
• Datailed engine mapping using advanced DoE techniques and test automation
• Emissions and fuel economy optimisation with integrated cross-functional approach
• Transmission control calibration Transmission Calibration [PDF; 562 KB]
• HEV / BEV energy management and battery management system (BMS) optimisation
• Evidence gathering and preparation of documentation for AES / BES, AECD
• Catalyst ageing, limit hardware generation and fault simulation
• Vehicle driveability and emotion
• On Board Diagnostic (OBD) calibration
• RDE development
• PEMS testing for RDE legislation
• Engine and vehicle benchmarking
• Certification testing and support, OBD demonstration testing (master proving) and Production Vehicle Evaluation (PVE) testing

State of the art facilities for Testing and Type approval

• eAxle testing capability eAxle Testing [PDF; 1183 KB]
• Battery test and emulation
• Advanced AVL engine dynos
• Fully equipped prototype vehicle build facility Prototype Assembly [PDF; 935 KB]
• Certified vehicle rolling road & emissions testing facilities including UK's only barometric vehicle test chamber
• Latest Horiba Portable Emissions measurement (PEMS) with VCA approved test routes for Real Driving EMissions (RDE) validation

Customer Benefits

• Enhanced product quality
• Reduced costs and improved project timescales
• Optimisation of data logging setup and data analysis
• Reduced warranty claims due to early concern identification
• Efficient resource utilisation
• Optimised 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