[PDF] MAHLE Powertrain – Company Overview - Mahle.com

gcY3FAu69S

[PDF] MAHLE Powertrain – Company Overview - Mahle.com

MAHLE PowertrainCompany Overview

MAHLE Powertrain Ltd.

St. James Mill Road

Northampton NN5 5TZ, United Kingdom

Q1 2012

MAHLE Powertrain Ltd., February 2012 © MAHLE


2

Overview

OUR COMPANY

INDUSTRY CHALLENGES

OUR SOLUTIONS & RESEARCH

CASE STUDIES

THE DIFFERENCE WE MAKE

MAHLE Powertrain Ltd., February 2012 © MAHLE


3

Our Company

ENGINEERING, MANUFACTURING & TEST SYSTEMS

MAHLE POWERTRAIN

click image to open

MARKET REACH

MAHLE Powertrain Ltd., February 2012 © MAHLE


4

Our Company

MAHLE Powertrain

Who We Are

An Engineering and Manufacturing Services Provider

specialising in research, design, development, testing

and production of high efficiency engines.

History

1958 Cos worth founded by Mike Costin & Keith Duckworth

1973 Foundry established at Worcester

1985 Manufacturing established at Wellingborough

1998 Road car division renamed Cosworth Technology

2005 MAHLE Powertrain established under MAHLE

2007 MAHLE Inline 3 Extreme Downsizing Engine runs

2010 Downsizing Demonstrator Vehicle presented

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


5

Our Company

Supporting a Global Customer Base

Detroit (Novi)

São Paulo (Jundiaí)

Wellingborough

Worcester

Northampton

Stuttgart

Shanghai

go to main menu →

Tokyo

MAHLE Powertrain Ltd., February 2012 © MAHLE


6

Our Company

Part of the MAHLE Group

MAHLE Group

One of the top 30 automotive suppliers globally

and a leading powertrain development partner

Engine Systems & Components

Access to development & production know-how,

but independent of actual component sourcing

Access to Test & Prototyping Facilities

‘Local’ support options available worldwide

Driven by Research & Development

Leading edge of IC engines and powertrains

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


7

5.50

5.00

4.50

4.00

3.50

3.00

2.50

2.00

1.50

1.00

0.50

0.00

MAHLE - Development to 2010

Sales (billion Euro) Headcount

4.12

4.31

5.06 5.01

3.86

5.26

2005 2006 2007 2008 2009 2010

50.000

45.000

40.000

35.000

30.000

25.000

20.000

15.000

10.000

37,500 38,600

47,900 49,200

43,500

47,500

MAHLE Powertrain Ltd., February 2012 © MAHLE

5.000

.000

2005 2006 2007 2008 2009 2010

go to main menu →


8

MAHLE – More than just pistons

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


9

MAHLE – More than just Automotive

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


10

MAHLE – ‘The Art of Engines’

