Integral Powertrain's team of test specialists, engineers and technicians provide a wealth of expertise in testing to regulations and standards, to client specific requirements and in the development of appropriate test procedures and methods.

Test Facilities

Integral Powertrain prides itself on being the UK’s only independent testing facility capable of providing certified emissions testing from passenger cars to light commercial vehicles.

A recent multi-million pound investment in the Milton Keynes facilities means we now have a compliant vehicle emissions testing facility, based around state of the art Horiba equipment, featuring a high power 4WD dynamometer, the latest emissions analysers, integrated STARS test automation, and a truly unique cold climate control system.

A flexible but professional approach to testing allows our experienced engineers to cover any client testing requirements; from cold climatic RDE development to high speed performance runs, and emissions and fuel economy testing from all global regions.

With 2 vehicle test cells, ambient (temperature controlled soak space for up to 6 vehicles -23° +/- 3°), and cold vehicle soak storage for up to 3 cars (down to -30°C), private customer offices, vehicle workshop and access to Portable Emissions Measurement Systems (PEMS), Integral Powertrain can cater for a wide range of client testing requirements.

These facilities enable test and development activities in controlled, repeatable conditions without the costs, inconvenience and uncertainties of “on-road” testing.

Key features include:

  • Vehicle emissions (legislative and development)
  • Worldwide Harmonised Light Vehicle Test Procedure (WLTP)
  • Federal 40 CFR Part 1066
  • Fuel consumption
  • Vehicle and powertrain control system development
  • OBD and calibration development
  • Performance work
  • Climatic testing
  • Real Driving Emissions (RDE) testing
  • Each test chamber can run tests independently with gasoline or diesel exhaust systems
  • Facilities are available for part or full project and turn-key work

Emissions

Integral Powertrain has an extensive range of vehicle exhaust emissions testing knowledge and capability developed over decades of emissions testing experience. Our upgraded vehicle exhaust emissions testing capability includes:

  • Horiba MEXA ONE Pre-Cat (engine out), Tailpipe and Dilute analysers
  • CO, CO2, NO, NOx, THC, CH4, O2
  • Dual raw lines allow true catalyst-efficiency analysis
  • Full heated dilution tunnel meeting WLTP and 1066 standards
  • 12 Bag (4 Phase) heated CVS exhaust gas dilution system up to 30m3
  • Horiba DLS & heated filters for Particle Matter (PM) mass calculations
  • Horiba Solid Particle Counting System (SPCS) for Particle Number (PN) measurements
  • Fourier Transform Infra-Red technology (FTIR) multi-component gas analysers for non-regulated species
  • Horiba STARS test automation system

Dynamometer

Our Emissions and Driveline Test Facility (EDTF) delivers:

  • The latest generation Horiba VULCAN II XtraCold Four-wheel-drive dynamometer with 48″ diameter rollers
  • At the wheel vehicle performance measurement capability of up to 350kW continuous power (520kW in overload)
  • Provides a wide simulated inertia range 450 – 4370Kg @ 3.76m/s²
  • The 4WD rolls includes a traversing rear roller which can be pre-set to suit the vehicle’s wheelbase – extendable wheelbase range from 1.8 – 3.4m
  • Maximum axle load of 2500Kg
  • Achieves a maximum speed of 250 Km/h
  • Dynamic gradient simulation
  • Speed tracking fan
    • 0-140 Kph tracking capability
    • Meets Euro and Federal requirements
    • Braking resistor to track vehicle speed accurately

Quality System

Integral Powertrain’s ISO 9001:2015 Certificate achieves and exceeds the requirements of the standards and the Customers’ expectations on Quality Management System and Processes, including design, development, software and electronics, manufacturing, testing and vehicle testing emission.

Our Quality Management System is designed to meet customer requirements and exceed their expectations while continually improving our existing operational processes.

We accomplish this by engaging our people and business partners for feedback to improve our practises, thereby delivering excellence through the following Quality Principles: Quality-focused leadership, Customer-focused organisation, Involvement of people, process approach to product and service delivery, mutual beneficial supplier relationship, risk management approach to processes.

Our Emissions and Driveline Test Facility supports a diverse range of customers and industries, helping to ensure our customers’ products are tested in compliance with national, EU and international standards and regulations.

It is the Policy of Integral Powertrain Ltd (IP) to recognise and reinforce the importance of compliance with all applicable regulatory, statutory and legal standards aimed at ensuring that Quality is seen as key to achieving our strategic business goals.

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 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’s e-Drive division 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, the engineers at Integral Powertrain 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 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

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. Integral Powertrain 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
  • 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, Integral Powertrain 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, Integral Powertrain have a track record of engineering successful high-performance products compatible with volume production.