MAHLE Powertrain Ltd | Engineering | Manufacturing | Test Systems

MAHLE Powertrain is an engineering service provider and a separate profit centre of MAHLE GmbH. We have three UK locations in Northampton, Wellingbourgh and Worcester. Additionally, we have locations in Germany, the USA, Brazil, Japan and China.

With engineers based all around the world, MAHLE Powertrain supports all major OEMs on a truly global basis.

Our engineering division uses experience and innovation to develop powertrain solutions with high efficiency. A full range of design and development activities for internal combustion engines  are carried out, either for the optimization of existing engines or for new 'clean sheet' designs.

Our engineering division has capabilities in the following areas:

• Gasoline Systems
• Diesel Systems
• Hybrid Systems
• Powertrain Design and Verification 
• Thermodynamics and Applications
• Engine and Component Testing

The manufacturing division provides our customers with comprehensive and highly efficient facilities for the production of complete engines, sub-assemblies, machined components (aluminium or cast iron) and precision castings.

The following manufacturing services are available at our UK facilities:

• Aluminium Block and Head Castings 
• Block and Component Machining 
• Cylinder Head and Engine Assembly
• Powertain Assembly
• Supply Chain Management

Our test systems division offers tools and technical expertise for optimizing vehicle electronic systems. We are a trusted supplier in the development of new testing solutions for a wide range of OEM applications, including component and subsystem applications.

For all our customers, we offer the combined resources of MAHLE Test Systems, MAHLE Powertrain and MAHLE GmbH. Our global footprint gives us the reach and resources to support our customers in all the major automotive development regions in the world.

By using the application of advanced turbocharging technology, we have designed and manufactured the MAHLE downsizing demonstrator -- a highly efficient, small gasoline engine designed to match the fuel economy and performance of modern diesels.

The key points of MAHLE's downsizing demonstrator engine are:

• Application of complementary technologies
• Focus on combustion system development
• Design driven by strength and robustness
• Engine optimised for low friction losses
• In-depth understanding of turbocharger behaviour

We have developed a range extender engine specifically for use in electric vehicles. Using our knowledge and experience of vehicle drive cycles, we were able to determine the critical factors in the design and development of an optimized range extender engine.

Key attributes for the range extender engine are:

• Low weight
• Low cost
• Small package volume
• Good noise, vibration and harshness (NVH) levels

We created a powerful and fully flexible control unit for a wide variety of engine management and vehicle tasks. Our Flexible ECU (MFE) is a robust, open architecture controller based on the proven AFT PROtroniC platform. 

Our Flexible ECU unit provides:

• Complete flexibility
• Controls all engine functions
• Fully configurable/modular software
• Covers current and future engine technologies
• Torque based structure
• Simple to use
• Matlab/Simulink compatible
• Intellectual Property Rights (IPR) protection
• Comprehensive documentation

Our work with turbulent jet ignition (TJI) has garnered us an international reputation. With a contract award from the US Department of Energy (DOE) of up to \$8.4 million, we are designing projects to improve performance levels of engines and powertrain systems for future vehicles.

Our turbulent jet ignition (TJI) projects will focus on developing and testing new cost-efficient technologies for engines and powertrain systems. We hope to remove the technical barriers for broad commercial use of advanced engine technologies.