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[PDF] MAHLE Powertrain â Company Overview - Mahle.com
[PDF] MAHLE Powertrain â Company Overview - Mahle.com
[PDF] MAHLE Powertrain â Company Overview - Mahle.com
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<strong>MAHLE</strong> <strong>Powertrain</strong> – <strong>Company</strong> <strong>Overview</strong><br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd.<br />
St. James Mill Road<br />
Northampton NN5 5TZ, United Kingdom<br />
Q1 2012<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
2<br />
<strong>Overview</strong><br />
OUR COMPANY<br />
INDUSTRY CHALLENGES<br />
OUR SOLUTIONS & RESEARCH<br />
CASE STUDIES<br />
THE DIFFERENCE WE MAKE<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
3<br />
Our <strong>Company</strong><br />
ENGINEERING, MANUFACTURING & TEST SYSTEMS<br />
<strong>MAHLE</strong> POWERTRAIN<br />
click image to open<br />
MARKET REACH<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
4<br />
Our <strong>Company</strong><br />
<strong>MAHLE</strong> <strong>Powertrain</strong><br />
Who We Are<br />
An Engineering and Manufacturing Services Provider<br />
specialising in research, design, development, testing<br />
and production of high efficiency engines.<br />
History<br />
1958 Cos worth founded by Mike Costin & Keith Duckworth<br />
1973 Foundry established at Worcester<br />
1985 Manufacturing established at Wellingborough<br />
1998 Road car division renamed Cosworth Technology<br />
2005 <strong>MAHLE</strong> <strong>Powertrain</strong> established under <strong>MAHLE</strong><br />
2007 <strong>MAHLE</strong> Inline 3 Extreme Downsizing Engine runs<br />
2010 Downsizing Demonstrator Vehicle presented<br />
go to main menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
5<br />
Our <strong>Company</strong><br />
Supporting a Global Customer Base<br />
Detroit (Novi)<br />
São Paulo (Jundiaí)<br />
Wellingborough<br />
Worcester<br />
Northampton<br />
Stuttgart<br />
Shanghai<br />
go to main menu →<br />
Tokyo<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
6<br />
Our <strong>Company</strong><br />
Part of the <strong>MAHLE</strong> Group<br />
<strong>MAHLE</strong> Group<br />
One of the top 30 automotive suppliers globally<br />
and a leading powertrain development partner<br />
Engine Systems & Components<br />
Access to development & production know-how,<br />
but independent of actual <strong>com</strong>ponent sourcing<br />
Access to Test & Prototyping Facilities<br />
‘Local’ support options available worldwide<br />
Driven by Research & Development<br />
Leading edge of IC engines and powertrains<br />
go to main menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
7<br />
5.50<br />
5.00<br />
4.50<br />
4.00<br />
3.50<br />
3.00<br />
2.50<br />
2.00<br />
1.50<br />
1.00<br />
0.50<br />
0.00<br />
<strong>MAHLE</strong> - Development to 2010<br />
Sales (billion Euro) Headcount<br />
4.12<br />
4.31<br />
5.06 5.01<br />
3.86<br />
5.26<br />
2005 2006 2007 2008 2009 2010<br />
50.000<br />
45.000<br />
40.000<br />
35.000<br />
30.000<br />
25.000<br />
20.000<br />
15.000<br />
10.000<br />
37,500 38,600<br />
47,900 49,200<br />
43,500<br />
47,500<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong><br />
5.000<br />
.000<br />
2005 2006 2007 2008 2009 2010<br />
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8<br />
<strong>MAHLE</strong> – More than just pistons<br />
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<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
9<br />
<strong>MAHLE</strong> – More than just Automotive<br />
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<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
10<br />
<strong>MAHLE</strong> – ‘The Art of Engines’<br />
go to main menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
11<br />
Our <strong>Company</strong><br />
Engineering, Manufacturing & Test Systems<br />
Engineering Manufacturing Test Systems<br />
<strong>Powertrain</strong> Design & Verification<br />
Thermodynamics & Application<br />
