We are continuing to strengthen our predevelopment activities in order to develop innovative products for series production. The focal points of development work are defined within agreed product and technology fields. The extensive advanced development projects deal primarily with the following topics: variable valve lift and timing, dethrottling, reduction of emissions, downsizing and reduction of frictional loss.

Variable valve timing can be achieved to optimum effect with the new SCP (Single Cam Phaser) camshaft with integrated phase adjustment. On the basis of this system, a fully variable valve train can also be developed to control the valve lift and valve opening. This allows throttle-free load control, which can deliver potential fuel savings of approximately ten percent – depending on the size of the vehicle and engine. As a result of optimized combustion, the raw emissions are also reduced.

Camshaft as basic component for fully variable valve lift and duration

Another technology that enables dethrottling results from using a fast-switching valve in the intake system of gasoline engines. This produces potential fuel savings of approximately seven percent. Advantages can also be created in terms of cold start characteristics, internal exhaust gas recirculation and charging.

Air pulse valve

Venturi nozzle with ring-shaped EGR inlet and poppet valve

The emission reductions that will be required for diesel vehicles in the future can be achieved by means of selective catalyst technology and exhaust gas recirculation. MAHLE is working on EGR with the aim of avoiding additional fuel consumption that might result from adverse pressure characteristics.

Just as turbochargers are already used in almost all passenger car diesel engines to increase power output, a similar trend can also be observed in the development of the new generation of gasoline engines. Downsizing involves using the additional power output achieved by charging to reduce engine displacement, thereby reducing fuel consumption. Various charging systems can be used in the process. The future potential of the various charging technologies is currently being investigated in a systematic analysis.