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MAHLE Profit Center Mechatronics

Mechatronics

Development and production of mechatronics systems and components for automotive applications.


 

In the field of mechatronics, MAHLE places particular emphasis on electronic controls, actuators, and engine-relevant heating systems. The expertise of our engineers is multifarious to say the least and ranges from plastic engineering and plastic joining technology through small transmission layout to hardware and software electronics.

Concept development, design, and testing is carried out by MAHLE in Stuttgart/Germany. Moreover, a mechatronics competence center has been established in Wolfsberg/Austria, where mechatronic components are manufactured and the appropriate testing facilities are available.

Our mechatronic engine management systems enable the realization of innovative and improved functions. Thereby, cost advantages can be gained, and the environment protected thanks to the optimization of engine functions—while increasing performance at the same time.

Electric wastegate actuator

Electric wastegate actuator

Fast actuation speed and precise regulation of the electric wastegate actuator for turbochargers enable low consumption levels. For the first time, MAHLE's wastegate actuator controls the wastegate irrespective of the pressure, thus reducing gas exchange losses. The result is a considerable fuel saving with improved turbocharger responsiveness, which leads to a noticeable improvement in performance.
Electric intake pipe

Electric intake pipe

The electric actuator for positioning the gate in diesel engines converts the actuation angles specified by the engine control unit (ECU) into precise, mechanical actuation angle movements. A software-based control algorithm guarantees the actuator's angle position to an accuracy of +/- 1 degree. As a result, emissions are reduced considerably.

Only four electrical connections are required, thanks to the integrated "intelligence" in the actuator (microprocessor), to operate the actuator independently in vehicles with an engine control unit. The ECU can thus be simplified, which in turn helps to save costs.

The defect analysis process is streamlined through the constant sending of status notifications to the engine control unit.

 

Blow-by heater


Blow-by heater

The gases of the crankcase ventilation—so-called blow-by gases—contain a large amount of water vapor. In case of cold ambient conditions, blow-by heaters reliably prevent ice accumulation in the crankcase ventilation line. This ensures reliable ventilation of the crankcase under any kind of ambient conditions.

The self-regulating PTC heater design provides a cost-optimized solution for the overall system since external control systems are no longer necessary. At the same time, this ensures maximum operational safety and reliability.

 

Fuel heater



Fuel heater

In case of very low ambient temperatures, the paraffin in diesel fuels has a tendency to coagulate and possibly clog the fuel filter. MAHLE fuel heaters preheat the diesel fuel and thus prevent clogging of the fuel filter. This ensures a reliable fuel supply of the engine. The self-regulating PTC heater design provides a cost-optimized solution for the overall system since external control systems are no longer necessary. At the same time, this ensures maximum operational safety and reliability.