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


11

Our Company

Engineering, Manufacturing & Test Systems

Engineering Manufacturing Test Systems

Powertrain Design & Verification

Thermodynamics & Application

Engine & Component Testing

From Clean Sheet to Production

Aluminium Block & Head Castings

Block & Component Machining

Cylinder Head & Engine Assembly

From Prototype to Production

Engineering Testing

Manufacturing Testing

Dealership Testing

From Development to Service

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


12

Our Company

Market Reach

AUTOMOTIVE COMMERCIAL & OFF-HIGHWAY

RESEARCH

MOTORSPORT POWER GENERATION GOVERNMENT PROGRAMMES

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


13

Industry Challenges

CO2 REDUCTION

LOW VOLUME

MANUFACTURING

OPTIMISING

PERFORMANCE

EFFICIENT

DEVELOPMENT PROJECTS

REDUCING

WEIGHT & COST

ELECTRONIC & DIAGNOSTIC

TESTING

ACHIEVE FUTURE

EMISSIONS STANDARDS

PROTOTYPE POWERTRAIN

SOLUTIONS

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


14

Industry Challenges

CO2 Reduction

Challenge

§ Social, ecological & economic drivers demand reduction

in consumption of fossil fuels

§ Increasing levels of electrification & hybridisation

§ Integration of new technologies

§ Increase in powertrain complexity

Considerations

§ Reliable and robust solutions

§ Achieve real-world benefits for all customers

§ Balancing available technologies against targets for fuel

economy, performance, driveability and costs

OUR SOLUTION

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


15

Industry Challenges

Efficient Development Projects

Challenge

§ Time-to-market crucial for commercial success

§ New markets, technologies and demands

§ Increasing engine and powertrain complexity

§ Spend less time / resources on development without

compromising product performance and quality

Considerations

§ First-time-right approach saves development loops

§ Complex interactions demand specialist expertise

§ Majority of product costs defined in initial development phase

OUR SOLUTION

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


16

Industry Challenges

Achieve Future Emissions Standards

Challenge

§ Ever more stringent regulations worldwide, e.g. EU6, LEV3

§ Large variety of tests, limits and directives applicable across

all markets and applications

§ Compliance with On Board Diagnostic (OBD) requirements

§ New requirements: particulate number, off-cycle emissions, …

Considerations

§ Balancing fuel economy against target emission levels

§ Integrated combustion system & aftertreatment development

§ Balancing available technologies against targets for fuel

economy, performance, driveability, project & piece costs

OUR SOLUTION

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


17

Industry Challenges

Optimising Performance

Challenge

§ Driver’s expectations: safety, comfort & performance

§ Trend to downsized, more efficient engines

§ Demanding driveability targets –

excellent transient response & high low end torque

§ Brand DNA

Considerations

§ Understanding performance trade-offs throughout

§ Balancing available technologies against targets for fuel

economy, performance, driveability and costs

§ Drive for efficiency impacts lubrication, cooling and structure

OUR SOLUTION

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


18

Industry Challenges

Electronic and Diagnostic Testing

Challenge

§ Increasing demand in electronics, emissions and on board

diagnostic regulations in vehicle development

§ Testing in engineering, manufacturing and dealership /

aftermarket service is increasingly important

§ Quality is key in customer perception

Considerations

§ Testing of components, sub-assemblies and vehicles is a

true product lifecycle task; from development to production

right through to service and aftermarket

§ Reporting results back to development / manufacturing is key

OUR SOLUTION

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


19

Industry Challenges

Reducing Weight & Cost

Challenge

§ Increased safety and comfort feature content significantly

adds weight and costs to state-of-the-art vehicles

§ A 100 kg reduction in vehicle mass can lower the

CO2 emissions by as much as 10 g/km with additional

benefits in vehicle dynamic behaviour (even braking)

Considerations

§ Earliest concept / design phase decisions account for more

than 75% of weight and costs of final powertrain and vehicle

§ Total cost of development, production and service

§ Common parts and platforms offer economies of scale

OUR SOLUTION

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


20

Industry Challenges

Low Volume Manufacturing

Challenge

§ Highly flexible on-time production volume requirements

§ Low volume production ramp-up and/or ramp-down phases

(Total Product Lifecycle Management)

§ Tight timescales with exacting specification and quality

requirements

Considerations

§ Program objectives and constraints

§ Production planning and quality assurance

§ Continuous improvement processes require simultaneous

engineering support and know-how

OUR SOLUTION

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


21

Industry Challenges

Prototype Powertrain Solutions

Challenge

§ Quickly assess new concepts / prototype technologies

§ Short production development programmes rely on proven,

implementation ready concepts

§ Minimise development risks

Considerations

§ Performance / emissions targets

§ Technologies & benchmarking

§ Target vehicle platform & packaging constraints

§ Timing

OUR SOLUTION

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


22

MAHLE Powertrain Solutions

CO2 REDUCTION

LOW VOLUME

MANUFACTURING

OPTIMISING

PERFORMANCE

EFFICIENT

DEVELOPMENT PROJECTS

REDUCING

WEIGHT & COST

ELECTRONIC & DIAGNOSTIC

TESTING

ACHIEVE FUTURE

EMISSIONS STANDARDS

PROTOTYPE POWERTRAIN

SOLUTIONS

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


23

Our Solutions

CO2 Reduction

Our Solution

§ Extensive experience in the analysis development &

application of CO2 reduction technologies across the

entire powertrain

§ Tools & approaches to support early assessment of complex

control system architectures & proposed solutions

Our Services

§ Rapid new engine concept development and demonstration

§ Driveline architecture & controls specification

§ Engine design, development and testing for series production

§ Technology benchmarking and research

CASE STUDY

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


24

Our Solutions

Efficient Development Projects

Our Solution

§ High level expertise combined with proprietary product

lifecycle and project management system

§ Interdisciplinary project teams co-located to provide

excellent cross-functional communication

§ From ‘clean sheet’ concepts to production upgrades

Our Services

§ Full ‘turn key’ project management (timing, cost and quality)

§ Detailed and costed proposals for project requests

§ Clear point of communication and project status report

against customer defined milestones

CASE STUDY

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


25

Our Solutions

Achieve Future Emissions Standards

Our Solution

§ Combustion system and aftertreatment expertise

§ Knowledge based approach for maximum benefit

§ Flexible methods from engine hardware specification,

integration and calibration development

§ Early assessment of system capability

Our Services

§ Rapid concept emissions development and demonstration

§ Combustion system, aftertreatment & controls development

§ Comprehensive steady-state/transient engine dynamometers

§ Fully certified, climatic chassis dyno test facilities

TEST FACILITIES

CASE STUDY

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


26

Our Solutions

Test Facilities

Northampton (UK)

