Mechatronic components for small engines

Flywheel and ignition coil with integrated ignition system

For electronic ignition systems, MAHLE supplies flywheels with integrated magnets and ignition coils with integrated ignition electronics. When the engine is operating, the magnets in the rotating flywheel generate an electrical current that is used in the engine to ignite the combustible mixture. The ignition coils with integrated electronics control the ignition process. MAHLE supplies systems for high-voltage capacitor discharge ignition (CDI) as well as transistor-controlled ignition (TCI). In CDI units, the discharge of a high-voltage capacitor is used—via ignition coil and spark plug—to ignite the air-fuel mixture. TCI ignition involves a steady current flowing through the ignition coils. If the contact is interrupted, the self-induction in the ignition coil gives rise to a voltage surge that generates the ignition spark in the spark plug.

MAHLE ignition systems are robust and designed for adverse conditions, making them ideal for use in hand-held power equipment or off-road motorcycles.

Fuel injection systems

MAHLE fuel injection systems match the fuel quantity and timing to the specific operating/load condition so that the engine delivers the required performance, coupled with low emissions and low consumption.  The MAHLE system comprises the electronic control unit, sensors, fuel pump, injectors, and throttle valve. MAHLE fuel injection systems are available in a battery-powered or battery-free concept.

ACGs (alternating current generators) and voltage regulators

MAHLE permanent-magnet alternating current generators are connected directly to the combustion engine crankshaft. They generate electricity that can be used to charge the battery, for instance, or to power electronic control units. The external circumference of the alternator is fitted with a ring gear that is probed by a sensor. As the alternator rotates, the probe relays signals to the ignition management system, which are used by the electronics to calculate the engine speed. The moment of inertia of the rotor in the alternator has a stabilizing effect on the engine speed, and the combustion engine runs more smoothly as a result. MAHLE voltage regulators convert the alternating current generated in the alternator to direct current, while at the same time ensuring a constant battery charge voltage.

MAHLE alternators thus combine several engine functions, reducing complexity and cost, as well as weight.