Advanced 48V eSupercharged demo vehicle unveiled by Mahle Powertrain

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Mahle Powertrain has revealed its eSupercharged downsized demonstrator vehicle equipped with 48V technology.

Mike Bassett, chief engineer for R&D at Mahle Powertrain, commented, “In the last 12 months, our Northampton-based engineering team has replaced the standard 2.0-liter turbocharged engine in our donor VW Golf GTi, with the latest development of our acclaimed 1.2 liter downsizing engine.

“This new power unit harnesses leading-edge 48V eSupercharger technology coupled with an innovative belt integrated starter generator (BISG) to deliver high performance combined with fuel efficiency and reduced emissions.”

Other key engine developments that have now been successfully integrated include Mahle’s flexible ECU (MFE), which plays a crucial role in both engine management and electrical system control simultaneously. This development control unit, including bespoke software, enables extremely rapid and flexible functional integration and comprehensive implementation of multiple control processes.

In addition to the eSupercharger and 10kW-rated BISG, the 48V architecture used in this unique demo car comprises a three-cell, advanced lead acid, 48V battery pack and a pair of DC/DC converters (to maintain the state of charge of the 12V battery).

Real-world road tests, driveability and emissions calibration on the demo vehicle are currently ongoing and initial performance results are encouraging.

When compared to the baseline data (based on the standard 2.0-liter Golf GTi), the test vehicle is reported to be comfortably achieving a 22% reduction in CO2 emissions. In terms of specific power, the Mahle engine produces an impressive 160kW/l (> 260 bhp), compared to the baseline of 100kW/liter.

The low-speed torque generated by the almost lag-free eSupercharger enables a 0-100km/h time of 6.4 seconds. While some of these figures are yet to be fully verified and tested, this eSupercharged engine has already shown significant potential as an attractive solution for mild hybridization.

One of the distinct characteristics of the eSupercharged downsizing engine is its ability to deliver steady-state torque even at engine speeds as low as 1,000rpm. While the original turbocharged, gasoline donor engine typically produces 23 bar BMEP at 2,500rpm, the Mahle Powertrain unit generates 33 bar BMEP with no evident lag.

Mahle’s application of 48V eSupercharging to its 1.2-liter engine achieves the same acceleration as a 2.0-liter Mk 7 Golf GTi, while significantly reducing CO2 emissions and improving fuel consumption.

September 14, 2016

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About Author

Dean has been with UKi Media & Events for over a decade, having previously cut his journalistic teeth writing and editing for various automotive and engineering titles. He combines extensive knowledge of all things automotive with a passion for driving, and experience testing countless new vehicles, engines and technologies around the world. As well as his role as editor-in-chief across a range of UKi's media titles, he is also co-chair of the judging panel of the International Engine + Powertrain of the Year Awards.

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