MAHLE Flexible ECU

The MAHLE Flexible ECU (MFE) is a rapid prototyping engine controller which can be configured to run any powertrain application. MAHLE’s full torque structure control software supports the integration of prototype engines into modern production vehicle systems.

Solutions for any powertrain application:

  • MAHLE develops all of the engine control software in-house
  • Growing library of control functions
  • Full torque structure for early vehicle integration
  • Key controls already in place for many of the key engine technologies and fuel types
  • Quick and easy implementation of new strategies & calibrations
  • ‘No fuss’ controls solutions
  • Software development in Simulink or TargetLink then auto-coded
  • Rapid debugging
  • Configurable hardware
  • Powerful processing
  • Customer intellectual property is protected

Faster, more efficient developments:

  • Software ‘optimised’ for development tasks
  • Extensive analogue, digital and power input/output capability
  • Closed loop combustion control
  • Direct triggering of diesel/direct injection gasoline solenoid injectors
  • Multiple CAN buses with easily configured message definition
  • Assisted manual operation modes
  • Familiar CCP/XCP communications protocols supporting e.g. INCA & ATI Vision

Flexible support for:

  • New powertrain concept development & demonstration
  • Integration into existing vehicle systems
  • Related controller products for in-vehicle displays and data logging

Project examples:

  • MAHLE 48V MHEV advanced technology demonstrator on test bed and in vehicle
  • Engine and vehicle control for MAHLE Range Extender series hybrid vehicle
  • Development of new customer engine family
  • Benchmarking & optimisation of OEM engines
  • Single cylinder research engines (gasoline and diesel)
  • Diesel aftertreatment research (DPF, SCR, LNT)
  • Control of Stirling engine for power generation

Utilising this basic platform, MAHLE Powertrain has also developed its own engine management code, based on extensive experience with many different production management systems. The software was initially set up for testbed running, but has now been developed into a fully transient torque-based vehicle system. More complex features can be easily turned off when not required, to improve ease of use during basic testing.

The executable code is auto-generated from graphical Simulink / TargetLink models, which greatly reduces the risk of errors and means code development does not have to be handled by software experts. The graphical source code also provides comprehensive documentation for users of the system.

Unlike many aftermarket / motorsport ECUs, the MFE is calibrated using standard tools such as Inca-PC. This allows a quick learning process for development engineers and provides powerful data logging, analysis and dataset management capabilities. Testbed integration using ASAP3 is also possible, so engine management system variables and test bed variables can be logged and analysed together.

While initially planned for in-house applications, the MFE is also used by external clients at their own sites. MAHLE Powertrain can offer a wide range of models for this usage, from “turnkey” solutions with code generation and configuration through to full open access to source code for client development.

MAHLE Flexible ECU (MFE) [PDF; 754 KB]