MAHLE Powertrain comes with a new 48-volt battery to boost mild-hybrid performance. The 48-volt battery optimized for use in mild-hybrid vehicles, to maximize the recovered energy that can be stored and released.

A New 48-volt battery to boost mild-hybrid performance

With this latest development, MAHLE Powertrain is increasing the capabilities of 48-volt systems, which offer increased safety and cost advantages when compared to high-voltage systems. This can significantly increase the efficiency of mild-hybrid vehicles. And also allows a fuel saving of between 12 and 15 percent.

During deceleration events, mild-hybrid vehicles need to recover energy efficiently at a relatively high-power. as the recovered energy can be deployed during the next acceleration, high storage capacity is not required for these applications. Thus, a compact and cost-effective battery which is capable of high charge and discharge power levels relative to its storage capacity is desirable.

As there were no suitable low-cost and compact batteries which able to deal with the necessary recharge and discharge cycles involving high currents, MAHLE Powertrain decided to develop its own. The LTO chemistry allows continuous charge and discharge rates of 10 kW and peak rates for short periods up to 20 kW in the selected cells from a battery pack which has only a 0.5 kWh storage capacity.

Optimal battery cooling guarantees charge or discharge performance and battery durability. However, the coolant should be electrically isolated from the cells. MAHLE Powertrain utilizes a robust cooling strategy, with simulations showing cooling performance to be exactly on target.

MAHLE Powertrain engineers paid the utmost attention in designing the busbars and electrical connections within the battery. Because any high resistance in these components can be an additional heat source and limit the power capability of the system.

Testing of the first prototype is currently underway to verify that the pack can meet the performance targets. Initial results indicate that all temperatures within the pack remain within the permissible range at a continuous discharge rate of over 10 kW. It is also capable of peak power levels in excess of 20 kW. Their next step is to install the prototype pack into MAHLE Powertrain’s 48V supercharged extreme downsizing demonstrator vehicle.

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