Engine & Component Testing<br />
From Clean Sheet to Production<br />
Aluminium Block & Head Castings<br />
Block & Component Machining<br />
Cylinder Head & Engine Assembly<br />
From Prototype to Production<br />
Engineering Testing<br />
Manufacturing Testing<br />
Dealership Testing<br />
From Development to Service<br />
go to main menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
12<br />
Our <strong>Company</strong><br />
Market Reach<br />
AUTOMOTIVE COMMERCIAL & OFF-HIGHWAY<br />
RESEARCH<br />
MOTORSPORT POWER GENERATION GOVERNMENT PROGRAMMES<br />
go to main menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
13<br />
Industry Challenges<br />
CO2 REDUCTION<br />
LOW VOLUME<br />
MANUFACTURING<br />
OPTIMISING<br />
PERFORMANCE<br />
EFFICIENT<br />
DEVELOPMENT PROJECTS<br />
REDUCING<br />
WEIGHT & COST<br />
ELECTRONIC & DIAGNOSTIC<br />
TESTING<br />
ACHIEVE FUTURE<br />
EMISSIONS STANDARDS<br />
PROTOTYPE POWERTRAIN<br />
SOLUTIONS<br />
go to main menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
14<br />
Industry Challenges<br />
CO2 Reduction<br />
Challenge<br />
§ Social, ecological & economic drivers demand reduction<br />
in consumption of fossil fuels<br />
§ Increasing levels of electrification & hybridisation<br />
§ Integration of new technologies<br />
§ Increase in powertrain <strong>com</strong>plexity<br />
Considerations<br />
§ Reliable and robust solutions<br />
§ Achieve real-world benefits for all customers<br />
§ Balancing available technologies against targets for fuel<br />
economy, performance, driveability and costs<br />
OUR SOLUTION<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
15<br />
Industry Challenges<br />
Efficient Development Projects<br />
Challenge<br />
§ Time-to-market crucial for <strong>com</strong>mercial success<br />
§ New markets, technologies and demands<br />
§ Increasing engine and powertrain <strong>com</strong>plexity<br />
§ Spend less time / resources on development without<br />
<strong>com</strong>promising product performance and quality<br />
Considerations<br />
§ First-time-right approach saves development loops<br />
§ Complex interactions demand specialist expertise<br />
§ Majority of product costs defined in initial development phase<br />
OUR SOLUTION<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
16<br />
Industry Challenges<br />
Achieve Future Emissions Standards<br />
Challenge<br />
§ Ever more stringent regulations worldwide, e.g. EU6, LEV3<br />
§ Large variety of tests, limits and directives applicable across<br />
all markets and applications<br />
§ Compliance with On Board Diagnostic (OBD) requirements<br />
§ New requirements: particulate number, off-cycle emissions, …<br />
Considerations<br />
§ Balancing fuel economy against target emission levels<br />
§ Integrated <strong>com</strong>bustion system & aftertreatment development<br />
§ Balancing available technologies against targets for fuel<br />
economy, performance, driveability, project & piece costs<br />
OUR SOLUTION<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
17<br />
Industry Challenges<br />
Optimising Performance<br />
Challenge<br />
§ Driver’s expectations: safety, <strong>com</strong>fort & performance<br />
§ Trend to downsized, more efficient engines<br />
§ Demanding driveability targets –<br />
excellent transient response & high low end torque<br />
§ Brand DNA<br />
Considerations<br />
§ Understanding performance trade-offs throughout<br />
§ Balancing available technologies against targets for fuel<br />
economy, performance, driveability and costs<br />
§ Drive for efficiency impacts lubrication, cooling and structure<br />
OUR SOLUTION<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
18<br />
Industry Challenges<br />
Electronic and Diagnostic Testing<br />
Challenge<br />
§ Increasing demand in electronics, emissions and on board<br />
diagnostic regulations in vehicle development<br />
§ Testing in engineering, manufacturing and dealership /<br />
aftermarket service is increasingly important<br />
§ Quality is key in customer perception<br />
