Module testing

Varying emissions legislation across different global automotive markets, brand identities, and specific regional expectations of the end customer continue to drive differences in component requirements, e.g., based on its point of use, despite increasing globalization and rising strategic use of modules and identical components. In addition, systematic application in the development of powertrains and vehicles is increasing. The interactions between components and systems are becoming more and more important for development and design.

Every component that MAHLE develops must therefore meet very specific requirements for the start of production. Regardless of the application and region, efficient functionality is just as important as operational safety over the specified service life.

Robust design lays the foundation, using the right materials and possibly coatings that suit the operating conditions for the component.

But it is not enough to develop a component in isolation. Investigating the interactions among components throughout the vehicle, especially within a system, is increasingly critical. This is the only way to evaluate the actual operating behavior of components and their interactions with other parts. An understanding of the overall system is thus the cornerstone of successful component development.

The module testing division at MAHLE is dedicated to investigating all of these aspects. Every component is tested in independent operation, within a system, and in the interactions between systems. Only this holistic testing approach can ensure durable components and ultimately a system that remains efficient throughout its specified service life.

This is made possible by the extensive experience that MAHLE has accumulated within its business segments and the basic philosophy of always understanding the overall system first before developing individual components.

A wide range of testing and research facilities around the world with cutting-edge technology are available for testing MAHLE components. These facilities include:

  • Materials lab
  • Chemistry lab
  • Component testing
  • Materials testing
  • Wear test benches
  • Vibration test benches
  • Pulsation and burst test benches
  • Endurance test equipment
  • Hot gas test bench
  • Leakage and leak tightness test benches
  • Thermodynamic labs
  • Climatic wind tunnels
  • Cooling wind tunnel

In addition to developing new products, MAHLE’s global module testing division also supports the quality departments in case of customer complaints. The guideline is always that each location can provide component testing to support the local market with its individual requirements.

This means that a global presence is necessary. MAHLE has therefore established extensive testing capabilities in all key regions and locations in Asia, Europe as well as North and South America. They reflect many regional characteristics and serve as specialists within the Group.

These facilities can be used, for example, to test the design level of products before we begin acceptance test runs on engine test benches.