Calling on 20 years’ experience in powertrain and controls engineering, Integral Powertrain is well positioned for all stages of the journey from an idea or product brief, through to a high quality, manufactured product. We can provide comprehensive, turn-key capability and integrated support to customer teams as the situation requires.

Design and Analysis

Integral Powertrain has pioneered advanced design processes at both ends of the product engineering cycle. Our unique Automated Intelligent Design system allows rapid, interactive concept synthesis whereas our integrated component and tooling design reduces cost and risk of validation activities.

We offer all the analytical capability expected of a premium consultant; in some cases this is through industry-standard tools, however in key specialist areas we have developed our own methods to improve the products we deliver to our clients:

  • Automated Intelligent Engine Design
  • Associative Tooling
  • Design for Manufacture
  • Cycle Simulation
  • Finite Element Analysis
  • Computational Fluid Dynamics
  • Downsizing/Pressure Charging
  • Research Engines

Prototyping and Design Verification

Based in Motorsport Valley in the UK Midlands, Integral Powertrain has well established links with many prototype component suppliers. Together with our in-house technician staff and build facilities, we can meet the highest specifications and offer outstanding quality to exacting timing requirements.

As hardware progresses to design intent and production suppliers are engaged, we ensure appropriate quality planning is implemented.

By keeping exhaustive records of specifications and critical characteristics, we ensure that prototype activities fully support the validation process.

From early stage shakedown through system optimisation and reliability growth, we have a track record of engineering successful high performance products compatible with volume production.

Optimal performance and refinement depends on the successful integration of the powertrain and its control system into the vehicle. At Integral Powertrain, theoretical understanding and analytical tools are complemented by practical knowledge and a high-tech vehicle test facilities.

Powertrain Controls

Integral Powertrain has always maintained strong capability in powertrain controls within its key markets (Automotive, Motorsport, Aerospace, Defence and Marine) to complement its industry experience in design and development of hardware and software. This is increasingly important with advanced systems complexity relating to engine, hybrid and electric motor functions.

The use of physically based strategies, desktop simulation & analysis and Design of Experiments (DoE) techniques is key to managing these developments.

Integral Powertrain has direct experience of working with the latest Engine Management Systems (EMS)/ Powertrain Control Systems (PCS) and of integrating systems via Controller Area Network (CAN). We can also provide customised embedded software for prototype evaluations.

Emission and After-Treatment Systems

More demanding government legislation and continued consumer focus on CO2 data, along with increasing system complexities and tighter budget and resource pressures, have driven the requirement for efficient and cost effective emission control systems with engine and vehicle calibration methods and tools that support the whole development cycle from concept through to production.

Integral Powertrain is aligned with upcoming emissions legislation introducing the requirement for Real Driving Emissions (RDE) testing utilising latest Portable Emissions Monitoring (PEMS) equipment.

CO2 Modelling and Benchmarking

Integral Powertrain has developed unique and powerful techniques to measure and characterise powertrain hardware and controls so that Carbon Dioxide (CO2) emissions can be tracked, allocated and optimised with greater accuracy.

Hybrid and Electric Vehicles

Integral Powertrain is a genuine leader in the rapidly developing area of hybrid and electric vehicles. We offer very high power density electric motors and low-voltage mild-hybrid, electro-mechanical turbo charging, electric motor drive and power re-generation and engine downsizing technologies such as SuperGen.

As hybridisation substantially impacts installation systems and controls, in many cases ‘standard’ solutions are not available. Our physics based analytical approach provides a firm foundation for optimisation.

With a strong background in engine management systems and electric motor controls, our engineers are well accustomed to developing and calibrating controls strategy, either for central powertrain controller or for intelligent sub-systems such as traction motors, ISG systems and electric boosting systems.

Hybrid vehicle development also requires specialised instrumentation and data processing techniques. We have developed systems for high voltage hybrid vehicles which track the energy flow using our 2/4WD dynamometer facility.

Installation Systems

The successful integration of powertrain into the vehicle, including packaging, can be as important as the powertrain itself. Whilst design of installation systems fits well with our analysis led approach, the validation process fits well with our Engine Management Systems (EMS) applications skills and combined projects can make optimal use of valuable prototypes to deliver exceptional value.

Capability includes:

  • Engine mounting
  • Cooling and intercooling
  • Intake and exhaust
  • Underhood heat management
  • Noise Vibration & Harshness (NVH) optimisation

Vehicle Test Facility (ECTC)

Integral Powertrain’s advanced vehicle test centre is certified for European Union (EU) legislative testing and supports gasoline, diesel and hybrid vehicle development and testing on two wheel drive (2WD) and four wheel drive (4WD) chassis rolls.

The facility includes a 2WD ambient temperature vehicle test chamber, suitable for running emissions and similar cycles, and a 4WD vehicle test chamber suitable for hot and cold climate testing (down to -20°C).  The 4WD chassis rolls currently supports absorption of up to 100kW, with the option of a simple upgrade for operation up to 200kW.

Key features include:

  • Designed to accept vehicles up to large size light duty trucks, and long wheelbase passenger cars
  • The 4WD rolls includes a traversing rear roller which can be pre-set to suit the wheelbase of most vehicles
  • Emission test facilities are also complemented by a multi-vehicle cold test chamber, capable of cold start and pre-test soak down to -35°C
  • Each test chamber can run tests independently with gasoline or diesel exhaust systems
  • The ECTC can also provide mobile in-vehicle testing facilities with their mobile test bed
  • Facilities are available for part or whole programme/projects and turn-key work