Integrated AC Charging Terminals and Thermal Management for EVs

MAHLE chargeBIG will showcase its expanded portfolio of electric vehicle charging infrastructure at the Power2Drive exhibition in Munich. The hardware lineup includes a new four-port AC charging terminal, a mobile charging unit for temporary deployments, and high-performance cooling modules for fast-charging cables.

Multi-Port AC Charging Terminal
Developed in cooperation with Langmatz Energy, the new charging terminal integrates payment functions and charging points within a single modular housing. The system can charge up to four electric vehicles simultaneously, delivering 22 kilowatts (kW) of alternating current (AC) per port. The architecture eliminates the need for additional standalone payment columns, streamlining integration into existing parking structures. Users can initiate and settle charging sessions using an integrated RFID or credit card reader.

Mobile Charging Architecture and Deployment Financing
For temporary deployments such as construction sites or events, the smallBOX PORTABLE provides a mobile charging solution without requiring permanent grid installation. The weatherproof enclosure houses four 22 kW charging points, features an integrated card reader for legally compliant billing, and operates across a temperature range of -25°C to +55°C. To facilitate the deployment of both permanent and mobile infrastructure, MAHLE has partnered with BNP Paribas Leasing Solutions to offer leasing and lease-purchase financing models, allowing operators to scale charging networks without large upfront capital expenditures.

Thermal Management for Fast-Charging Cables
To support high-power direct current (DC) fast-charging stations, MAHLE has engineered a cooling module designed to dissipate the thermal load generated within charging cables. The system integrates proprietary heat exchangers, pumps, and a control unit to maintain maximum charging capacity under extreme climatic conditions. The module is CE and UL certified, operating reliably in ambient temperatures ranging from -35°C to +50°C without necessitating a reduction in charging current.

Additional Context: This section details technical specifications not included in the original announcement
In high-power EV charging infrastructure, managing thermal loads is critical for operational efficiency. Standard uncooled CCS (Combined Charging System) cables are typically limited to 200 Amps to prevent the copper conductors from exceeding safety temperature limits. To achieve the 350 kW to 500 kW charging rates required for heavy commercial vehicles (drawing 500 Amps or more), active liquid cooling must be circulated through the charging cable jacket. The integration of advanced heat exchangers prevents cable overheating, which would otherwise trigger the station's thermal derating algorithms—artificially throttling the current and extending charge times. In the AC charging space, providing 22 kW across four simultaneous ports requires a robust 88 kW localized grid connection, necessitating integrated dynamic load management software to prevent tripping local substation breakers during peak utilization.

Edited by Lekshman Ramdas, Induportals editor – adapted by AI.

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