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 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