Engine testing - MAHLE Japan

Testing at MAHLE: In-Depth Insights for Future Powertrain Technologies

Why Testing Matters …

Testing provides essential and objective insights into the functionality, quality, and performance of powertrain components. As powertrain technologies become increasingly complex, precise testing procedures are more critical than ever to meet the highest standards of efficiency, emissions reduction, and durability. As a trusted partner to the global automotive industry, MAHLE operates state-of-the-art test benches and maintains a presence wherever its customers are located. This enables efficient and closely integrated collaboration as both a development partner and service provider.

… Where MAHLE Makes the Difference

As a globally leading development partner and supplier to the automotive industry with over 100 years of experience, MAHLE offers its customers a comprehensive range of testing and analysis capabilities for powertrain systems – across both passenger car and commercial vehicle segments.

From the development of innovative measurement, testing, and evaluation methods to fundamental research and the validation of new products, MAHLE supports the entire development process – from initial prototypes to series release. During the development and validation process, MAHLE testing experts accelerate problem resolution through in-depth root cause analysis.

Electrification: Setting New Standards for Electric Powertrain Systems

In the field of electrification, MAHLE draws on its long-standing expertise to test electric drive components at the highest level. Specialized test benches enable comprehensive testing – from individual components and subsystems to fully integrated electric drive units.

Experienced test engineers analyze efficiency, performance, and thermal management under conditions that closely reflect real-world scenarios. In doing so, MAHLE supports its customers in developing electric drive solutions that are efficient, durable, and reliable – meeting the growing demands of the market.

Technical Specifications

Electric Specifications

1,000 V DC, 600 A DC, 160 kW
1,000 VDC, 600 ADC, 160 kW

Motor Emulations

Three-phase and six-phase motor emulations (PMSM, EESM, and IM)

Fault management

Short-circuit fault simulation / Short-circuit failure simulation

Electric Motor Test Stand

n: 20,000 rpm
Pel: 350 kW peak
Ambient environment: -40 °C to 150 °C
Coolant: -20 °C to 140 °C

Component Test Stand

Power supply 80 V, 800 V optional
Data acquisition: NI cDAQ
Test parameters: voltage, current, power, torque, speed (U, I, P, Md, n)

Electronics/Mechatronics

Software-level Hardware-in-the-Loop / SW-level HiL
Power-level Hardware-in-the-Loop HV / Power-level HiL HV
Real-time system simulation
Commissioning
Functional testing / Function verification
System characterization / Determination of system properties

Electric Motor Test Stand

Machine characterization
Performance and efficiency verification
Cooling optimization
Cold-start testing
Transient Profiles
Endurance run / Long-duration testing

Efficient Combustion Engine: Optimizing for the Future

The combustion engine remains a relevant part of future Powertrain Systems – provided it runs on sustainable fuels. At MAHLE’s advanced testing facilities, combustion engines can be operated using biofuels, hydrogen, and synthetic fuels. This enables MAHLE experts to conduct emissions and efficiency analyses, as well as to test innovative components and forward-looking concepts under real-world engine conditions – demonstrating their robustness and reliability.

Technical Specifications

Test Bench Specifications

13 engine test cells for LD and MHD applications with cutting-edge automation systems

Test benches for LD

Up to 460 kW
Biofuels, e-fuels, gas, and diesel fuels
Air intake conditioning unit
- air mass flow 1,600 kg/h
- humidity 20 – 85% rH
- temperature 15 – 30°C

Test benches for MHD

Up to 800 kW
Hydrogen, biofuels, e-fuels and diesel
Air intake conditioning unit
- air mass flow 1,600 kg/h
- humidity 20 – 85% rH
- temperature 15 – 30°C

Anechoic chamber

Class 1 corresponding to DIN 45 635
Cutoff frequency 100 Hz

Fuel Cell: Future Technology Under Real-World Testing

MAHLE is actively engaged in the further development of fuel cell systems and sees great potential in this technology – particularly for long-distance applications involving heavy-duty commercial vehicles. On our customized test benches, we analyze key performance parameters, system efficiency, and long-term stability of fuel cell systems and their components. Through targeted test series, MAHLE establishes a solid foundation for evaluating and optimizing system reliability under realistic operating conditions.

MAHLE’s validation approach for fuel cell systems begins at the system level, with a focus on the air path and water management – including humidification and water separation. As part of component testing on dedicated test benches for MAHLE humidifiers, key performance indicators are captured and analyzed using advanced measurement techniques. The insights gained are directly integrated into product development. All MAHLE components are tested under real operating conditions within a complete fuel cell system.

Technical Specifications

Fuel Cell System Test Bench