The current demands on modern engines are: to reduce emissions, improve fuel economy, downsize, and increase power density, reliability and durability even further. The main, prerequisite for developing innovative concepts is an in-depth fundamental understanding of the relationships and interdependencies between the individual components throughout the entire engine. Only by means of comprehensive engineering competence can cost-saving potential be fully exploited – whether through detailed optimization of all components or through intelligent integration of functions within a complete system. The trend toward completely pre-built assemblies, made available as modules or sub-systems, also requires the systems suppliers involved in the first supply stage to have an infrastructure that reliably ensures high quality from assembly to logistics.

Main focus areas of research established
These demands raise issues for research and development at MAHLE, which are addressed with a high level of commitment. In order to optimize our products, we regularly evaluate current and future technologies relevant to these products and systems.

Another area of focus is the consistent consideration of all components in their respective environments. We use the knowledge gained from this approach to further improve our simulation tools. This helps us to better analyze component behavior in terms of strength, service life, wear, noise and numerous other aspects. The simulation tools are realistically formulated in detail using physically-based models and thus constantly refined.

In order to achieve a reliable projection, it is vital that the simulation tools are compared with the reality. For example, we use efficient telemetry technology to measure piston temperatures in the complete engine via thermocouples – as a function of the operating point and other parameters.

MAHLE has an innovative frictional loss test bench for performing tests on the complete engine. In laboratory tests, we check the fatigue resistance of bearings under realistic conditions, with a dynamic load comparable to that of an engine.

MAHLE intensively promotes the development of materials and, in particular, the definition of the properties of materials. Our objective is to extend the boundaries of the materials’ applications to allow weight-optimized designs and provide accurate material data – strength, thermal characteristics, etc. – for design and component simulation. An important role is played by the creation of material models, which allow for an improved evaluation of the service life, especially taking into account thermal fatigue.

Fundamental research for new materials

With the ongoing development and testing of innovative coatings and the modification of machining processes, we put forth considerable efforts to improve product characteristics in a targeted manner. Optimizing the functionality of surfaces, particularly with respect to wear, friction and susceptibility to seizure, offers considerable development potential for improving fuel efficiency even further.

In a joint project with the Massachusetts Institute of Technology in Boston, we are developing a comprehensive simulation tool. This tool will be used to analyze the effects of various parameters in the total power cell – taking a decisive step forward in the wider issue of reducing oil consumption.

R&D centers for progress
Today, approximately 2,000 development engineers and technicians are involved in fundamental research and the ongoing development of the combustion engine at the seven R&D centers in Stuttgart, Northampton, Detroit (Farmington Hills and Novi), São Paulo, Tokyo and Shanghai. This allows MAHLE to take on specific development tasks, carry out component optimization and tuning, and perform complex vehicle and engine tests on-site in close cooperation with all our customers worldwide.

Our R&D centers are networked globally and continuously exchange knowledge with each other constantly. This ensures that information is passed on quickly, response times to the customer are reduced and all available resources can be used to optimum effect.