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MAHLE has developed a heavily downsized demonstrator engine to explore the limits, and potential benefits, of engine downsizing. The 1.2 litre, 3-cylinder, MAHLE downsizing (Di3) engine, in conjunction with an Aeristech 48 V electric supercharger (eSupercharger, eSC), achieves a BMEP level of 35 bar and a specific power output in excess of 160 kW/litre. The eSupercharger enables high specific power output, good low speed torque and excellent transient response. The resulting heavily downsized engine has been installed into a demonstrator vehicle that also features 48 V mild hybridization. At specific power output levels above 90 kW/litre the engine is operated with excess fuel in order to protect the turbine from excessive exhaust gas temperatures. In this analytical study, the boosting system requirements to maintain lambda 1 fuelling, via the use of EGR, across the entire engine operating map for the eSupercharged version of the MAHLE Di3 engine, have been explored.

MAHLE Powertrain has developed an industrialized version of its 3-cylinder downsizing engine as a low cost, high specific output engine, for the global automotive market. The engine has been developed in both 1.2 and 1.5 liter capacities, with the maximum commonality being maintained between the two variants. Through careful design, the engines are capable of delivering exceptionally high-specific torque and power outputs whilst utilizing only simple low-cost technology. At the same time the engines have also been engineered to meet the requirements of the latest Euro 6c and China 6a emissions standards. This was demonstrated very early in the project through use of a representative development vehicle. The 1.2 and 1.5 liter engines are rated at 30bar Brake Mean Effective Pressure (BMEP) and 100 kW/l and 28 bar BMEP and 94 kW/l respectively and are both capable of achieving these outputs whilst operating on 92 RON gasoline.