Mahle tests the effects of fast charging in the climate chamber

Over 40 degrees Celsius of heat, the sun scorches the car, and there is scarcely a cooling breeze. These are challenging conditions for the temperature-sensitive Li-ion battery. If an electric car is quickly charged under such conditions, the battery can become too hot and suffer damage. To test this realistically, Mahle has now equipped its climate wind tunnel in Stuttgart with a direct current fast-charging system. Test engineers can charge electric vehicles with up to 350 kilowatts in under five minutes for 100 kilometers of range – under all climatic conditions, including extreme heat. The measurement data provide insights into the effects on the Li-ion battery and interior comfort, thereby delivering crucial knowledge for vehicle development.

“With the expansion of our Climatic Wind Tunnel's service offering towards e-mobility, we will be able to support our customers even better in the development of their e-cars in the future,” said Jumana Al-Sibai, member of the Mahle Management Board and responsible for the Thermal Management business unit. “The battery, in particular, is especially demanding.”

Fast Charging - Stress for the Battery

Fast charging with up to 350 kilowatts of charging power poses a significant thermal load on the lithium-ion battery. This is especially true when the electric vehicle is charged in high heat and strong sunlight. For the longest possible lifespan, the battery must consistently be kept within the optimal temperature range of 15 to a maximum of 40 degrees Celsius. The vehicle's thermal management system, which is the complex interaction between the cooling and climate systems, ensures that the sensitive battery does not overheat and become damaged in the worst case. At the same time, the driver’s cabin must not become too hot.