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MAHLE designs diagnostic technology for EV systems

MAHLE is debuting a state-of-the-art electric vehicle solution for independent workshops, claiming the potential for comprehensive diagnostic services for most electrified powertrains.

Presented at Automechanika in Frankfurt, Germany next month, MAHLE Aftermarket will showcase the MAHLE BatteryPRO diagnostic and service solutions including E-Scan, E-Health and E-Care modes.

Additionally, the automotive supplier is demonstrating workshop equipment for calibrating driver assistance systems and air conditioning and transmission oil service solutions. The Stuttgart company therefore specifically supports its independent workshops with spare and service parts.

Mahle claims to be the first supplier in the world to enable independent workshops to perform EV battery diagnostics with the Mahle TechPRO diagnostic tool launched in March. By the end of the year, E-Scan capabilities will be enhanced by his E-Health and E-Care devices.

e-health (picture below) Diagnose the vehicle’s battery via the charging plug and evaluate the measurement data in the cloud. In this way, a battery’s condition can be categorized in relation to all other recorded batteries of the same model in the fleet.


Additionally, E-Health produces a prediction of the remaining expected life of the vehicle.

Since its launch in 2022, the new diagnostic solution has been tested in practice with TÜV NORD Mobilität and an unnamed European fleet operator. E-Care is a service unit for maintenance of vehicle battery cooling circuits.

As for emissions from internal combustion powertrains, Germany will mandate the measurement of both tailpipe emissions and particulate matter from the beginning of 2023. For this, Mahle presents the EmissionPRO instrumentation and the PMU 400 device for measuring particulates.

Mahle claims that the device can measure individual nanoparticles in exhaust gas streams, even at very low concentrations. This means that samples taken from the exhaust pipe can be diluted up to 200-fold with clean air to minimize particle and dirt build-up on the most sensitive parts of the instrument.

Mahle will also introduce the Tech PRO Digital ADAS 2.0 for calibrating driver assistance systems and the latest generation ACX A/C service unit series and ATX transmission oil service unit series. Continued development of Digital ADAS 2.0 is claimed to further reduce calibration times, enabling calibration in minutes. Thanks to a special laser distance gauge directly connected to the diagnostic tool, the tool can directly record all parameters of the vehicle alignment, so calibration can be performed without manual input. Vertical placement of the monitor is also done automatically. At the same time, by automatically collecting the vehicle type from the license plate number, the operator does not have to manually select the vehicle type.

Olaf Henning, Member of the Management Board and Director of the Aftermarket Business Unit at MAHLE, said: Our solutions have allowed us to far outperform our global competition, especially in the area of ​​battery diagnostics. ”

Automechanika takes place September 13-17.