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.

Performance

  • Extensive knowledge of:
    • Combustion and fuel system development
    • Port flow development
    • Base engine systems
  • Performance optimization
  • Emissions and fuel economy optimization
  • Full testing and validation support
  • Flexible support for customers
  • Utilization of MFE for rapid concept development
  • Teams in UK, Germany, USA & China

Calibration

Our Value Add

  • Extensive knowledge base
  • Calibration for gasoline and diesel 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

  • 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

  • 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

  • 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 

  • 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

  • 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

Controls

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

  • Concept and production systems & architecture development
  • Benchmarking, trade-off studies & target setting
  • Support for sensors, actuators and wiring harnesses
  • System integration & optimization
  • Safety analysis
  • Model based function design in Simulink and TargetLink
  • Simulation and validation of models using HIL and SIL methods
  • Hybrid vehicle system controllers
  • Intelligent gateway modules
  • Battery management systems
  • In-vehicle displays and data logging options 
  • 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
  • Range of MAHLE Flexible ECU rapid prototype and production solutions
  • Low and high volume applications
  • Bespoke control hardware design and manufacturing options