please help improve it or discuss these issues on the talk page . learn how and when to remove these template messages this article contains content that is written like an advertisement . please help improve it by removing promotional content and inappropriate external links and by adding encyclopedic content written from a neutral point of view . june 2013 learn how and when to remove this template message this article needs additional citations for verification . please help improve this article by adding citations to reliable sources . unsourced material may be challenged and removed . august 2016 learn how and when to remove this template message learn how and when to remove this template message mahle powertrain ltd type limited company industry automotive founded 2005 headquarters northampton uk products engineering services manufacturing services test systems services number of employees 550 2013 slogan integrated powertrain solutions website www.mahle powertrain.com mahle powertrain ltd is the wholly owned engineering services division of mahle gmbh . 1 with its headquarters in northampton uk and sister company in farmington hills michigan united states the company specialises in the design development testing and production of internal combustion engines and provides a broad spectrum of engineering and manufacturing services to its global customer base . mahle powertrain s engineers and technical specialists are also present in the mahle research and development centres in stuttgart germany s o paulo brazil and shanghai people s republic of china . contents 1 history 2 company profile 3 engineering services 4 internal research and development 5 references 6 external links history edit the ownership of mahle powertrain can be traced back to cosworth which from march 1990 was owned by the vickers group . in september 1998 audi bought the cosworth business for 117 million then split it into two halves . 2 cosworth racing was sold on to ford for an undisclosed sum while audi retained a new company cosworth technology 3 which was spearheaded to run production engineering and casting as well as the consultancy side . the newly formed cosworth technology group consisted of the engineering headquarters at northampton the engine assembly and machining facilities at wellingborough and the low volume aluminium alloy sand casting facility at worcester retaining the famous coscast process capability within the group . the group also included a sister engineering company in novi mi previously known as intelligent controls inc. on 1 january 2005 mahle acquired the cosworth technology group 4 with the competence it has built up as an integral part of cosworth since 1958 in developing and producing high performance engines . its integration into the mahle group and the change of name to mahle powertrain on 1 july 2005 opens up unique prospects for the long term . company profile edit mahle powertrain ltd is the engineering services division of mahle gmbh . it specialises in the design development testing and manufacture of internal combustion engines . in addition to the head office in northampton uk it has a sister company in farmington hills mi near detroit usa which includes the test systems sub division of the business . the company also has engineers and technical staff based at the parent company mahle gmbh r & d centres in stuttgart shanghai and s o paulo . the uk facilities also include a manufacturing plant in wellingborough and an aluminium sand casting foundry in worcester . engineering services edit mahle powertrain provides engineering expertise in all aspects of engine development . this involves concept studies the design and simulation phases development and calibration work validation and finally delivering production ready powertrain solutions . some projects are stand alone and may employ specialists from a single department ; others involve engineers from all disciplines within the company . citation needed design verification & purchasing design and analysis engineers use computer aided engineering tools to design whole engines and subsystems from initial concept ideas to production ready detailed designs . the company also designs performance upgrade packages for existing powertrains . citation needed thermodynamics & applications performance and emissions engineers carry out development and optimisation of combustion systems appraising and selecting the most appropriate combinations of hardware during an engine development programme . calibration engineers at mahle powertrain configure engine management systems to optimise performance efficiency and driveability . they also calibrate the on board diagnostic systems that are now mandatory on road vehicles ref directive 98 69 ec 13 10 1998 . additionally mahle powertrain performs drive cycle emissions testing on in house dynamometers . engine calibrations are tailored to target specific emissions legislation . build & test at their northampton uk site mahle powertrain has extensive engine and vehicle testing facilities which are used to develop performance and reliability and reduce co2 emissions and fuel consumption . mahle powertrain s engine manufacturing services include the production of aluminium sand castings the machining of cylinder heads and blocks in both aluminium and cast iron and the assembly of cylinder head systems and complete engines . test systems the test systems sub division of mahle powertrain based in farmington hills provides test equipment tools and service applications to support engineering vehicle fleets end of line production testing and service dealership diagnostics . internal research and development edit advanced downsizing engine mahle powertrain designed and developed the mahle advanced downsizing technology demonstrator engine which has become a recognised industry benchmark for highly optimised gasoline engine performance . bench tests initially proved that it was capable of delivering abundant