Considerations<br />
§ Testing of <strong>com</strong>ponents, sub-assemblies and vehicles is a<br />
true product lifecycle task; from development to production<br />
right through to service and aftermarket<br />
§ Reporting results back to development / manufacturing is key<br />
OUR SOLUTION<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
19<br />
Industry Challenges<br />
Reducing Weight & Cost<br />
Challenge<br />
§ Increased safety and <strong>com</strong>fort feature content significantly<br />
adds weight and costs to state-of-the-art vehicles<br />
§ A 100 kg reduction in vehicle mass can lower the<br />
CO2 emissions by as much as 10 g/km with additional<br />
benefits in vehicle dynamic behaviour (even braking)<br />
Considerations<br />
§ Earliest concept / design phase decisions account for more<br />
than 75% of weight and costs of final powertrain and vehicle<br />
§ Total cost of development, production and service<br />
§ Common parts and platforms offer economies of scale<br />
OUR SOLUTION<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
20<br />
Industry Challenges<br />
Low Volume Manufacturing<br />
Challenge<br />
§ Highly flexible on-time production volume requirements<br />
§ Low volume production ramp-up and/or ramp-down phases<br />
(Total Product Lifecycle Management)<br />
§ Tight timescales with exacting specification and quality<br />
requirements<br />
Considerations<br />
§ Program objectives and constraints<br />
§ Production planning and quality assurance<br />
§ Continuous improvement processes require simultaneous<br />
engineering support and know-how<br />
OUR SOLUTION<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
21<br />
Industry Challenges<br />
Prototype <strong>Powertrain</strong> Solutions<br />
Challenge<br />
§ Quickly assess new concepts / prototype technologies<br />
§ Short production development programmes rely on proven,<br />
implementation ready concepts<br />
§ Minimise development risks<br />
Considerations<br />
§ Performance / emissions targets<br />
§ Technologies & benchmarking<br />
§ Target vehicle platform & packaging constraints<br />
§ Timing<br />
OUR SOLUTION<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
22<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Solutions<br />
CO2 REDUCTION<br />
LOW VOLUME<br />
MANUFACTURING<br />
OPTIMISING<br />
PERFORMANCE<br />
EFFICIENT<br />
DEVELOPMENT PROJECTS<br />
REDUCING<br />
WEIGHT & COST<br />
ELECTRONIC & DIAGNOSTIC<br />
TESTING<br />
ACHIEVE FUTURE<br />
EMISSIONS STANDARDS<br />
PROTOTYPE POWERTRAIN<br />
SOLUTIONS<br />
go to main menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
23<br />
Our Solutions<br />
CO2 Reduction<br />
Our Solution<br />
§ Extensive experience in the analysis development &<br />
application of CO2 reduction technologies across the<br />
entire powertrain<br />
§ Tools & approaches to support early assessment of <strong>com</strong>plex<br />
control system architectures & proposed solutions<br />
Our Services<br />
§ Rapid new engine concept development and demonstration<br />
§ Driveline architecture & controls specification<br />
§ Engine design, development and testing for series production<br />
§ Technology benchmarking and research<br />
CASE STUDY<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
24<br />
Our Solutions<br />
Efficient Development Projects<br />
Our Solution<br />
§ High level expertise <strong>com</strong>bined with proprietary product<br />
lifecycle and project management system<br />
§ Interdisciplinary project teams co-located to provide<br />
excellent cross-functional <strong>com</strong>munication<br />
§ From ‘clean sheet’ concepts to production upgrades<br />
Our Services<br />
§ Full ‘turn key’ project management (timing, cost and quality)<br />
§ Detailed and costed proposals for project requests<br />
§ Clear point of <strong>com</strong>munication and project status report<br />
against customer defined milestones<br />
CASE STUDY<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
25<br />
Our Solutions<br />
Achieve Future Emissions Standards<br />
