Mahle Debuts New Range of Electronic Components for EVs

Mahle has debuted a complete range of power electronics components for e-mobility. The new range comprises power electronics, traction motors, and charging infrastructure solutions.

Power electronics are key components in the case of modern EVs. Noise filters play a major role in meeting strict norms regarding minimizing electrical interference. Mahle noise filters are not only highly compact and robust but also offer minimal power loss. They cover a frequency band of 150 kilohertz to 300 megahertz with a voltage of 400 volts. They also identify the type of charging current and verify the quality of the ground connection.

The onboard chargers are capable of adjusting the charging parameters during AC charging so that they match the requirements of the battery management system. This contributes to speeding up the charging process and also helps save power. However, the direct current needed to charge the traction battery can generally be obtained at DC charging stations on freeways.

In the case of urban charging stations or local household connections, they supply alternating current, and the onboard charger generates power by means of rectifying and conversion. Mahle says that its onboard chargers are notable for their high power density and are protected against under- and overvoltage, overcurrent, and overheating from both a software and a hardware perspective.

In electric cars, batteries deliver a voltage level of well over 12 volts. The DC/DC converter in an electric vehicle can be compared to the alternator in a vehicle with a combustion engine and provides a constant voltage while supplying power to the air conditioning system, power steering, lighting, or the infotainment system.

DC/DC converters from Mahle demarcate the high- and low-voltage electrical systems safely and reliably. These convertors offer flexibility in terms of installation space and design and are also protected against under- and overvoltage, overcurrent, and overheating.

Generally, in modern electric cars, brushless electric motors are used and the rotating field needed to operate these motors has to be generated electronically. The inverter is sued for generating this rotating field and controls the electric motor depending on the position of the accelerator. The motor acts as an alternator during the recuperation process while the inverter rectifies the generated AC voltage. This AC voltage is then stored in the traction battery and can be made available again.

Mahle claims that its inverters are modular and scalable, cover a voltage range from 400 to 800 volts, and are compatible with all common types of traction motor.