Vehicle Development

Our Value Add

Comprehensive, fully certified on-site facilities for vehicle emissions testing and driveability optimization.

MAHLE Powertrain's 4WD vehicle test facility

Our Tools, Facilities and Services in Northampton, UK:

  • New Vehicle Development Centre for comprehensive testing of all vehicle types
  • 4WD chassis dyno with climatic and altitude capability (up to 5000m)
  • 2 fully equipped 4WD chassis dynos for climatic and ambient testing
  • Hydrogen sensing and rapid extraction systems
  • Solar array to Federal SC03 specifications
  • Full size dilution tunnel
  • Particulate mass and count measurement
  • Horiba analysers for gaseous, Pn/Pm
  • VCA certified to EURO 6c
  • Capable of testing to proposed 2024 standards
  • Cold environment vehicle testing
  • ISO/IEC 17025 accreditation for vehicle emissions testing to latest Euro 6 standards
  • -40 °C to +60 °C climatic control for cold start and drive away development
  • Dynamometers rated to 6000 Nm
  • Max tractive effort 8000 N with up to 250 km/h wind velocity
  • Vehicles up to 3000 kg accommodated (max weight 2000 kg per axle)
  • Full range of standard and alternative fuels available
  • FTIR analyser for unregulated gaseous emission analysis and speciation
  • Dedicated soak area for up to 15 vehicles

Vehicle Development Centre [PDF; 24 MB]

MAHLE Powertrain Vehicle Testing (USA)

Our Tools, Facilities and Services in Plymouth, Michigan, USA:

New 4WD Powertrain Dyno

    • 4-dyno set up with road speed fan (LTG - 84MPH)
    • 623 kW battery simulator
    • Raw gas emissions sampling (dual stream)
    • Vehicle simulation software (IPG Carmaker & Truckmaker)
  • Operating strategy optimisation for BEV, hybrid & ICE powertrains
  • Component integration & release testing without a full vehicle
  • Driveability evaluation & development
  • Highly repeatable drive schedules
  • ADAS development & integration

CARB Accredited Vehicle Emissions Lab (40 CFR Part 1066)

  • Four Wheel Drive Chassis Dynamometer
    • Froude Chassis Dyno 4WD
    • 150 kW / roll
    • Adjustable wheel base
    • 200 kph

  • Automation System
    • AVL IGEM Engine Suite
  • Canister Purge Station
    • Automated canister loading
  • Ambient Air Temperature Control
    • 10 - 50 deg C
  • Emissions Measurement
    • 1066 Compliant
    • AVL i60 CVS Bag
    • AVL i60 Dual Stream Raw Gas
  • Vehicle Cooling Fan
    • Fixed speed 5,300 CFM fan
    • Variable speed 25,000 CFM fan (84 mph)
  • Driver's Aid
    • Full catalog of US and EU drive cycles
    • Programmable cycles for RDE simulation
  • Add-On Devices Available
    • Particle count - AVL Smart sampler
    • Particle mass - AVL Particle counter
    • Modal soot - AVL Micro soot sensor
    • GHG - AVL I-60 FTIR
    • HEV – AVL battery simulator and Hioki power analyzer
    • Adjoining engine cell for OBD work
    • QCL for N2O measurement

AVL i60 Constant Volume Exhaust Sampling

  • 350 mm Dilution tunnel shared between chassis & engine dynamometer test cells meeting regulatory requirements as specified in CFR Parts 1065 & 1066
  • Flow capacities to handle up to 330 kW on the engine dynamometer and 220 kW on the chassis dynamometer