Our Solution<br />
§ Combustion system and aftertreatment expertise<br />
§ Knowledge based approach for maximum benefit<br />
§ Flexible methods from engine hardware specification,<br />
integration and calibration development<br />
§ Early assessment of system capability<br />
Our Services<br />
§ Rapid concept emissions development and demonstration<br />
§ Combustion system, aftertreatment & controls development<br />
§ Comprehensive steady-state/transient engine dynamometers<br />
§ Fully certified, climatic chassis dyno test facilities<br />
TEST FACILITIES<br />
CASE STUDY<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
26<br />
Our Solutions<br />
Test Facilities<br />
Northampton (UK)<br />
Durability, performance & emissions (aftertreatment) testing<br />
§ 12 engine test cells (130 to 700 kW, transient/motoring)<br />
§ Two 48” single-roll chassis dynamometers rated at 210 kW<br />
Ambient and climatic test capabilities (-40°C to +50°C)<br />
§ Compliant with Euro 6, LEV2, Tier 2, ULEV requirements<br />
Detroit/Novi (USA)<br />
Durability, performance & emissions (aftertreatment) testing<br />
§ 7 heavy duty diesel test cells (transient/motoring)<br />
12 medium/light duty test cells<br />
§ 48” AWD roll chassis dynamometer rated at 150 kW<br />
Ambient and climatic test capabilities (+10°C to +40°C)<br />
§ Compliant with Euro 6, LEV2, Tier 2, ULEV requirements<br />
Additional Test Facilities (worldwide)<br />
§ 30+ test cells across Germany, Brazil, China & Japan<br />
§ Two climatic wind tunnels in Germany & USA<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
27<br />
Our Solutions<br />
Electronic and Diagnostic Testing<br />
Our Solution<br />
§ Component, subassemblies and vehicle diagnostic testing<br />
and tools at all stages (development, manufacturing, service)<br />
§ Efficient, agile and cost effective modular test solutions<br />
providing an increase in quality and customer satisfaction<br />
§ > 1500 dealers and > 46 production sites on 5 continents<br />
Our Services<br />
§ Quick identification of concerns in calibration development<br />
§ Vehicle End of Line and Repair Station test (TestLogiq®)<br />
§ In-process testers (e.g. evaporative leakage tester)<br />
§ Service tool software (ServiceLogiq®) and reporting tools<br />
CASE STUDY<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
28<br />
Our Solutions<br />
Optimising Performance<br />
Our Solution<br />
§ Experience based tools and approaches to tailor powertrains<br />
to meet customer requirements<br />
§ Unique engine <strong>com</strong>ponent and systems expertise<br />
§ Fully integrated analysis led methods<br />
§ No restrictions in size: city car or supercar<br />
Our Services<br />
§ 'Clean sheet' concept or performance upgrade<br />
§ Analysis, development & rapid concept demonstration<br />
§ Low volume production of engines<br />
CASE STUDY<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
29<br />
Our Solutions<br />
Reducing Weight & Cost<br />
Our Solution<br />
§ Detailed knowledge of design for manufacture with target<br />
costing methods and unique engine <strong>com</strong>ponent expertise<br />
§ Philosophy of using simple, practical design features adapted<br />
to specific customer needs<br />
§ Innovative approach not constrained by current practices<br />
Our Services<br />
§ Consultation to advise on feasibility of initial concepts<br />
§ Clean sheet designs or modifications / upgrades<br />
§ Structural analysis, rig testing and durability assessment<br />
§ Target costing and manufacturing support<br />
CASE STUDY<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
30<br />
Our Solutions<br />
Low Volume Manufacturing<br />
Our Solution<br />
§ Based on extensive experience in design, manufacturing and<br />
assembly of ‘class leading’ powertrains<br />
§ Project management and advanced quality planning systems<br />
to promote fault-free on-time production and delivery<br />
§ Engineering and manufacturing ‘under one roof’<br />
Our Services<br />
§ High quality aluminium casting foundry using COSCAST<br />
