Mahle, a leading automotive supplier, has upgraded its climatic wind tunnel in Stuttgart by adding a DC fast charging system. The facility now allows test engineers to charge electric vehicles with up to 350 kilowatts in any weather condition, even in extreme heat. This new capability allows for more realistic simulations of challenges that batteries face in real-world scenarios.
For instance, fast charging in sweltering summer temperatures can be particularly taxing on batteries. During the fast charging process, the battery generates heat and without proper cooling, the temperature can rise to the point of damaging the cells. The thermal management of the battery must regulate the temperature to stay within a specific range of 15 to 40 degrees, while also maximizing charging performance.
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Thanks to the upgraded climatic wind tunnel, Mahle is now able to test these scenarios in a controlled environment. The tests performed in the tunnel are accurate and reproducible, providing valuable insights into the effects of fast charging on the lithium-ion battery, as well as interior comfort. These findings can aid in the development of more advanced electric vehicles.
Mahle’s climatic wind tunnel was first modernized in the year 2000 and has been continuously updated to offer “realistic, precise, and repeatable measurement and test conditions.” The addition of the fast charging system further expands the wind tunnel’s capabilities and supports the development of electric vehicles. As Jumana Al-Sibai, a member of the Mahle management board, stated, “Mahle’s expertise in temperature management makes a valuable contribution to the battery, a particularly demanding component.”