power and torque with very low fuel consumption in a high durability package . during 2010 this engine was installed into a mid sized vehicle for further optimisation and driveability assessment . the potential for significant fuel economy benefits under real world driving conditions were then demonstrated and verified . citation needed mahle downsizing engine key features of the downsizing engine include aggressive engine downsizing 50 % displacement reduction high specific output 100 kw l fuel economy benefit proven 5.8 l 100 km 49 mpg co2 emissions nedc 135 g km mahle coscast for all major castings mahle nikasil parent bore cylinder coating bmts single stage turbocharger compact range extender engine mahle powertrain was commissioned by its parent company mahle to develop an engine for use as a range extender for electric vehicles . the design started from a completely clean sheet and working prototypes were being tested 9 months after the start of concept work in 2009 . the principle behind range extended electric vehicles is to use an internal combustion engine to recharge the onboard battery to enhance the distance the vehicle can travel between charges something that is currently a major limitation of fully electric vehicles . a demonstrator vehicle has recently being built . key features of the range extender engine include 900 cm3 2 cylinder spark ignition engine 30 kw output compliant with euro 6 emissions legislation fully integrated axial flux generator range extender optimised for cost weight 70 kg incl . generator package volume the engine is the size of an a3 sheet of paper in plan view nvh single cylinder research engine mahle powertrain has undertaken several research projects using their bespoke single cylinder optical engine . the engine is capable of providing optical access to the combustion chamber at speeds of up to 5000rpm and can be run without optical access at up to 8500rpm thanks to careful first and second order balancing . mahle flexible ecu mfe the mahle flexible ecu mfe is a robust open architecture controller based on the proven aft protronic platform . it has the capability to control any powertrain application utilising mahle s highly optimised functional software . the flexible ecu overcomes traditional prototype controller development issues and provides a cost effective solution that is representative of a series production unit . citation needed the mahle flexible ecu can be used to support development and calibration activities for gasoline and diesel products in the following areas full integration with existing vehicle systems ideal for producing close to production level demonstration vehicles for new hardware concepts citation needed software control algorithms and system development benchmarking research and development programmes demonstration of new engine hardware concepts mahle stirling engine the mahle stirling engine develops 25 kw for use in renewable power generation applications . the engine was designed for use with a solar mirror dish configuration to collect and focus the sun s heat on to the engine s heat exchanger to provide power . the engine employs four cylinders which are arranged in a square u4 pattern using two crankshafts geared together using a configuration known as double leading alpha . this compact and symmetrical cylinder arrangement minimises heat losses and offers the best thermodynamic efficiency . the pistons are double acting with pressurised hydrogen at up to 200 bar above and below . a cross head arrangement with a sliding gas seal is used to connect to the connecting rod and seal the lower volume . extensive cae analysis calculations were used to guide and validate the design in the concept phase . a dedicated 1 d thermodynamic simulation software was developed to assist with optimising the geometry of the engine . during the concept development phase four prototype engines and two seal development rigs were built for testing as using solar energy as the heat source is not feasible for concept development the natural gas burner technology from the mahle powertrain foundry was used to maintain the engine heat exchanger at a continuous 750 c. the engine exceeded its performance targets by achieving up to 26 kw and a peak thermal efficiency of up to 43 % . citation needed references edit mahle gmbh annual report 2010 cosworth the search for power 5th edition by graham robson . isbn 1 84425 015 6 audi ag annual report 1999 mahle gmbh annual report 2005 external links edit mahle powertrain website retrieved from https en.wikipedia.org w index.php title mahle powertrain & oldid 735799311 categories manufacturing companies of the united kingdomcompanies based in northamptonhidden categories articles with a promotional tone from june 2013all articles with a promotional tonearticles needing additional references from august 2016all articles needing additional referencesuse dmy dates from june 2013use british english from june 2013all articles with unsourced statementsarticles with unsourced statements from august 2016 navigation menu personal tools not logged intalkcontributionscreate accountlog in namespaces article talk variants views read edit view history more search navigation main pagecontentsfeatured contentcurrent eventsrandom articledonate to wikipediawikipedia store interaction helpabout wikipediacommunity portalrecent changescontact page tools what links hererelated changesupload filespecial pagespermanent linkpage informationwikidata itemcite this page print export create a bookdownload as pdfprintable version languages sloven inasvenska edit links this page was last modified on 23 august 2016 at 05 08 . text is available under the creative commons attribution sharealike license ; additional terms may apply . by using this site you agree to the terms of use and privacy policy . wikipedia is a registered trademark of the wikimedia foundation inc. a non profit 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