§ Versatile aluminium and cast-iron CNC machining facilities<br />
§ Assembly operations and end-of-line testing<br />
§ Supply chain management and Supplier Quality Assurance<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
31<br />
Our Solutions<br />
Prototype <strong>Powertrain</strong> Solutions<br />
Our Solution<br />
§ Rapid new engine concept development solutions<br />
§ From clean sheet designs to major engine upgrades<br />
§ To support dyno &/or vehicle assessment / demonstration<br />
§ Integration of engine concept into carryover or <strong>com</strong>pletely<br />
new concept vehicle architectures<br />
Our Services<br />
§ Multi-disciplinary teams offer full range of capabilities<br />
§ Support for engineering, manufacturing, procurement,<br />
engine / vehicle build & testing<br />
§ <strong>MAHLE</strong> Flexible ECU for prototype control solutions<br />
CASE STUDY<br />
CASE STUDY<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
32<br />
Our Case Studies<br />
Recent Case Studies<br />
DOWNSIZING ENGINE OFF-HIGHWAY ENGINE<br />
RANGE EXTENDER<br />
HIGH PERFORMANCE<br />
TEST SYSTEMS<br />
CALLOGIQ & PROLOGIQ<br />
go to main menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
33<br />
Our Case Studies<br />
Advanced Downsizing Demonstrator<br />
Motivation<br />
§ Technology demonstrator to showcase<br />
<strong>MAHLE</strong>’s engineering & <strong>com</strong>ponent expertise<br />
§ R&D platform to develop new technologies<br />
Highlights<br />
§ From a clean sheet to a running engine<br />
in only 9 months<br />
§ 50% ‘extreme’ downsizing achieved<br />
2.4l V6 1.2l Inline 3 cylinder with 120 kW<br />
§ 30% reduction in CO2 emissions<br />
§ Additional prototype engines produced for<br />
various customer projects<br />
§ Demonstration car presented in 2010<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
34<br />
Our Case Studies<br />
High Performance<br />
Customer vision<br />
“To challenge the <strong>com</strong>petitors high performance<br />
engine supremacy”<br />
<strong>MAHLE</strong> was a key development partner<br />
Multiple engines / applications, including :<br />
450 bhp V8 BiTurbo<br />
650 bhp V10 BiTurbo<br />
MPT involved from rapid concept development<br />
through to production<br />
Highlights<br />
Strong relationship developed with client<br />
Based on <strong>MAHLE</strong> capabilities & many<br />
successful projects<br />
go to chapter menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
35<br />
Our Case Studies<br />
Performance Concept Demonstrator<br />
Customer target<br />
Rapid development of a new high performance<br />
engine concept & demonstration in-vehicle<br />
Project summary<br />
V8 Biturbo, Bosch ME 17 control & many<br />
novel features<br />
Highlights<br />
22 wks from project start to first engine running,<br />
including design, procurement & build activities<br />
in action - from first running on dyno…<br />
12 wks to full torque structure vehicle cal<br />
17 wks to emissions feasibility demonstration<br />
Customer transmission partner <strong>com</strong>ment:<br />
‘… best base calibration they had worked with…’<br />
3.8l Turbo V8 Performance Targets<br />
0<br />
0<br />
0 1000 2000 3000 4000 5000 6000 7000 8000 9000<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong><br />
Power (PS)<br />
700<br />
600<br />
500<br />
400<br />
300<br />
200<br />
100<br />
Engine Speed (RPM)<br />
Power PS<br />
Torque Nm<br />
go to chapter menu →<br />
700<br />
600<br />
500<br />
400<br />
300<br />
200<br />
100<br />
Torque (Nm)
36<br />
Our Case Studies<br />
Compact Range Extender<br />
Motivation<br />
§ Pure electric vehicles face range limitations<br />
due to current battery technology<br />
§ Develop range extender engine as a solution<br />
Highlights<br />
§ 2-cylinder, in-line, 4-stroke, gasoline engine<br />
§ Compact and lightweight package with fully<br />
integrated electrical generator:<br />
− 65 litres and 65 kg<br />
§ Horizontal or vertical installation<br />
§ Maximum continuous power: 30 kW<br />
