eSupercharged demo vehicle to preview at LCV 2016

This year’s event, 14^th-15^th September will see the 48V equipped vehicle take to the test track for the first time.

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 2.0l turbocharged engine in our donor VW Golf GTi, with the latest development of our acclaimed 1.2l downsizing engine.”

Bassett added: “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 been successfully integrated since LCV 2015 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 3-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, drive-ability 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 2.0l Golf GTi), the test vehicle is 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/l.

The low-speed torque generated by the almost lag-free eSupercharger enables a 0-100km/h time of 6.4s. 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 hybridisation.

Clearly, 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 1,000rev/min. While the original turbocharged, gasoline donor engine typically produces 23 Bar BMEP at 2,500rev/min, the MAHLE Powertrain unit generates 33 Bar BMEP with no evident lag.

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