Case Study: Integral Powertrain achieves 500 HP, up to 50% lower emissions, and 80% faster testing with MathWorks Model-Based Design

Integral Powertrain Helps Bentley Motors Increase Horsepower, Reduce Emissions, and Improve Driveability

Integral Powertrain (IP) worked with Bentley Motors to lift the Arnage’s engine performance from 450 HP to 500 HP while meeting stricter CARB LEV-2 and Euro Stage 4 emissions and improving driveability — all with limited access to prototype vehicles. To tackle this challenge, IP used MathWorks Model-Based Design tools, including MATLAB, Simulink, and the Model-Based Calibration Toolbox, to explore hardware and calibration changes virtually before testing on rare prototypes.

Using MathWorks’ tools, IP built and validated a dynamic valve‑train model, evaluated multiple camshaft profiles, and calibrated a new ECU strategy, then tuned cold-start and pre-light-off behavior with statistical models and design-of-experiments. The MathWorks-based workflow delivered measurable results: power increased to 500 HP, emissions dropped by up to 50% to meet LEV-2/Stage 4, camshaft iteration time fell from about three weeks to 1–2 days, test cycle time was reduced by ~80%, and the design changes entered production on the 2007 Bentley Arnage.

Integral Powertrain

John McLean

IP’s Director