§ Battery storage capacity can be reduced,<br />
whilst maintaining an acceptable vehicle range<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong><br />
481 m<br />
go to chapter menu →
37<br />
Our Case Studies<br />
&<br />
Calibration validation for an engine family<br />
Multiple engine variants & vehicle platforms<br />
Markets: US, EU & ROW<br />
<strong>MAHLE</strong> used an integrated approach<br />
calibration & simulation tools used to<br />
develop OBD settings<br />
Maximising benefits of a small vehicle fleet<br />
Highlights<br />
fleet data processing to validate<br />
Many subtle issues found & fixed<br />
Customer reported ’95% fewer MILs in 3 years’<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong><br />
Exhaust back<br />
pressure<br />
1<br />
0.9<br />
0.8<br />
0.7<br />
0.6<br />
0.5<br />
0.4<br />
0.3<br />
0.2<br />
0.1<br />
0<br />
15<br />
24.75<br />
30<br />
rl<br />
KFFMSML<br />
35.25<br />
40<br />
45<br />
50<br />
69<br />
2000<br />
880<br />
nmot<br />
go to chapter menu →
38<br />
Our Case Studies<br />
Secondary Air Flow Error & ‘Fix’<br />
Low relative secondary air mass flows detected in ProLogiq IDAA report<br />
Root cause confirmed as an error in the back pressure model<br />
Simulated improvements due to a new back pressure model with the same ‘old’ data<br />
<br />
<br />
15<br />
24.75<br />
30<br />
35.25<br />
40<br />
45<br />
50<br />
69<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong><br />
Exhaust back<br />
pressure<br />
1<br />
0.9<br />
0.8<br />
0.7<br />
0.6<br />
0.5<br />
0.4<br />
0.3<br />
0.2<br />
0.1<br />
0<br />
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rl<br />
KFFMSML<br />
2000<br />
880<br />
nmot
39<br />
39<br />
Our Case Studies<br />
Off-Highway Engine<br />
Re-design an engine family to meet Tier IV<br />
§ Inline 4, approx. 1l displacement per cylinder<br />
§ Concept design (incl. all engine <strong>com</strong>ponents)<br />
§ Procurement and demonstration engine build<br />
§ Support OEM production design<br />
Problem solving - Head Gasket Failures<br />
§ OEM warranty costs ≈ £1m over 18 months<br />
§ <strong>MAHLE</strong> analysed root cause and implemented<br />
new design Problem “effectively solved”<br />
Highlights<br />
§ Collaboration with customer including on-site<br />
support through resident engineers<br />
§ Successful approval of demonstration engine<br />
§ Fast and effective problem solution<br />
0<br />
0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong><br />
Pressure (MPa)<br />
250<br />
200<br />
150<br />
100<br />
50<br />
Thickness (mm)<br />
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Stopper 0,010 mm<br />
Backland<br />
VS1020<br />
HS4040
40<br />
Our Case Studies<br />
Development & Production of Fuel Leak Tester<br />
Customer target<br />
Fast & cost effective solution to meet 100% leak<br />
test requirement on high volume lines<br />
<strong>MAHLE</strong> Test Systems solution<br />
Fast accurate detection of 0.010“ diameter leaks<br />
Typical leak test time of 10 seconds<br />
Designed to integrate easily into line<br />
Highlights<br />
In use at 14 assembly plants and growing…<br />
With several major OEMs<br />
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<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
41<br />
The Difference We Make<br />
OPTIMISED TECHNICAL SOLUTIONS<br />
REDUCE PROJECT COST BY 25%*<br />
REDUCE PROJECT TIMESCALE BY 50%*<br />
* as per acknowledgement by a customer<br />
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<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
42<br />
Summary<br />
EFFICIENT PROCESSES<br />
TECHNICAL EXPERTISE<br />
FOCUSED RESEARCH<br />
ENGINEERING AND MANUFACTURING<br />
OPTIMISED APPROACH FOR BEST VALUE<br />
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<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
Thank you for your attention<br />
go to main menu →<br />
<strong>MAHLE</strong> <strong>Powertrain</strong> Ltd., February 2012 © <strong>MAHLE</strong>
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