German supplier and thermal management specialist Mahle has secured its first series order for a new cooling module designed for megawatt charging systems (MCS). The module will be integrated into fast-charging stations for electric commercial vehicles, the company said on [DAY].
Mahle did not disclose the customer but described it as a European cable manufacturer and supplier of MCS charging systems. The customer selected Mahle’s solution due to its “performance and cost efficiency,” the company stated. While the initial application is for megawatt charging stations, Mahle said the modular cooling unit could also be adapted for fast-charging systems used in passenger cars, light commercial vehicles, maritime applications, and rail transport.
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The MCS standard, developed for long-haul electric trucks and buses, supports charging capacities of up to 3.75 megawatts. However, initial commercial deployments are expected to operate around one megawatt, in line with current vehicle capabilities.
According to Mahle, MCS charging generates heat losses of up to 8 kilowatts, depending on ambient temperatures. “In our cooling module, we connect up to four heat exchangers in series to cool down the waste heat of the cable using air that is drawn in. Fans transport the air to the outside,” said Norman Nagel, Head of Business Development at Mahle Industrial Thermal Systems.
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“With this innovative cooling module, Mahle is expanding its product portfolio for intelligent charging solutions and setting new standards in the charging infrastructure for electric trucks and heavy-duty vehicles,” added Christian Küchlin, Vice President of Mahle’s industrial thermal division.
The cooling module, which includes heat exchangers, pumps, and fans, has a modular design that allows customization for different charging station configurations. It is rated for operation in temperatures ranging from -35°C to +50°C without performance loss. Mahle plans to begin series production at its Namestovo, Slovakia, plant by late 2025.