MAHLE has secured its first series order for a MAHLE megawatt cooling module, designed for the high-performance megawatt charging sector. A European cable manufacturer and outfitter of megawatt charging systems (MCS) has selected this cooling module for installation in fast-charging stations for electric commercial vehicles. MAHLE said it plans to begin series production at the end of 2025 at its Námestovo, Slovakia, plant.

“With this cooling module, MAHLE is expanding its product portfolio for intelligent charging solutions and setting new standards in the charging infrastructure for electric trucks and electric heavy-duty vehicles,” said Christian Kuechlin, Vice President MAHLE Industrial Thermal Systems.

MAHLE Megawatt Cooling Module

Megawatt charging systems (MCS) for electric commercial vehicles primarily operate at service stations on and off motorways. These charging stations generate up to 8 kilowatts (kW) of waste heat, depending on outside temperatures. With rapid-charging capacities reaching 3.75 megawatts (MW) per station, efficient cooling is essential.

“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,” explained Norman Nagel, Head of Business Development at MAHLE Industrial Thermal Systems.

MAHLE said its engineers designed the cooling module to fit various charging station configurations. It operates in ambient temperatures ranging from -35 to +50°C without losing performance.

Fast-charging systems for passenger cars and light commercial vehicles can achieve up to 500 kW of charging capacity. The modular cooling module, which includes heat exchangers, pumps, and fans, adapts to customer specifications and available installation space.