Durability, performance & emissions (aftertreatment) testing

§ 12 engine test cells (130 to 700 kW, transient/motoring)

§ Two 48” single-roll chassis dynamometers rated at 210 kW

Ambient and climatic test capabilities (-40°C to +50°C)

§ Compliant with Euro 6, LEV2, Tier 2, ULEV requirements

Detroit/Novi (USA)

Durability, performance & emissions (aftertreatment) testing

§ 7 heavy duty diesel test cells (transient/motoring)

12 medium/light duty test cells

§ 48” AWD roll chassis dynamometer rated at 150 kW

Ambient and climatic test capabilities (+10°C to +40°C)

§ Compliant with Euro 6, LEV2, Tier 2, ULEV requirements

Additional Test Facilities (worldwide)

§ 30+ test cells across Germany, Brazil, China & Japan

§ Two climatic wind tunnels in Germany & USA

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


27

Our Solutions

Electronic and Diagnostic Testing

Our Solution

§ Component, subassemblies and vehicle diagnostic testing

and tools at all stages (development, manufacturing, service)

§ Efficient, agile and cost effective modular test solutions

providing an increase in quality and customer satisfaction

§ > 1500 dealers and > 46 production sites on 5 continents

Our Services

§ Quick identification of concerns in calibration development

§ Vehicle End of Line and Repair Station test (TestLogiq®)

§ In-process testers (e.g. evaporative leakage tester)

§ Service tool software (ServiceLogiq®) and reporting tools

CASE STUDY

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


28

Our Solutions

Optimising Performance

Our Solution

§ Experience based tools and approaches to tailor powertrains

to meet customer requirements

§ Unique engine component and systems expertise

§ Fully integrated analysis led methods

§ No restrictions in size: city car or supercar

Our Services

§ 'Clean sheet' concept or performance upgrade

§ Analysis, development & rapid concept demonstration

§ Low volume production of engines

CASE STUDY

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


29

Our Solutions

Reducing Weight & Cost

Our Solution

§ Detailed knowledge of design for manufacture with target

costing methods and unique engine component expertise

§ Philosophy of using simple, practical design features adapted

to specific customer needs

§ Innovative approach not constrained by current practices

Our Services

§ Consultation to advise on feasibility of initial concepts

§ Clean sheet designs or modifications / upgrades

§ Structural analysis, rig testing and durability assessment

§ Target costing and manufacturing support

CASE STUDY

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


30

Our Solutions

Low Volume Manufacturing

Our Solution

§ Based on extensive experience in design, manufacturing and

assembly of ‘class leading’ powertrains

§ Project management and advanced quality planning systems

to promote fault-free on-time production and delivery

§ Engineering and manufacturing ‘under one roof’

Our Services

§ High quality aluminium casting foundry using COSCAST

§ Versatile aluminium and cast-iron CNC machining facilities

§ Assembly operations and end-of-line testing

§ Supply chain management and Supplier Quality Assurance

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


31

Our Solutions

Prototype Powertrain Solutions

Our Solution

§ Rapid new engine concept development solutions

§ From clean sheet designs to major engine upgrades

§ To support dyno &/or vehicle assessment / demonstration

§ Integration of engine concept into carryover or completely

new concept vehicle architectures

Our Services

§ Multi-disciplinary teams offer full range of capabilities

§ Support for engineering, manufacturing, procurement,

engine / vehicle build & testing

§ MAHLE Flexible ECU for prototype control solutions

CASE STUDY

CASE STUDY

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


32

Our Case Studies

Recent Case Studies

DOWNSIZING ENGINE OFF-HIGHWAY ENGINE

RANGE EXTENDER

HIGH PERFORMANCE

TEST SYSTEMS

CALLOGIQ & PROLOGIQ

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


33

Our Case Studies

Advanced Downsizing Demonstrator

Motivation

§ Technology demonstrator to showcase

MAHLE’s engineering & component expertise

§ R&D platform to develop new technologies

Highlights

§ From a clean sheet to a running engine

in only 9 months

§ 50% ‘extreme’ downsizing achieved

2.4l V6 1.2l Inline 3 cylinder with 120 kW

§ 30% reduction in CO2 emissions

§ Additional prototype engines produced for

various customer projects

§ Demonstration car presented in 2010

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


34

Our Case Studies

High Performance

Customer vision

“To challenge the competitors high performance

engine supremacy”

