Commercial Director Lotus Engineering, Mark Stringer on Control Systems

Control systems have been an integral element of vehicles for many years, from safety and security hardware and software through all aspects of powertrain and propulsion to the complete human machine interface. The rapid development of battery electric vehicles is well-publicised and we’re working on ECUs that will support Lotus Engineering consultancy clients in this and other developing sectors of the transport industry.

What we don’t talk about so much is our internal combustion engine (ICE) controllers. Despite Emira being the last petrol-powered car from Lotus, ICE engine controllers are still very much a focus area for our client offering.?

I spoke to Andy Green, our Chief Engineer for Propulsion Systems, to gain a greater insight and understand his thoughts on the Lotus engine controller, and its unique properties and applications. We also talked about the future of control systems and what differences, if any, need to be considered for management of sports cars.

Andy has been at Lotus since 1985. After graduating with a Master’s degree in Automotive Engineering from Cranfield, he has subsequently spent the majority of his time at Lotus delivering client programmes for OEMs worldwide.

?Andy, how did the Lotus Engineering ECU offering come about?

In my current role I’m responsible for delivering external powertrain-related programmes. With my background in engine development and running major engine programmes, I realised there was an opportunity to use the Lotus-developed ECU for low-volume applications as an alternative to that supplied by mainstream OEM suppliers.

What’s the background of the Lotus ECU?

It’s a great example of the innovation that Lotus is renowned for and has been in continuous development for more than 30 years. It’s been proven operation in Lotus vehicles such as the Emira, as well as demontration programmes for hybrid and BEV vehicles for our clients. The Lotus ECU was a critical feature on the supply of upgraded powertrains for the Toyota Yaris GRMN programme and, and, more recently, production hypercars for our clients, where low volumes and high technical complexity make Lotus control systems a great fit.

What is unique about the Lotus ECU?

With an in-house software and calibration group – and our own test facilities in terms of dynos, emission lab and a test track – we can offer a complete turn-key solution. The ECU hardware can be tailored to the customer’s needs and the diagnostic monitors required for homologation are recognised for worldwide certification in line with emissions requirements.

What applications can it be used for?

Whilst we’ve generally concentrated on automotive applications – including research engines, proof of concept work as well as hybrid applications – there no reasons to stop us supporting other industries, such as marine.

Do ECUs differ for sports cars?

No, but the software and calibration activities, combined with switchable modes, can easily be tuned to suit a sports car application.

What unique capabilities do you think Lotus Engineering has with regards to integrating these technologies for other OEMs?

An enthusiastic group of engineers with a can-do attitude who relish a challenge!

Lotus has a great history in control systems, and in particular the ICE ECU. What do you see as the future for this?

Whilst current legislation is pushing us away from the use of fossil fuels as a mainstream energy source, there is a continued desire for specialist low-volume vehicles with ICE and hybrid applications.

Are there any other examples of innovation in control systems available through Lotus Engineering?

Another great example is the Lotus Active Valve Train? (AVT) system, which can be used to carry out various programmes to support R&D. Whilst the AVT technology has been around for more than 20 years, it is still in demand by companies and research establishments looking into the continued development of internal combustion engines. With the system replacing the conventional camshaft and poppet valves with a hydraulic controlled valve, it allows a greater flexibility and control. It is still being supplied to clients and the operating range in terms of both speed and amplitude has increased.

Lotus Engineering can define and implement complete control system requirements for production, developing software and integrating hardware elements across the whole vehicle for improved efficiency and functionality. It’s an essential part of promoting brand character and vehicle personality. The consultancy has expertise in complex electronics across all vehicle systems and can use its own technology to work with, or substitute for, individual controllers within engineering programmes for cost-effective results. With more than 40 years of skill and experience, Lotus Engineering can provide fast and effective integration of many separate vehicle systems, even if they have not previously been used together for an application.

If you would like further information, or want to get in touch with us, please feel free to contact us [email protected]