MAHLE was a key development partner

Multiple engines / applications, including :

450 bhp V8 BiTurbo

650 bhp V10 BiTurbo

MPT involved from rapid concept development

through to production

Highlights

Strong relationship developed with client

Based on MAHLE capabilities & many

successful projects

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


35

Our Case Studies

Performance Concept Demonstrator

Customer target

Rapid development of a new high performance

engine concept & demonstration in-vehicle

Project summary

V8 Biturbo, Bosch ME 17 control & many

novel features

Highlights

22 wks from project start to first engine running,

including design, procurement & build activities

in action - from first running on dyno…

12 wks to full torque structure vehicle cal

17 wks to emissions feasibility demonstration

Customer transmission partner comment:

‘… best base calibration they had worked with…’

3.8l Turbo V8 Performance Targets

0

0

0 1000 2000 3000 4000 5000 6000 7000 8000 9000

MAHLE Powertrain Ltd., February 2012 © MAHLE

Power (PS)

700

600

500

400

300

200

100

Engine Speed (RPM)

Power PS

Torque Nm

go to chapter menu →

700

600

500

400

300

200

100

Torque (Nm)


36

Our Case Studies

Compact Range Extender

Motivation

§ Pure electric vehicles face range limitations

due to current battery technology

§ Develop range extender engine as a solution

Highlights

§ 2-cylinder, in-line, 4-stroke, gasoline engine

§ Compact and lightweight package with fully

integrated electrical generator:

− 65 litres and 65 kg

§ Horizontal or vertical installation

§ Maximum continuous power: 30 kW

§ Battery storage capacity can be reduced,

whilst maintaining an acceptable vehicle range

MAHLE Powertrain Ltd., February 2012 © MAHLE

481 m

go to chapter menu →


37

Our Case Studies

&

Calibration validation for an engine family

Multiple engine variants & vehicle platforms

Markets: US, EU & ROW

MAHLE used an integrated approach

calibration & simulation tools used to

develop OBD settings

Maximising benefits of a small vehicle fleet

Highlights

fleet data processing to validate

Many subtle issues found & fixed

Customer reported ’95% fewer MILs in 3 years’

MAHLE Powertrain Ltd., February 2012 © MAHLE

Exhaust back

pressure

1

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0

15

24.75

30

rl

KFFMSML

35.25

40

45

50

69

2000

880

nmot

go to chapter menu →


38

Our Case Studies

Secondary Air Flow Error & ‘Fix’

Low relative secondary air mass flows detected in ProLogiq IDAA report

Root cause confirmed as an error in the back pressure model

Simulated improvements due to a new back pressure model with the same ‘old’ data



15

24.75

30

35.25

40

45

50

69

MAHLE Powertrain Ltd., February 2012 © MAHLE

Exhaust back

pressure

1

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0

go to chapter menu →

rl

KFFMSML

2000

880

nmot


39

39

Our Case Studies

Off-Highway Engine

Re-design an engine family to meet Tier IV

§ Inline 4, approx. 1l displacement per cylinder

§ Concept design (incl. all engine components)

§ Procurement and demonstration engine build

§ Support OEM production design

Problem solving - Head Gasket Failures

§ OEM warranty costs ≈ £1m over 18 months

§ MAHLE analysed root cause and implemented

new design Problem “effectively solved”

Highlights

§ Collaboration with customer including on-site

support through resident engineers

§ Successful approval of demonstration engine

§ Fast and effective problem solution

0

0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85

MAHLE Powertrain Ltd., February 2012 © MAHLE

Pressure (MPa)

250

200

150

100

50

Thickness (mm)

go to chapter menu →

Stopper 0,010 mm

Backland

VS1020

HS4040


40

Our Case Studies

Development & Production of Fuel Leak Tester

Customer target

Fast & cost effective solution to meet 100% leak

test requirement on high volume lines

MAHLE Test Systems solution

Fast accurate detection of 0.010“ diameter leaks

Typical leak test time of 10 seconds

Designed to integrate easily into line

Highlights

In use at 14 assembly plants and growing…

With several major OEMs

go to chapter menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


41

The Difference We Make

OPTIMISED TECHNICAL SOLUTIONS

REDUCE PROJECT COST BY 25%*

REDUCE PROJECT TIMESCALE BY 50%*

* as per acknowledgement by a customer

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


42

Summary

EFFICIENT PROCESSES

TECHNICAL EXPERTISE

FOCUSED RESEARCH

ENGINEERING AND MANUFACTURING

OPTIMISED APPROACH FOR BEST VALUE

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE


Thank you for your attention

go to main menu →

MAHLE Powertrain Ltd., February 2012 © MAHLE

More magazines by this user
Similar magazines